Lincoln Electric 718118 User Manual
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User's Manual
Spirit II 400
High Current Density Plasma Cutting System
with Manual Gas Console (MGC)
718118 Rev D
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
Rev
ECO#
Author
Date
Description of Change
Added 100A/150A silver electrodes, replaced RHF with ISC,
pressure.
clarify cabling requirements for various configurations.
Corrected contact ratings on page 3-19.
Added pinouts to CII, FII, JII cables in Parts List.
Revision History
A - CAD 02/04/2013 Initial Release
B LAD0202 CAD 06/07/2013
C LAD0217 CAD 08/06/2013
D LAD0228 CAD 08/28/2013
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 Kaliburn Inc.
4130 Carolina Commerce Parkway
corrected system interconnect diagrams, changed rated inlet
gas pressure to 115 psi, added 100 psi minimum to inlet gas
Deionization filter cartridge (500510) replaced sediment filter
(300152). Parts list updated.
Expanded notes on System Interconnection diagrams to
a Lincoln Electric Company
Ladson, SC 29456 USA
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ii
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 ................................................................................ 1-4
Safety Standards Booklet Index ........................................................................ 1-5
Section 2: Specifications
System Description ........................................................................................... 2-1
System Components ......................................................................................... 2-2
Power Supply Specifications ............................................................................. 2-3
Cooling System Specifications .......................................................................... 2-4
Torch Coolant Specifications ............................................................................. 2-5
Manual Gas Console (MGC) Specifications ...................................................... 2-6
Gas Supply Requirements ................................................................................ 2-7
Impulse Start Console (ISC) Specifications ....................................................... 2-8
Torch and 2-Gang Manifold Specifications ........................................................ 2-9
5-Gang Manifold Specifications ......................................................................... 2-10
Airborne Noise Emissions ................................................................................. 2-11
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
Initial Filling of the Cooling System ................................................................... 3-20
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iii
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 .................................................................................... 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 Cutting 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
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iv
Spirit II User’s Manual Prologue
Section 7: Parts List
Power Supply (300232 - 300239) ...................................................................... 7-1
Cooling System (300275) .................................................................................. 7-4
Manual Gas Console (300600) ......................................................................... 7-5
Impulse Start Console (300500) ........................................................................ 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
Cooling System Control Cable .......................................................................... 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
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
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v
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. 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.
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vi
Spirit II User’s Manual Section 1: Safety
Ultraviolet Radiation Protection
Noise Protection
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.
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.
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.
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 Spirit II User’s Manual
Toxic Fume Prevention
Electric Shock 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.
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.
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
Spirit II User’s Manual Section 1: Safety
Fire Prevention
Explosion Prevention
• 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.
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.
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.
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
Section 1: Safety Spirit II User’s Manual
Health Support Equipment
• 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.
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.
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
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.
2. AWS Standard C5.2, Recommended Practices for Plasma Arc Cutting, obtainable
from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
3. AWS Standard FSW, Fire Safety in Welding and Cutting, obtainable from the
American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
4. AWS Standard F4.1, Recommended Safe Practices for Preparation for Welding and
Cutting of Containers and Piping, obtainable from the American Welding Society,
550 NW LeJeune Road, Miami, FL 33126.
5. AWS Standard ULR, Ultraviolet Reflectance of Paint, obtainable from the American
Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
6. AWS / ANSI Standard Z49.1, Safety in Welding, Cutting, and Allied Processes,
obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL
33126.
7. ANSI Standard Z41.1, Standard For Men’s Safety-Toe Footwear, obtainable from
the American National Standards Institute, 11 West 42nd Street, New York, NY
10036.
8. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding
Processes, obtainable from the American National Standards Institute, 11 West
42nd Street, New York, NY 10036.
9. ANSI Standard Z87.1, Safe Practices For Occupation and Educational Eye and
Face Protection, obtainable from the American National Standards Institute, 11
West 42nd Street, New York, NY 10036.
10. ANSI Standard Z88.2, Respiratory Protection, obtainable from the American
National Standards Institute, 11 West 42nd Street, New York, NY 10036.
