Lincoln Electric BURNY KALIBURN Spirit II 150 User Manual
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Lincoln Electric BURNY KALIBURN Spirit II 150 User Manual

Lincoln Electric BURNY KALIBURN Spirit II 150 User Manual

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User's Manual
Spirit II 150
High Current Density Plasma Cutting System
with Manual Gas Console (MGC)
BK718114 Rev F
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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Summary of Contents for Lincoln Electric BURNY KALIBURN Spirit II 150

  • Page 1 User's Manual Spirit II 150 High Current Density Plasma Cutting System with Manual Gas Console (MGC) BK718114 Rev F 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 © Copyright 2013-2014 Lincoln Global, Inc. Kaliburn Inc. a Lincoln Electric Company 4130 Carolina Commerce Parkway Ladson, SC 29456 USA This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to...

  • Page 3: Table Of Contents

    Spirit II User’s Manual Prologue Table of Contents Section 1: Safety General Precautions ..................1-1 Ultraviolet Radiation Protection ................. 1-1 Noise Protection ....................1-1 Toxic Fume Prevention ..................1-2 Electric Shock Prevention ................. 1-2 Fire Prevention ....................1-3 Explosion Prevention..................1-3 Health Support Equipment ................
  • Page 4 Prologue Spirit II User’s Manual Section 4: Operation Operating the Manual Gas Console (MGC) ............4-1 Setting up to Cut ....................4-2 Setting up to Mark (Overrides Cut) ..............4-3 Verifying Input Gas Pressures ................4-3 Making a Cut or Mark ..................4-4 Piercing Thick Materials ..................
  • Page 5 Spirit II User’s Manual Prologue Section 7: Parts List Power Supply (BK300211 - BK300219) ............7-1 Manual Gas Console (BK300600) ..............7-5 Impulse Start Console (BK300500) ..............7-7 Torch and Manifold Assemblies ................ 7-8 Shielded Torch Leads ..................7-9 CAN Communication Cable and Termination Plug ........... 7-9 Manifold Control Cables ..................
  • Page 6 Prologue Spirit II User’s Manual Limited Warranty KALIBURN expressly warrants that this product shall be free from defects in materials and workmanship, under proper and normal use for the intended function of such product, for a period of three (3) years for the Spirit II plasma power supply (includes the cooling system and internally installed Inova option) and one (1) year for all other Spirit II system component.

  • Page 7: Section 1: Safety

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

  • Page 8: Toxic Fume Prevention

    Section 1: Safety Spirit II User’s Manual Toxic Fume Prevention Care should be taken to ensure adequate ventilation in the cutting area. Some materials give off toxic fumes that can be harmful or fatal to people in the vicinity of the cutting area.

  • Page 9: Fire Prevention

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

  • Page 10: Health Support Equipment

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

  • Page 11: Safety Standards Booklet Index

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

  • Page 13: Section 2: Specifications

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

  • Page 14: System Components

    Section 2: Specifications Spirit II User’s Manual System Components The Spirit II 150 System consists of the following components: Standard Components • Power Supply • Manual Gas Console • CAN Cable • CAN Termination Plug • Impulse Start Console (ISC) •...

  • Page 15: Power Supply Specifications

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

  • Page 16: Torch Coolant Specifications

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

  • Page 17: Manual Gas Console (Mgc) Specifications

    Spirit II User’s Manual Section 2: Specifications Manual Gas Console (MGC) Specifications Part Number ............ BK300600 Weight .............. 50 lb (23 kg) 12.4" [315] 12.0" [305] 13.7" [348] (4) Ø .300 [7.6] 10.9" [277] 7.0" [178] This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 18: Gas Supply Requirements

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

  • Page 19: Impulse Start Console (Isc) Specifications

    Spirit II User’s Manual Section 2: Specifications Impulse Start Console (ISC) Specifications Part Number ............. BK300500 Weight .............. 22 lb (10 kg)  8.00" [203]  (4) Ø.312 [8]    12.75" [324] 12.00" [305] 13.50" [343]  10.00" [254] ...

