Kaliburn Spirit200a User manual

High Current Density Plasma Cutting System
with
Automatic Gas Console
User’s Manual - Part Number 718086 Rev J
10/15/2012
J
REVISION
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.

Spirit200a User’s Manual Rev J
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
REVISION HISTORY
Rev
ECO#
Author
Date
Description of Change
A
-
As released
B
-
05/08/07
Changed location of coolant level switch
C - 05/23//07
Changed 30A mild steel preflow pressure from 30 to 35
psi
D - 07/02/07
•Changed cutting charts to have separate metric and
imperial versions.
•
Changed 575V control xfmr part number to 706205
E - 10/15/07
Added PAR relay in series with surge injection circuit to
schematic and parts list
F - 10/21/09
Section Updates:
•Contents
•Section 2
•Section 3
•Section 7
•
Section 8
G - 10/25/10
Section Updates:
•Contents
•Section 3
•Section 4
•Section 5
•Section 6
•Section 7
•Section 8
•Appendix A
•
Appendix B - deleted
H 05/10/2011
Section Updates:
•Max Input Pressure changed to 145 psi in: 2-4, 3-1,
3-13, 3-14, 8-8
•AGC fan added to drawings in: 3-1, 3-13
•
Postflow label changed in 8-9
I 08/01/2012
•Section1, added pointers to Section 7.
•Section 4, corrected cut chart for
Aluminum/70amp/Air Plasma/Nitro Shield.
•Section 7, added chopper warning.
•Section 8, updated drawing of power supply
microprocessor board.
J 10/15/2012
•Added Quick-Disconnect Torch information
throughout manual.
•
Section 7, defective flow switch (25 blinks).
This documentation may not be copied, photocopied, reproduced, translated, or reduced to
any electronic medium or machine-readable format without explicit written permission from
Kaliburn.
4130 Carolina Commerce Parkway
Ladson, SC 29456 USA
[phone] - Phone
[phone] - Fax
www.kaliburn.net

Spirit200a User’s Manual Rev J
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
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
equipment, for a period of one (1) year for the Spirit200a torch and leads and three (3)
years for the Spirit200a power supply and automatic gas console. This product is
intended for commercial use and is not intended for personal, family, or household
purposes. There are no warranties that extend beyond the description on the face
hereof. All other warranties, either expressed or implied, including any implied
warranty of merchantability or fitness for any particular purpose, are expressly
excluded.
If this product or any component thereof is determined to be defective in manufacture,
KALIBURN will repair or replace the defective component or product. The buyer’s
remedies are limited to the return of the product for repair or replacement of any non-
conforming product or part at the sole discretion of KALIBURN. No freight charges of
any kind are covered under this warranty. All returned goods shall be at the buyer’s risk
and expense. Beyond this remedy, KALIBURN will not be responsible for any special,
incidental or consequential damages or injury to the person or property of anyone by
reason of any defect in any equipment sold hereunder.
This warranty will be considered void if torches or
torch consumables manufactured by anyone other
than KALIBURN are incorporated into this product.
RETURNED GOODS PROCEDURE
KALIBURN utilizes a returned goods procedure that must be followed before returning
any items for repair, replacement, or restocking. This means that a returned goods
authorization number must be obtained prior to shipment to KALIBURN. It will be
necessary for the customer to provide a description, along with the stock number and
serial number, if applicable, of the item to be returned. In no case will KALIBURN
accept a returned shipment without the proper returned goods authorization number.
For shipments inside the U.S., parts must be returned to KALIBURN within 30 days of
the invoice date to be considered for credit. For shipments outside the U.S., parts must
be returned within 60 days of the invoice date to be considered for credit.
ELECTROMAGNETIC COMPATIBILITY (EMC)
The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit200a plasma cutting systems
are manufactured to comply with the European standard EN 60974-10 (Electromagnetic
compatibility (EMC) – Product standard for arc welding equipment). Information about
the EMC standard EN 60974-10 can be found in Appendix A.

