Lincoln Electric BURNY KALIBURN Spirit II 150 User manual

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.

Prologue Spirit II User’s Manual
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.
ii
Revision History
Rev
ECO#
Author
Date
Description of Change
A - CAD 02/04/2013 Initial Release
B LAD0202 CAD 06/07/2013
Added 100A/150A silver electrodes, replaced RHF with
ISC, corrected system interconnect diagrams, changed
rated inlet gas pressure to 115 psi, added 100 psi minimum
to inlet gas pressure.
C LAD0217 CAD 08/06/2013
Deionization filter cartridge (500510) replaced sediment
filter (300152). Parts list updated.
Expanded notes on System Interconnection diagrams to
clarify cabling requirements for various configurations.
D LAD0228
LAD0223 CAD 08/28/2013
Corrected contact ratings on page 3-19.
Added pinouts to CII, FII, JII cables in Parts List.
Corrected part numbers for coolant/power leads and work
ground in Parts List.
E LADC0260 CAD 03/18/2014
Inductor (707150) replaced by (707155). 10” fan (500516)
replaced by (284031). Added notes about torch handle
vent hole. Updated Chopper Test Procedure.
F LAD0264 CAD 03/31/2014
Added “BK” prefix to all part numbers. Added PCB Outline
Dwgs and corrected electrode tool in Part List. Corrected
Remote On/Off info in Installation section.
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.
FASTON is a trademark of the TE Connectivity Ltd family of companies.
Other logos, products and company names mentioned herein
may be trademarks of their respective owners.
© Copyright 2013-2014 Lincoln Global, Inc.
Kaliburn Inc.
a Lincoln Electric Company
4130 Carolina Commerce Parkway
Ladson, SC 29456 USA

Spirit II User’s Manual Prologue
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.
iii
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................................................................................1-4
Safety Standards Booklet Index........................................................................1-5
Section 2: Specifications
System Description ...........................................................................................2-1
System Components.........................................................................................2-2
Power Supply Specifications.............................................................................2-3
Torch Coolant Specifications.............................................................................2-4
Manual Gas Console (MGC) Specifications......................................................2-5
Gas Supply Requirements ................................................................................2-6
Impulse Start Console (ISC) Specifications.......................................................2-7
Torch and 2-Gang Manifold Specifications........................................................2-8
5-Gang Manifold Specifications.........................................................................2-9
Airborne Noise Emissions.................................................................................2-10
Section 3: Installation
Initial Inspection ................................................................................................3-1
Component Placement......................................................................................3-1
System Interconnection.....................................................................................3-2
Power Supply Primary Power Connections.......................................................3-5
Power Supply Output Connections ...................................................................3-7
ISC Control Cable and ISC Ground Connections..............................................3-9
Cooling System Connections............................................................................3-9
Torch Leads to Impulse Start Console Connections.........................................3-11
Torch Leads to Torch Base Connections..........................................................3-13
Torch Gas Connections.....................................................................................3-14
Gas Supply Connections...................................................................................3-17
CAN Communication Connections....................................................................3-18
CNC Machine Interface Connections................................................................3-19
Filling the Cooling System.................................................................................3-20

Prologue Spirit II User’s Manual
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.
iv
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....................................................................................4-5
Moving Pierces and Edge Starts.......................................................................4-5
Cut Quality ........................................................................................................4-6
Checking Errors ................................................................................................4-7
Checking the Version and Serial Number .........................................................4-7
Changing the Language....................................................................................4-8
Adjusting the Screen Contrast...........................................................................4-8
Section 5: Torch Consumables and Cut Charts
Installing / Removing the Torch Head...............................................................5-1
Installing / Replacing Consumables..................................................................5-2
Maximizing Consumable Life ............................................................................5-3
Inspecting for Damage......................................................................................5-4
Selecting Consumables.....................................................................................5-5
Cutting Charts...................................................................................................5-12
Section 6: Maintenance and Troubleshooting
Routine Maintenance ........................................................................................6-1
Replacing the Torch Coolant and Filter.............................................................6-4
Microprocessor (DSP) Status Indicators ...........................................................6-5
Microprocessor (DSP) Sequence of Operation.................................................6-5
Error Codes.......................................................................................................6-7
General Troubleshooting...................................................................................6-9
Chopper Test Procedure...................................................................................6-11

Spirit II User’s Manual Prologue
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.
v
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....................................................................................7-9
Gas Hose Package with MGC...........................................................................7-10
Coolant and Power Leads.................................................................................7-11
Work Ground Lead............................................................................................7-11
Oxygen Supply Gas Hose (Optional)................................................................7-12
Nitrogen Supply Gas Hose (Optional)...............................................................7-12
Air Supply Gas Hose (Optional)........................................................................7-12
H17 Supply Gas Hose (Optional)......................................................................7-12
"CII" Cable (for Optional External Inova)...........................................................7-13
"FII" Cable (for Optional Internal Inova).............................................................7-14
"JII" Cable (for Optional Internal Inova).............................................................7-15
PCB Assemblies – Component Reference Locations.......................................7-16
Section 8: Internal Inova Console Option
Overview...........................................................................................................8-1
Plug Identification..............................................................................................8-1
Unique Interconnect Cables..............................................................................8-1
Grounding .........................................................................................................8-2
Parts List...........................................................................................................8-3
Appendix A: Electromagnetic Compatibility (EMC)
Background.......................................................................................................A-1
Installation and Use...........................................................................................A-1
Assessment of Area..........................................................................................A-2
Methods of Reducing Emissions.......................................................................A-2

Prologue Spirit II User’s Manual
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.
vi
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. This warranty does not apply to torch consumable parts.
The warranty period starts three (3) months after the product ships from the factory.
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 express limited
warranty set forth immediately above. All other warranties, whether expressed, implied,
statutory or made herein or in any other communication, including any implied warranty
of merchantability, fitness for any particular purpose or non-infringement, are expressly
excluded.
This warranty will be considered void if the Spirit II system is operated with non-genuine
KALIBURN torch consumables, or if the equipment has been subjected to improper
installation, improper care or abnormal operation.
If this product or any component thereof is determined to be defective in materials or
workmanship, 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 defective 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. In no event will KALIBURN 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.
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 part 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 Spirit II 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.

Spirit II User’s Manual Section 1: Safety
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 Spirit system should only be performed
by qualified personnel. The 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 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.

Section 1: Safety Spirit II User’s Manual
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
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 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 Spirit 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 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 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 power supply. Make sure the connection is securely tightened.
•Make sure the positive output (work ground) of the 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 system is switched off at the wall disconnect before servicing the
power supply or torch.

Spirit II User’s Manual Section 1: Safety
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
•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.
•Never bypass the safety interlock devices.
•Before removing any of the 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 6 for additional safety
precautions.
•Never operate the system without all of the covers in place. See Section 6 for
additional safety precautions.
•Preventive maintenance should be performed daily to avoid possible safety hazards.
Fire Prevention
When using the Spirit 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 Spirit 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 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.

Section 1: Safety Spirit II User’s Manual
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 Spirit 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 system. Observe the following guidelines to minimize
exposure to these electric and magnetic fields:
•Stay as far away from the power supply, torch, torch leads, and impulse start
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.