  • Page 20: Torch And 2-Gang Manifold Specifications

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

  • Page 21: 5-Gang Manifold Specifications

    Spirit II User’s Manual Section 2: Specifications 5-Gang Manifold Specifications Part Number ............ BK280022 Weight .............. 6 lb (2.7 kg)  6.18" [157]  0.327" [8.3]  0.25" [6.4] (4) 0.187" [4.8] Mounting Holes   1.18" [30] 3.80"  [97] 4.20"...

  • Page 22: Airborne Noise Emissions

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

  • Page 23: Section 3: Installation

    Spirit II User’s Manual Section 3: Installation Section 3: Installation Initial Inspection All systems undergo full testing before being shipped from Kaliburn. In the unlikely event that one of the components is defective or missing, please contact Kaliburn so a replacement item can be sent.

  • Page 24: System Interconnection

    Section 3: Installation Spirit II User’s Manual 2-Gang Manifold The 2-gang manifold assembly must be mounted to the torch. See Section 2 for mounting dimensions. Torch The torch must be installed on the positioner of an arc voltage control (height control) capable of maintaining the cutting arc voltage within 1 arc volt.
  • Page 25 Spirit II User’s Manual Section 3: Installation Figure 1: Spirit II System with Manual Gas Console and Internal Inova System This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
  • Page 26 Section 3: Installation Spirit II User’s Manual Figure 2: Spirit II System with Manual Gas Console and External Inova System This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 27: Power Supply Primary Power Connections

    Spirit II User’s Manual Section 3: Installation Power Supply Primary Power Connections ** Before connecting primary power, check the data plate on the power supply to verify the voltage required ** A primary disconnect switch, switching all ungrounded supply conductors, should be provided for each Spirit system.
  • Page 28 Section 3: Installation Spirit II User’s Manual L1 (U) L2 (V) L3 (W) Ground Disconnect Box Strain Relief Connections L1 L2 L3 Gnd TB5 Connections Figure 3: Power Supply Primary Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 29: Power Supply Output Connections

    Spirit II User’s Manual Section 3: Installation Power Supply Output Connections Perform the following steps to connect the output of the power supply to the impulse start console and the work table. See Figure 4 on the next page. Power Supply Electrode Lead 1.
  • Page 30 Section 3: Installation Spirit II User’s Manual Strain Relief Strain Relief Figure 4: Power Supply Output Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

  • Page 31: Isc Control Cable And Isc Ground Connections

    Spirit II User’s Manual Section 3: Installation ISC Control Cable and ISC Ground Connections Perform the following steps to connect the ISC control cable and ISC ground. See Figure 5 on the next page. ISC Control Cable 1. Connect the ISC control cable plug labeled P16 to the connector labeled P16 on the rear of the power supply.
  • Page 32 Section 3: Installation Spirit II User’s Manual Figure 5: Cooling System Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 3-10...

  • Page 33: Torch Leads To Impulse Start Console Connections

    Spirit II User’s Manual Section 3: Installation Torch Leads to Impulse Start Console Connections Perform the following steps to connect the torch leads to the impulse start console. See Figure 6 on the next page. Note: When making hose connections, only tighten the brass fittings enough to make water or gas seals.
  • Page 34 Section 3: Installation Spirit II User’s Manual Figure 6: Torch Leads to Impulse Start Console Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 3-12...

  • Page 35: Torch Leads To Torch Base Connections

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

  • Page 36: Torch Gas Connections

    Section 3: Installation Spirit II User’s Manual Torch Gas Connections Perform the following steps to connect the torch gas hoses to the manual gas console, torch base, and manifold assemblies. See figure 8. Note: When making hose connections, only tighten the brass fittings enough to make gas seals.
  • Page 37 Spirit II User’s Manual Section 3: Installation Postflow Gas Hose 1. Connect one end of the postflow hose to the postflow outlet on the rear of the MGC. 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 manifold.
  • Page 38 Section 3: Installation Spirit II User’s Manual Manual Gas Console GREEN BLUE GREEN RED REAR PORT REAR PORT BLUE Figure 8: Torch Gas Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 39: Gas Supply Connections

    Spirit II User’s Manual Section 3: Installation Gas Supply Connections Perform the following steps to connect the gas supply lines to the MGC. See Section 2 for gas supply requirements. Mating hose barbs and connectors are supplied with the system and are sized for 3/8 inch inside diameter hose. Do not change the inlet gas supply fittings to quick-connect fittings.