11. OSHA Standard 29CFR 1910.252, Safety and Health Standards, obtainable from
the U.S. Government Printing Office, Washington, D.C. 20402.
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.
1-5
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.
14. NFPA Standard 70, National Electrical Code, obtainable from the National Fire
Protection Association, 1 Batterymarch Park, Quincy, MA 02269.
15. CGA booklet P-1, Safe Handling of Compressed Gases in Containers, obtainable
from the Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004,
Arlington, VA 22202.
16. CGA booklet P-14, Accident Prevention in Oxygen-Rich and Oxygen-Deficient
Atmospheres, obtainable from the Compressed Gas Association, 1725 Jefferson
Davis Highway, Suite 1004, Arlington, VA 22202.
17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from the
Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004,
Arlington, VA 22202.
18. CSA Standard W117.2, Safety in Welding, Cutting, and Allied Processes,
obtainable from Canadian Standards Association, 178 Rexdale Boulevard, Toronto,
Ontario M9W lR3, Canada.
19. Canadian Electrical Code Part 1, Safety Standard for Electrical Installations,
obtainable from the Canadian Standards Association, 178 Rexdale Boulevard,
Toronto, Ontario M9W 1R3, Canada.
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-6
Spirit II User’s Manual Section 2: Specifications
Section 2: Specifications
System Description
The Spirit II 400 is a 400 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 3" thick and stainless steel up to 1-1/2” thick.
The system contains a manually controlled gas console, which also provides the
primary interface to the entire Spirit system.
For cutting mild steel, the system uses oxygen for the plasma gas and either oxygen or
air for the shielding gas. When cutting stainless steel or other non-ferrous materials, air
or H17 (17.5% hydrogen, 32.5% argon, 50% nitrogen) is used for the plasma gas and
either air or nitrogen is used for the shielding gas. Oxygen and nitrogen are used for
the preflow and postflow gases.
The torch is water-cooled and consumables are machined to exacting dimensions and
checked with the latest computerized measuring systems. Nine nozzle sizes (30, 50,
70, 100, 150, 200, 260, 275, and 400 amps) are available to produce excellent cut
quality throughout the cutting range.
Each enclosure in the system is rated for IP21S sealing, which is intended for
indoor use only. The system is not suitable for use in rain or snow.
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-1
Section 2: Specifications Spirit II User’s Manual
System Components
The Spirit II 400 System consists of the following components:
Standard Components
• Power Supply
• Cooling System (includes torch coolant)
• Cooling System Control Cable
• Manual Gas Console
• CAN Cable
• CAN Termination Plug
• Impulse Start Console (ISC)
• ISC Control Cable
• ISC Ground Cable
• Torch and Handle Assembly
• Torch Lead Set
• 5-gang Manifold Assembly
• 5-gang Manifold Control Cable
• 2-gang Manifold Assembly
• 2-gang Manifold Control Cable
• 17 Inch Plasma Hose
• Coolant and Power Leads
• Gas Hose Package
• Work Ground Lead
• Spirit II User’s Manual
Optional Components
• Supply Gas Hoses
• Internal Inova Console
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-2
Spirit II User’s Manual Section 2: Specifications
Input Current at
Maximum Output
220 VAC, 3Ø, 60Hz
300232
262 amps
240 VAC, 3Ø, 60Hz
300233
240 amps
380 VAC, 3Ø, 50/60Hz
300234
152 amps
400 VAC, 3Ø, 50/60Hz
300235
144 amps
415 VAC, 3Ø, 50/60Hz
300236
140 amps
440 VAC, 3Ø, 50/60Hz
300237
131 amps
480 VAC, 3Ø, 60Hz
300238
120 amps
600 VAC, 3Ø, 60Hz
300239
96 amps
34.2" [869]
49.5" [1257]
Power Supply Specifications
Power Supply Description Part Number
Open Circuit Voltage ......................................... 370 VDC
Output Current (drooping characteristic) ........... 10 - 400 amps
Maximum Output Voltage ................................. 200 VDC
Duty Cycle ........................................................ 100% @ 80 kW
Maximum Ambient Temperature ....................... 104° F (40° C)
Weight .................................... .......................... 1922 lb (872 kg)
39.9"
[1013]
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-3
Section 2: Specifications Spirit II User’s Manual
36.0" [914]
23.0" [584]
15.8" [401]
Cooling System Specifications