Spirit200a User’s Manual Rev J
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
TABLE OF CONTENTS
Section 1 Safety
General Precautions ............................................................................................... 1-1
Ultraviolet Radiation Protection ...............................................................................1-1
Noise Protection ......................................................................................................1-1
Toxic Fume Prevention ........................................................................................... 1-1
Electric Shock Prevention ....................................................................................... 1-2
Fire Prevention ........................................................................................................1-3
Explosion Prevention .............................................................................................. 1-3
Health Support Equipment ......................................................................................1-4
Safety Standards Booklet Index ..............................................................................1-5
Section 2 Specifications
System Description ................................................................................................. 2-1
System Components ...............................................................................................2-2
Power Supply Specifications ...................................................................................2-3
Automatic Gas Console Specifications ................................................................... 2-5
Remote High Frequency Console Specifications ....................................................2-6
Torch Specifications ................................................................................................2-7
5-Gang Manifold Specifications .............................................................................. 2-8
Airborne Noise Emissions .......................................................................................2-9
Section 3 Installation
Initial Inspection ...................................................................................................... 3-1
System Interconnection .......................................................................................... 3-1
Power Supply Installation ........................................................................................3-2
Remote High Frequency Installation .......................................................................3-2
5-Gang Manifold Installation ................................................................................... 3-2
Torch Installation .....................................................................................................3-2
Primary Power Connection ..................................................................................... 3-3
Power Supply Output Connections ......................................................................... 3-5
RHF Console Ground Connection .......................................................................... 3-6
Torch Leads to RHF Console Connections ............................................................ 3-8
Torch Leads to Torch Base Connections.................................................................3-10
Torch Gas Connections .......................................................................................... 3-11
Torch Head Connection .......................................................................................... 3-14
Automatic Gas Console Input Connections ............................................................ 3-15
CNC Machine Interface Connections ......................................................................3-16
Torch Coolant Requirements .................................................................................. 3-18
Initial Filling of the Torch Coolant Reservoir............................................................ 3-19

Spirit200a User’s Manual Rev J
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
Section 4 Operation
Power Supply Front Panel Controls ........................................................................4-1
Automatic Gas Console Keypad ............................................................................. 4-3
Automatic Gas Console Help Prompt ..................................................................... 4-4
Automatic Gas Console Status Screen ...................................................................4-5
Setting up a Cut or Mark ......................................................................................... 4-6
Torch Consumable Selection ..................................................................................4-11
Installing or Removing Torch Consumables............................................................ 4-18
Making a Cut or Mark ..............................................................................................4-19
Piercing Thick Materials…………………………………………………………..…….. 4-20
Cut Quality .............................................................................................................. 4-21
Changing Consumable Parts .................................................................................. 4-22
Consumable Life ..................................................................................................... 4-23
Cutting Charts ......................................................................................................... 4-24
Section 5 Automatic Gas Console Advanced Functions
Altering the Current Set Point ................................................................................. 5-1
Setting the Pierce Time .......................................................................................... 5-2
Altering Gas Types ................................................................................................. 5-3
Altering Gas Pressures ........................................................................................... 5-4
Altering Arc Voltage Control and X/Y Machine Parameters ....................................5-5
Saving a User Created Cutting or Marking Condition ............................................. 5-6
Gas Purge ...............................................................................................................5-6
Maintenance Screen ............................................................................................... 5-7
Viewing Messages .................................................................................................. 5-8
Viewing Cut Errors .................................................................................................. 5-9
Pressure Diagnostics .............................................................................................. 5-12
Restoring Factory Default Cutting or Marking Conditions .......................................5-13
Measurement System ............................................................................................. 5-14
Communication Node ............................................................................................. 5-15
Inova Parameter Transmit ...................................................................................... 5-16
Viewing Serial Communication ............................................................................... 5-17
Configuring Hydrogen Cutting .................................................................................5-18
Setting an Arc Off Delay ......................................................................................... 5-19
Switching Between Cutting and Marking ................................................................ 5-20
Software Updates ................................................................................................... 5-21
Section 6 Serial Communication
Initializing the Spirit System .................................................................................... 6-1
Transmitting Parameters to the Spirit System ........................................................ 6-1
Communication Error Checking .............................................................................. 6-2
Default Cutting Parameters .....................................................................................6-3
Troubleshooting Serial Communication .................................................................. 6-3
RS-422 Serial Commands ...................................................................................... 6-4