  • Page 40: Can Communication Connections

    Section 3: Installation Spirit II User’s Manual 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.

  • Page 41: Cnc Machine Interface Connections

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

  • Page 42: Filling The Cooling System

    Section 3: Installation Spirit II User’s Manual Filling the Cooling System WARNING: Do not touch the fans inside the power supply. Important: Never turn on the system when the coolant reservoir is empty. Important: When handling coolant, wear nitrile gloves and safety glasses. Important: Only use Kaliburn approved coolant.

  • Page 43: Section 4: Operation

    Spirit II User’s Manual Section 4: Operation with Manual Gas Console Section 4: Operation Operating the Manual Gas Console (MGC) The Manual Gas Console (MGC) is the interface to the entire Spirit system when the MGC is used instead of the Automatic Gas Console (AGC). OFF Button Push to disable the Spirit system.

  • Page 44: Setting Up To Cut

    Section 4: Operation with Manual Gas Console Spirit II User’s Manual Setting up to Cut The following procedure uses the information from the cutting charts in Section 5 to prepare the system to cut. Press the UP or DOWN button on the MGC to move the pointer through the menu as described below.

  • Page 45: Setting Up To Mark (Overrides Cut)

    Spirit II User’s Manual Section 4: Operation with Manual Gas Console Setting up to Mark (Overrides Cut) The system will automatically switch between cutting and marking based upon commands in the part program. However, all cutting commands in the part program can be overridden with marking commands by simply changing the Process to Marking.

  • Page 46: Making A Cut Or Mark

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

  • Page 47: Piercing Thick Materials

    Spirit II User’s Manual Section 4: Operation with Manual Gas Console 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 48: Cut Quality

    Section 4: Operation with Manual Gas Console Spirit II User’s Manual 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 49: Checking Errors

    Spirit II User’s Manual Section 4: Operation with Manual Gas Console Checking Errors The last ten (10) system errors are available through the MGC as described below. On the main menu, move the pointer to Errors. Press SELECT. Press SELECT to cycle through the last ten (10) error codes.

  • Page 50: Changing The Language

    Section 4: Operation with Manual Gas Console Spirit II User’s Manual Changing the Language The language displayed on the MGC can be changed as described below. On the main menu, move the pointer to Configure. Press SELECT. Press SELECT on Languages. Move the pointer to the desired language and then press SELECT.

  • Page 51: Installing / Removing The Torch Head

    Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Section 5: Torch Consumables and Cutting Charts Installing / Removing the Torch Head WARNING: Remove primary power from the Spirit system! 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 52: Installing / Replacing Consumables

    Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Installing / Replacing Consumables WARNING: Remove primary power from the Spirit system! 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 53: Maximizing Consumable Life