Part Number ..................................................... 300275
Discharge pressure .......................................... 150 psi (10.2 bar)
Flow rate .......................................................... 2.1 gal/min (7.9 liters/min)
Coolant fluid ..................................................... Propylene glycol solution
Coolant tank capacity ....................................... 3.2 gal (12 liters)
Weight .............................................................. 141 lb (64 kg) (without coolant)
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-4
Spirit II User’s Manual Section 2: Specifications
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. Only use Kaliburn
approved torch coolant solution for optimal system performance as commercially
available antifreeze contains corrosion inhibitors that will damage the cooling
system. The standard coolant solution consists of 25% industrial grade
propylene glycol and provides freezing protection down to -13º C (9º F). The
standard solution can be ordered in one-gallon containers, PN 500695. For
operating temperatures below -13º C, a 50% solution of industrial grade
propylene glycol can be ordered in one-gallon containers, PN 500895, providing
protection down to -36º C (-33º F).
Failure to use the proper propylene glycol solution may result in cooling
system and/or torch damage.
The torch coolant should be flushed out of the Spirit system every six months
and replaced with new coolant. The coolant filter / deionization cartridge should
also be changed at the same time. See Section 6 for details.
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.
2-5
Section 2: Specifications Spirit II User’s Manual
12.4" [315]
12.0" [305]
13.7" [348]
10.9" [277]
7.0" [178]
(4) Ø .300 [7.6]
Manual Gas Console (MGC) Specifications
Part Number .................................................... 300600
Weight .............................................................. 50 lb (23 kg)
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-6
Spirit II User’s Manual Section 2: Specifications
Gas Supply Requirements
Plasma gas types:
Mild Steel ..................................................... Oxygen
Stainless Steel ............................................ Air, Nitrogen, or H17
Aluminum .................................................... Air or Nitrogen
Shield gas types:
Mild Steel ..................................................... Oxygen or Air
Stainless Steel ............................................. Air or Nitrogen
Aluminum .................................................... Air or Nitrogen
Preflow gas type ............................................... Oxygen and Nitrogen
Marking gas type............................................... Nitrogen
Plasma gas flow rate (maximum):
Oxygen ........................................................ 78 scfh (2209 liters/hour)
Air ................................................................ 67 scfh (1897 liters/hour)
H17 or Nitrogen ........................................... 106 scfh (3002 liters/hour)
Shield gas flow rate (maximum):
Oxygen ........................................................ 19 scfh (538 liters/hour)
Air ................................................................ 258 scfh (7306 liters/hour)
Nitrogen ...................................................... 326 scfh (9231 liters/hour)
Preflow gas flow rate (maximum) ...................... 60 scfh (1699 liters/hour)
Marking gas flow rate (maximum) ..................... 89 scfh (2520 liters/hour)
Rated Inlet gas pressure ................................... 115 psi (7.9 bar)
Minimum Inlet gas pressure .............................. 110 psi (7.6 bar)
Maximum Inlet gas pressure ............................. 145 psi (10.0 bar)
Oxygen and nitrogen should be supplied with a purity of at least 99.5%.
H17 should be supplied with a purity of at least 99.995%.
A potential fire hazard exists when cutting with oxygen. KALIBURN recommends
that an exhaust ventilation system be used when cutting with oxygen. Flashback
arrestors must be supplied (unless they are not available for the chosen gases
and pressures) to prevent a possible fire from propagating back to the gas
supplies.
Ensure that oxygen lines remain free from contaminants such as oil and grease. The
mixture of such contaminants with oxygen presents an additional fire hazard.