Spirit200a User’s Manual Rev J
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
Section 7 Maintenance and Troubleshooting
Routine Maintenance .............................................................................................. 7-1
Replacing the Torch Coolant .................................................................................. 7-4
Microprocessor Status LED’s ..................................................................................7-5
Microprocessor Sequence of Operation ................................................................. 7-6
Troubleshooting Using the Control Panel Status LED’s ......................................... 7-7
Troubleshooting Using the Automatic Gas Console Messages Screen ................. 7-8
General Troubleshooting ........................................................................................ 7-9
Chopper Test Procedure .........................................................................................7-12
Section 8 Parts List
Power Supply ..........................................................................................................8-1
Automatic Gas Console .......................................................................................... 8-7
Remote High Frequency Console ...........................................................................8-10
Torch and Manifold Assemblies ..............................................................................8-11
Shielded Torch Leads ............................................................................................. 8-12
Gas Hose Package ................................................................................................. 8-13
Coolant and Power Leads .......................................................................................8-14
Work Ground Cable ................................................................................................ 8-15
Oxygen Supply Gas Hose (Optional) ......................................................................8-16
Nitrogen Supply Gas Hose (Optional) .....................................................................8-16
Air Supply Gas Hose (Optional) ..............................................................................8-16
H17 Supply Gas Hose (Optional) ............................................................................8-16
Power Supply Microprocessor P.C. Board ..............................................................8-17
A.C. Detect P.C. Board ........................................................................................... 8-18
Relay P.C. Board .................................................................................................... 8-19
Power Supply I/O P.C. Board ................................................................................. 8-20
Automatic Gas Console I/O P.C. Board ..................................................................8-21
Consumable Spare Parts Kit ...................................................................................8-22
Appendix AElectromagnetic Compatibility (EMC)
Background .............................................................................................................A-1
Installation and Use ................................................................................................ A-1
Assessment of Area ................................................................................................A-2
Methods of Reducing Emissions .............................................................................A-2

Safety Spirit200a User’s Manual Rev J
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-1
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.
Installation, operation, and repairs made to the Spirit200a system should
only be performed by qualified personnel. The Spirit system makes use of
both A.C. and D.C. circuitry for operation. Fatal shock hazard does
exist. Exercise 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 provides protection up to 400 amperes. All
exposed skin areas should be covered with flame-retardant clothing. The
cutting area should also be prepared in such a way that ultraviolet light
does not reflect. Walls and other surfaces should be painted with dark
colors to reduce reflected light. Protective screens or curtains should be
installed to protect additional workers in the area from ultraviolet radiation.
Noise Protection
The Spirit200a system generates high noise levels while cutting.
Depending on the size of the cutting area, distance from the cutting torch,
and arc current cutting level, acceptable noise levels may be exceeded.
Proper ear protection should be used as defined by local or national
codes. See Section 2 for noise emission levels.
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. Also, some solvents decompose and