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

  • Page 54: Inspecting For Damage

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

  • Page 55: Selecting Consumables

    Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Selecting Consumables Mild Steel Copper Electrode Inner Outer Shield Swirl Copper Torch Retaining Nozzle Retaining Cap Ring Electrode Head BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100 BK277140/ BK284150 BK277115 BK277153 BK277122 BK277142 BK277131...
  • Page 56 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel Silver Electrode Inner Outer Shield Swirl Silver Torch Retaining Nozzle Retaining Cap Ring Electrode Head BK279410 BK284150 BK277286 BK277151 BK279484 BK279483 BK279060 (brown o-ring) 100A BK277151/ BK279420 BK284150 BK277117 BK277152...
  • Page 57 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - H17 Plasma Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head BK284150 BK277150 BK277113 BK277124 BK277140 BK277132 BK279100 BK284150 BK277146 BK277113 BK277126 BK277141 BK277133...
  • Page 58 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - Air or Nitrogen Plasma Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head BK284150 BK277144 BK277110 BK277121 BK277138 BK277137 BK279100 BK284150 BK277149...
  • Page 59 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - Air or Nitrogen Plasma Silver Electrode Outer Shield Inner Swirl Silver Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head BK279410 BK284150 BK277286 BK277151 BK279484 BK279483 BK279060 (brown o-ring) 100A...
  • Page 60 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100 BK284150 BK277150 BK277153 BK277122 BK277142 BK277131 BK279100 BK284150 BK277150...
  • Page 61 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum Silver Electrode Outer Shield Inner Swirl Silver Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head BK279410 BK284150 BK277286 BK277151 BK279484 BK279483 BK279060 (brown o-ring) 100A BK279420 BK284150 BK277117 BK277152 BK279493 BK279439...
  • Page 62 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Cutting Charts The cutting charts shown on the following pages are intended to give the operator the best starting point to use when making a cut on a particular material type and thickness.
  • Page 63 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 30 Amps - Oxygen Plasma / Oxygen Shield Copper Electrode Shield Cap Nozzle Electrode BK277145 BK277120 BK277130 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140 BK279100...
  • Page 64 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel - 50 amps - Oxygen Plasma / Oxygen or Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277115 BK277122 BK277131 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140/BK277142...
  • Page 65 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 70 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100...
  • Page 66 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel - 100 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK277283 BK279100...
  • Page 67 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 150 Amps - Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151/BK277152 BK277139 BK279100...
  • Page 68 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 30 Amps - Air Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode BK277144 BK277121 BK277137 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277110 BK277138 BK279100...
  • Page 69 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 50 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277149 BK277123 BK277137 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277110 BK277142 BK279100...
  • Page 70 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 70 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen) This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode...
  • Page 71 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 70 Amps - Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 Outer Cap...
  • Page 72 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 100 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen) This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode...
  • Page 73 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 Outer Cap...
  • Page 74 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 150 Amps - H17 Plasma / Nitrogen Shield Copper Electrode (H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen) This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode...
  • Page 75 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 Outer Cap...
  • Page 76 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 30 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277145 BK277120 BK277130 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277140 BK279100 Imperial*...
  • Page 77 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum - 50 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277150 BK277122 BK277131 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial*...
  • Page 78 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 70 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277150 BK277125 BK277131 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277153 BK277142 BK279100 Imperial*...
  • Page 79 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum - 100 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277286 BK277284 BK277282 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK277283 BK279100 Imperial*...
  • Page 80 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 150 Amps - Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode BK277117 BK277293 BK277292 Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK277139 BK279100 Imperial*...
  • Page 81 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Mild Steel - 100 Amps - Oxygen Plasma / Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 (brown o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK279483...
  • Page 82 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Mild Steel - 150 Amps - Oxygen Plasma / Air Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 (green o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151/BK277152 BK279439...
  • Page 83 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Stainless Steel - 100 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 (brown o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK279483...
  • Page 84 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Stainless Steel - 150 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 (green o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK279439...
  • Page 85 Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts Aluminum - 100 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277286 BK279484 BK279410 (brown o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277151 BK279483...
  • Page 86 Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual Aluminum - 150 Amps - Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode BK277117 BK279493 BK279420 (green o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head BK284150 BK277152 BK279439...

  • Page 87: Section 6: Maintenance And Troubleshooting

    Spirit II User’s Manual Section 6: Maintenance &Troubleshooting Section 6: Maintenance & Troubleshooting WARNING: Only qualified maintenance personnel should perform maintenance on the Spirit system. The system utilizes potentially fatal A.C. and D.C. voltages. All maintenance should be performed with safety in mind. Use extreme caution when working near the power conversion module (i.e., chopper).
  • Page 88 Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Manual Gas Console (MGC) 1. Remove the cover of the manual gas console. Using clean, dry, compressed air, blow out all accumulated dust inside the unit. In an excessively dirty environment, blow out the unit on a weekly basis. 2.
  • Page 89 Spirit II User’s Manual Section 6: Maintenance &Troubleshooting Impulse Start Console (ISC) 1. Open the cover (door) of the impulse start console and verify that all leads and hoses are tightened securely. Only tighten the fittings enough to make a water or gas seal.

  • Page 90: Replacing The Torch Coolant And Filter

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

  • Page 91: Microprocessor (Dsp) Status Indicators

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

  • Page 92: Microprocessor (Dsp) Sequence Of Operation

    Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Microprocessor (DSP) Sequence of Operation The following DSP Indicators should illuminate after primary power is applied:  D77 3.3V Supply  D78 1.8V Supply  D50 ISC (Door)  D33 Coolant Level ...