Compressed air must be clean, dry, and oil-free and may be supplied from compressed
cylinders or from an air compressor. Be aware that shop air systems are prone to oil
and moisture contamination. If shop air is used, it must be cleaned to ISO 8573.1:
Class 1.4.1. Specify dry air when using compressed cylinders. Breathing quality air
contains moisture and must not be used.
3/8” (inside diameter) hoses are required for all inlet gas connections. Mating
connectors are supplied with the unit. Quick-connect fittings must not be used.
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.
2-7
Section 2: Specifications Spirit II User’s Manual
12.75" [324]
8.00" [203]
12.00" [305]
13.50" [343]
10.00" [254]
5.35" [136]
(4) Ø.312 [8]
Impulse Start Console (ISC) Specifications
Part Number ..................................................... 300500
Weight .............................................................. 22 lb (10 kg)
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.
2-8
Spirit II User’s Manual Section 2: Specifications
Torch Head
Torch Base
Torch Handle
1.99"
Alignment Indicator
Attachment Ring
Manifold
Torch and 2-Gang Manifold Specifications
Part Number:
2-Gang Manifold Assembly .................................................. 284214
Torch Handle (standard) ...................................................... 278001
Torch Handle (short) ............................................................ 278018
Torch Base........................................................................... 279000
Torch Head (Copper Electrode) ........................................... 279100
Torch Head (Silver Electrode) .............................................. 279060
Max Weight:
Manifold/Bracket, Handle (278001), Base and Head ........... 8.3 lbs (3.8 kg)
3.38" [86]
278001 = 9.46" [240]
278018 = 7.06" [179]
[51]
1.87" [47]
5.08" [129]
(Slot)
Alignment Indicator
(Circle)
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.
2-9
Section 2: Specifications Spirit II User’s Manual
4.20"
6.18" [157]
0.327" [8.3]
0.25" [6.4]
1.18" [30]
3.035" [77]
(4) 0.187" [4.8] Mounting Holes
5-Gang Manifold Specifications
Part Number .................................................... 280022
Weight .............................................................. 6 lb (2.7 kg)
3.80"
[97]
[107]
8.35" [212]
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.
2-10
Spirit II User’s Manual Section 2: Specifications
A-Weighted Sound
Pressure Level
C-Weighted Sound
Pressure Level
1 meter horizontal / 1.6
workpiece
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. The following chart gives the noise levels generated by the
system when operating at 400 amps, 205 arc volts. The measurements were made
with a sound level meter.
Distance From Torch
meters above the
120 dB 115 dB
The maximum noise level is 131 dB at a distance of 3 inches (76.2 mm) from the torch
while cutting at 400 amps, 205 arc volts.
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.
2-11
Section 2: Specifications 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.
2-12
Spirit II User’s Manual Section 3: Installation
WARNING
when lifting.
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. Also, Kaliburn has taken special care in packaging the
system. If the system was damaged during shipment, file a claim with the shipping
company, and then contact Kaliburn to order replacement parts.
Component Placement
Plasma Power Supply
The power supply should be lifted by a forklift, pallet jack or crane. In order to prevent
damaging the power supply when lifting with a forklift or pallet jack, the forks should be
of adequate length to protrude on the far side of the power supply. If lifting with a sling
(lifting straps), ensure the following:
• Sling and material handling equipment must comply with local and national laws
and regulations. The personnel involved in the move must be properly trained
and qualified to use such equipment.
• All power supply covers must be securely installed.
• Two slings are required. Each sling should pass through all three (3) structural
members on the bottom of the power supply. See sling access holes below.
• Lift slowly -not more than 8 in. (203 mm) high- to ensure even weight distribution.
• Move slowly to prevent uncontrollable acceleration/deceleration.
Falling equipment
can cause injury.
• Lift only with
equipment of
adequate lifting
capacity.
• Be sure power
Sling
Access
Hole
supply is stable
The proper location of the power supply will provide dependable service and reduce
periodic maintenance time. Choose a location that will provide unrestricted air
movement into and out of the power supply. Maintain at least 24 inches of space on
all sides of the unit. The location should subject the power supply to the least amount
of dust, dirt, moisture, and corrosive vapors. The surface on which the power supply is
located should have a grade of no greater than 10º to eliminate the risk of toppling over.