Safety Spirit200a User’s Manual Rev J
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-2
form harmful gases when exposed to ultraviolet radiation. These solvents
should be removed from the area prior to cutting.
Galvanized metal can produce harmful gases during the cutting process.
Ensure proper ventilation and use breathing equipment when cutting these
materials.
Certain metals coated with or containing lead, cadmium, zinc, beryllium,
and mercury produce harmful toxins. Do not cut these metals unless all
people subjected to the fumes wear proper air breathing equipment.
Electric Shock Prevention
The Spirit200a system uses high open circuit voltages that can be fatal.
Extreme care should be used when operating or performing maintenance
on the system. Only qualified personnel should service the Spirit system.
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 the operator. In addition, it should be sized according
to local and national electrical codes. Inspect the primary power cord
frequently. Never operate the Spirit system if the power cord is
damaged in any way.
•Make sure the primary power ground wire is connected to the input
power ground stud on the Spirit power supply. Make sure the
connection is securely tightened.
•Make sure the positive output (work ground) of the Spirit power supply
is connected to a bare metal area on the cutting table. A driven ground
rod should be placed no further than five feet from this connection.
Make sure this ground point on the cutting table is used as the star
ground point for all other ground connections.
•Inspect the torch leads frequently. Never use the system if the leads
are damaged in any way.
•Do not stand in wet, damp areas when operating or performing
maintenance on the system.
•Wear insulated gloves and shoes while operating or performing
maintenance on the system.
•Make sure the Spirit system is switched off at the wall disconnect
before servicing the power supply or torch.
•Never change torch consumable parts unless the Spirit system is
switched off at the wall disconnect.

Safety Spirit200a User’s Manual Rev J
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-3
•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.
•Never bypass the safety interlock devices.
•Before removing any of the Spirit covers, switch the system off at the
wall disconnect. Wait at least five (5) minutes before removing any
cover. This will give the capacitors inside the unit time to discharge.
See Section 7 for additional safety precautions.
•Never operate the Spirit system without all of the covers in place. See
Section 7 for additional safety precautions.
•Preventive maintenance should be performed daily to avoid possible
safety hazards.
Fire Prevention
When using the Spirit200a system, it is necessary to exercise good
judgment. While cutting, the arc produces sparks that could cause a fire if
they fall on flammable materials. Make sure that all flammable materials
are a suitable distance away from the cutting area. 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 flammable materials. Make sure that fire extinguishers are
readily accessible in the cutting area.
Make sure that the cutting area is properly ventilated when using oxygen
as a cutting gas.
Explosion Prevention
The Spirit200a system uses compressed gases. Use proper techniques
when handling compressed gas cylinders and other compressed gas
equipment. Observe the following guidelines to protect against explosion:
•Never operate the Spirit system in the presence of explosive gases or
other explosive materials.
•Never cut pressurized cylinders or any closed container.
•When using a water table and cutting aluminum under water or with
water touching the underside of the aluminum plate, hydrogen gas is
produced. This hydrogen gas may collect under the plate and explode
during the cutting process. Make sure the water table is properly
aerated to help prevent the accumulation of hydrogen gas.
•Handle all gas cylinders in accordance with safety standards published
by the U.S. Compressed Gas Association (CGA), American Welding
Society (AWS), Canadian Standards Association (CSA), or other local
or national codes.

Safety Spirit200a User’s Manual Rev J
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-4
•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.
•If a compressed gas cylinder is not being used, replace the protective
valve cover.
•Never attempt to repair 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 than which it is intended.
•Never use a pressure regulator for any gas other than which it is
intended.
•Never use a pressure regulator that is leaking or has other signs of
physical damage.
•Never use oxygen hoses and pressure regulators for any gas other
than oxygen.
•Never use any gas hose that is leaking or has other signs of physical
damage.
Health Support Equipment
The Spirit200a system creates electric and magnetic fields that may
interfere with certain types of health support equipment, such as
pacemakers. Any person who uses a pacemaker or similar item should
consult a doctor before operating, observing, maintaining, or servicing the
Spirit system. Observe the following guidelines to minimize exposure to
these electric and magnetic fields:
•Stay as far away from the Spirit power supply, torch, torch leads, and
remote high frequency console as possible.
•Route the torch leads as close as possible to the work ground cable.
•Never place your body between the torch leads and work ground
cable. Keep the work ground cable and the torch leads on the same
side of your body.
•Never stand in the center of a coiled up set of torch leads or work
ground cable.