  • Page 93: Error Codes

    Spirit II User’s Manual Section 6: Maintenance &Troubleshooting Error Codes The following is a comprehensive list of error codes for the Spirit system. When the system uses a Manual Gas Console, only the numeric error code is displayed. When an Automatic Gas Console is used, the text description is also displayed.
  • Page 94 Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Gas Console Code Short Description Long Description 20100 Plasma Adjust Could not adjust Plasma Gas 20110 Shield Adjust Could not adjust Shield Gas 20120 Preflow Adjust Could not adjust Preflow Gas 20130 Postflow Adjust Could not adjust Postflow Gas 20140...

  • Page 95: General Troubleshooting

    Spirit II User’s Manual Section 6: Maintenance &Troubleshooting General Troubleshooting The following contains general troubleshooting guidelines for the Spirit system. Please contact KALIBURN technical support for any issues not covered in this section. Before any tests are performed, make sure that all system fuses are good; remove top cover of power supply to check these fuses.
  • Page 96 Section 6: Maintenance &Troubleshooting Spirit II User’s Manual Problem Possible Cause Primary power has been 1. Check power/communications CAN cable applied to the system, but connection on back of manual gas console. the manual gas console 2. Check for blown DIN rail fuse. screen is blank 3.

  • Page 97: Chopper Test Procedure

    Spirit II User’s Manual Section 6: Maintenance &Troubleshooting Chopper Test Procedure WARNING: Only qualified maintenance personnel should perform the chopper test procedure. The system utilizes potentially fatal A.C. and D.C. voltages. All maintenance should be performed with safety in mind. Use extreme caution when working near the power conversion module (i.e., chopper).
  • Page 98 Section 6: Maintenance &Troubleshooting Spirit II User’s Manual 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 TABLE 1 for the proper three phase AC voltage. Note that the system will only energize for approximately two seconds each time a start signal is applied.
  • Page 99 Spirit II User’s Manual Section 6: Maintenance &Troubleshooting 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.
  • Page 100 Section 6: Maintenance &Troubleshooting Spirit II User’s Manual BLANK This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 6-14...

  • Page 101: Power Supply (Bk300211 - Bk300219)

    Spirit II User’s Manual Section 7: Parts List Section 7: Parts List Power Supply (BK300211 - BK300219) Right Side View Item Part Number Quantity Description BK707155 L1 Inductor BK706409 T2 Control Transformer, 200-480 V / 60 Hz BK706410 T2 Control Transformer, 600 V / 60 Hz BK706405 T1 Main Transformer, 200-480 V / 60 Hz / 3Ø...
  • Page 102 Section 7: Parts List Spirit II User’s Manual Power Supply (BK300211 - BK300219) Left Side View Item Part Number Quantity Description BK300101 Printed Circuit Board (PCB), Microprocessor (DSP) BK300112 Printed Circuit Board (PCB), A.C. Detect BK708118 CR3/PAR Relay BK705011 PAT IGBT BK702075 PAT IGBT Filter Capacitor BK300108...
  • Page 103 Spirit II User’s Manual Section 7: Parts List Power Supply (BK300211 - BK300219) Top View Item Part Number Quantity Description BK501163 Light Housing BK501164 Bulb BK501162 White Lens BK706409 T2 Control Transformer, 200-480 V / 60 Hz BK706410 T2 Control Transformer, 600 V / 60 Hz BK709359 F3 Fuse, 5A, Slow Blow BK709358...
  • Page 104 Section 7: Parts List Spirit II User’s Manual Power Supply (BK300211 - BK300219) Cooling Section View Item Part Number Quantity Description BK709105 Strain Relief BK200092 Coolant Reservoir, without Fittings or Cap BK500518 Coolant Reservoir Cap/Level Gauge BK300135 Coolant Level Switch BK505024 Coolant Temperature Switch BK500052...

  • Page 105: Manual Gas Console (Bk300600)

    Spirit II User’s Manual Section 7: Parts List Manual Gas Console (BK300600) Right Side View Item Part Number Quantity Description BK300412 Power Supply, 24VDC, 8.3A BK300301 Printed Circuit Board (PCB), Gas Console DSP BK280030 Fan, 24VDC BK300602 Keypad BK300603 LCD Display BK708111 Switch, Pushbutton (OFF Button) BK280032...
  • Page 106 Section 7: Parts List Spirit II User’s Manual Manual Gas Console (BK300600) Left Side View Item Part Number Quantity Description BK300412 Power Supply, 24VDC, 8.3A BK300301 Printed Circuit Board (PCB), Gas Console DSP BK280030 Fan, 24VDC BK708111 Switch, Pushbutton (OFF Button) BK500562 Preflow Regulator, 0-60 PSI BK280032...