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.
3-1
Section 3: Installation Spirit II User’s Manual
The power supply must be cleaned as often as necessary to prevent the accumulation
of metallic dust inside the unit. See Section 2 for unit dimensions.
Manual Gas Console (MGC)
The MGC should be mounted near the CNC controller so that it is easy accessible by
the operator. See Section 2 for mounting dimensions.
Impulse Start Console (ISC)
The ISC should be mounted in a convenient location that is away from other electronic
control devices. The ISC offers significantly reduced emissions compared to traditional
high frequency, however, the high voltage pulse generated inside the unit may interfere
with the operation of sensitive control electronics. The ISC is usually mounted on the
gantry of the cutting machine or on the cutting table. See Section 2 for mounting
dimensions.
5-Gang Manifold
The 5-gang manifold assembly must be mounted within 6 feet (1.8 m) of the torch. See
Section 2 for mounting dimensions.
2-Gang Manifold
The 2-gang manifold assembly must be mounted to the torch. See Section 2 for
mounting dimensions.
Torch
The torch must be installed on the positioner of an arc voltage control (height control)
capable of maintaining the cutting arc voltage within 1 arc volt. The arc voltage must be
adjustable in 1 arc volt increments. The positioner must be rigid to ensure cut quality
and a torch collision sensor is highly recommended. See Section 2 for mounting
dimensions.
Cooling System
The cooling system must be located within 8 feet (2.4 meters) of the plasma power
supply. The surface on which the cooling system is located should have a grade of no
greater than 10º to eliminate the risk of toppling over. See Section 2 for unit
dimensions.
System Interconnection
The Spirit II system interconnection diagrams on the following pages will assist in the
planning and installation of the system as well as identifying cables and hoses upon
receipt.
The optional Inova torch height control is also shown to assist with its connections,
whether as an external console or internal to the plasma power supply.
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.
3-2
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. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-3
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. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-4
Spirit II User’s Manual Section 3: Installation
Input Current
Output (amps)
Recommended
Size (amps)
220 VAC, 60Hz
262
350
240 VAC, 60Hz
240
300
380 VAC, 50/60Hz
152
200
400 VAC, 50/60Hz
144
175
415 VAC, 50/60Hz
140
175
440 VAC, 50/60Hz
131
175
480 VAC, 60Hz
120
150
600 VAC, 60Hz
96
125
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. The disconnect switch should be located as close as
possible to the power supply so it can be turned off quickly in case of an emergency.
The disconnect switch should be equipped with time delay fuses only. The
magnetic inrush current of the power supply will cause fast acting fuses to blow. The
disconnect switch should be sized according to local and national codes. The rating
must meet or exceed the continuous rating of the fuses used. See the following chart
for recommended fuse sizes:
3 Phase
Input Voltage (VAC)
at Maximum
Time-Delay Fuse
Connection to the supply circuit can be by means of flexible supply cables or supply
cables through conduit to a permanent installation. The supply cables should have a
600 volt minimum rating and should be sized according to local and national codes.
Route flexible supply cables through the strain relief on the back of the power supply
and connect to the input terminal block TB5 as shown. For supply cables through
conduit, install the conduit in place of the strain relief and connect the associated supply
cables to the input terminal block TB5. See Figure 3 on the next page.
TB5 is located on the rear of the power supply and is accessible with the right-side
cover removed. Be sure to connect the primary ground cable to the ground stud
on the input terminal block.
Under no circumstances are the supply cables to be routed through the opening in the
power supply cabinet without conduit or an appropriate strain relief as per local and
national codes.
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.
3-5
Section 3: Installation Spirit II User’s Manual
Strain Relief
Disconnect Box
TB5 Connections
L1 (U)
L1 L2 L3 Gnd
TB5
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.
Figure 3: Power Supply Primary Connections
3-6
L2 (V)
L3 (W)
Ground
Connections
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