  • Page 107: Impulse Start Console (Bk300500)

    Spirit II User’s Manual Section 7: Parts List Impulse Start Console (BK300500) Item Part Number Quantity Description BK715051 Coolant Return Fitting (left hand) BK715050 Coolant Supply Fitting (right hand) BK715021 Coolant Supply Fitting (right hand) BK709001 4 Pin Receptacle BK708057 Door Interlock Switch BK500503 Cathode Manifold...

  • Page 108: Torch And Manifold Assemblies

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

  • Page 109: Shielded Torch Leads

    Spirit II User’s Manual Section 7: Parts List Shielded Torch Leads Part Number Length BK284304-XX Where -XX is the length in feet. Available in 5 foot increments up to 40 feet. CAN Communication Cable and Termination Plug Item Part Number Length CAN Termination Plug BK300408...

  • Page 110: Gas Hose Package With Mgc

    Section 7: Parts List Spirit II User’s Manual Gas Hose Package with MGC Part Number Length* BK300085-20 20 ft. (6.1m) BK300085-30 30 ft. (9.1m) BK300085-40 40 ft. (12.2m) BK300085-50 50 ft. (15.2m) BK300085-60 60 ft. (18.3m) *Custom lengths are available. Contact factory. ...

  • Page 111: Coolant And Power Leads

    Spirit II User’s Manual Section 7: Parts List Coolant and Power Leads Part Number Part Number Length (Non-CSA Systems) (CSA Systems) BK280306-XX BK288306-XX Where -XX is the length in feet. Available in 5 foot increments.      ...

  • Page 112: Oxygen Supply Gas Hose (Optional)

    Section 7: Parts List Spirit II User’s Manual Oxygen Supply Gas Hose (Optional) Part Number Length BK200362-25 25 ft. (7.6 m) BK200362-50 50 ft. (15.2 m) BLUE BLUE Nitrogen Supply Gas Hose (Optional) Part Number Length BK200365-25 25 ft. (7.6 m) BK200365-50 50 ft.

  • Page 113: Cii" Cable (For Optional External Inova)

    Spirit II User’s Manual Section 7: Parts List “CII” Cable (for Optional External Inova) Part Number Length BK300902-XX Where -XX is the length in feet. Available in 10 foot increments. STRAIN RELIEF BK709015 CABLE BK711001 PLUG BK709016 PLUG BK709364 STRAIN RELIEF BK709025 BK709365 PIN BK709018 SOCKET BK709365 PIN...

  • Page 114: Fii" Cable (For Optional Internal Inova)

    Section 7: Parts List Spirit II User’s Manual “FII” Cable (for Optional Internal Inova) Part Number Length BK300903-XX Where -XX is the length in feet. Available in 10 foot increments. CABLE BK711002 PLUG BK709364 PLUG BK709095 STRAIN RELIEF BK709025 STRAIN RELIEF BK709021 BK709018 SOCKET BK709365 PINS BK709018 SOCKET...

  • Page 115: Jii" Cable (For Optional Internal Inova)

    Spirit II User’s Manual Section 7: Parts List “JII” Cable (for Optional Internal Inova) Part Number Length BK300904-XX Where -XX is the length in feet. Available in 10 foot increments. STRAIN RELIEF BK709025 STRAIN RELIEF BK709021 PLUG BK709364 PLUG BK709020 CABLE BK711049 BK709365 PIN BK709018 SOCKET...

  • Page 116: Pcb Assemblies - Component Reference Locations

    Section 7: Parts List Spirit II User’s Manual PCB Assemblies – Component Reference Locations Power Supply, Microprocessor DSP (BK300101) – Quadrant 1 PCB Quadrant Map U37 - RHF U34 – Impulse Start U32 - Marking U31 – Postflow U30 - Vent U29 - Shield This information is subject to the controls of the Export Administration Regulations [EAR].
  • Page 117 Spirit II User’s Manual Section 7: Parts List Power Supply, Microprocessor DSP (BK300101) – Quadrant 2 PCB Quadrant Map U28 - Plasma U27 - Preflow U19 – Solenoid (not used) U21 – Mtr / Sol U22 - PAR U24 - Surge U26 - Fan U23 - Con This information is subject to the controls of the Export Administration Regulations [EAR].
  • Page 118 Section 7: Parts List Spirit II User’s Manual Power Supply, Microprocessor DSP (BK300101) – Quadrant 3 PCB Quadrant Map This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-18...
  • Page 119 Spirit II User’s Manual Section 7: Parts List Power Supply, Microprocessor DSP (BK300101) – Quadrant 4 PCB Quadrant Map J4-1 J4-2 This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
  • Page 120 Section 7: Parts List Spirit II User’s Manual Power Supply, Output (BK300108) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-20...
  • Page 121 Spirit II User’s Manual Section 7: Parts List Power Supply, A.C. Detect (BK300112) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-21...
  • Page 122 Section 7: Parts List Spirit II User’s Manual Gas Supply, Microprocessor DSP (BK300301) – Quadrant 1 PCB Quadrant Map This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-22...
  • Page 123 Spirit II User’s Manual Section 7: Parts List Gas Supply, Microprocessor DSP (BK300301) – Quadrant 2 PCB Quadrant Map This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-23...
  • Page 124 Section 7: Parts List Spirit II User’s Manual Gas Supply, Microprocessor DSP (BK300301) – Quadrant 3 PCB Quadrant Map This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-24...
  • Page 125 Spirit II User’s Manual Section 7: Parts List Gas Supply, Microprocessor DSP (BK300301) – Quadrant 4 PCB Quadrant Map This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-25...
  • Page 126 Section 7: Parts List Spirit II User’s Manual Chopper, Gate Driver (BK300106) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. 7-26...

  • Page 127: Section 8: Internal Inova Console Option

    Spirit II User’s Manual Section 8: Internal Inova Console Option Section 8: Internal Inova Console Option Overview This optional Inova system is designed to provide arc voltage control to any plasma cutting system, however, combining it with the Spirit II provides the added convenience of having Inova console built directly into the plasma power supply.

  • Page 128: Grounding

    Section 8: Internal Inova Console Option Spirit II User’s Manual 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 mm ) wire.

  • Page 129: Parts List

    Spirit II User’s Manual Section 8: Internal Inova Console Option Parts List Item Part Number Quantity Description BK110200 Printed Circuit Board (PCB), Microprocessor BK110705 Printed Circuit Board (PCB), Power Distribution BK110900 Printed Circuit Board (PCB), H-Bridge BK706003 Transformer BK709360 F7 Fuse, 6.3A BK709370 F8 Fuse, 3A BK301200...
  • Page 130 Section 8: Internal Inova Console Option Spirit II User’s Manual Location in Spirit II 150 & 275 - Continued This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
  • Page 131 Spirit II User’s Manual Section 8: Internal Inova Console Option Location in Spirit II 400 (pos A) (pos B) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
  • Page 132 Section 8: Internal Inova Console Option Spirit II User’s Manual Location in Spirit II 400 - Continued This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

  • Page 133: Appendix A: Electromagnetic Compatibility (Emc)

    Spirit II User’s Manual Appendix A: Electromagnetic Compatibility (EMC) Appendix A: Electromagnetic Compatibility (EMC) Background The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit plasma cutting systems are manufactured to comply with the European standard EN 60974-10 (Electromagnetic compatibility (EMC) – Product standard for arc welding equipment). The system has been tested in accordance with CISPR 11, EMC classification –...

  • Page 134: Assessment Of Area

    Appendix A: Electromagnetic Compatibility (EMC) Spirit II User’s Manual Assessment of Area Before installing plasma cutting equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the plasma cutting equipment;...
  • Page 135 Spirit II User’s Manual Appendix A: Electromagnetic Compatibility (EMC) Equipotential Bonding Bonding of all metallic components in the plasma cutting installation and adjacent to it should be considered. However, metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time.
  • Page 136 Appendix A: Electromagnetic Compatibility (EMC) Spirit II User’s Manual BLANK This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

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