Manual Del Kaliburn

User's Manual
Spirit II 275
High Current Density Plasma Cutting System
with Manual Gas Console (MGC)
BK718116 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
Revision History
Rev ECO# Author Date Description of Change
A - CAD 02/04/2013 Initial Release.
Added 100A/150A silver electrodes, replaced RHF with
ISC, corrected system interconnect diagrams, changed
B LAD0202 CAD 06/07/2013
rated inlet gas pressure to 115 psi, added 100 psi
minimum to inlet gas pressure.
Deionization filter cartridge (500510) replaced sediment
filter (300152). Parts list updated.
C LAD0217 CAD 08/06/2013
Expanded notes on System Interconnection diagrams to
clarify cabling requirements for various configurations.
Corrected contact ratings on page 3-19.
LAD0228 Added pinouts to CII, FII, JII cables in Parts List.
D CAD 08/28/2013
LAD0223 Corrected part numbers for coolant/power leads and
work ground in Parts List.
Inductor (707150) replaced by (707155). 10” fan
E LAD0260 CAD 03/18/2014 (500516) replaced by (284031). Added notes about torch
handle vent hole. Updated Chopper Test Procedure.
Added “BK” prefix to all part numbers. Added PCB
F LAD0264 CAD 03/31/2014 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
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
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
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
iii
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
iv
Spirit II User’s Manual Prologue
Section 7: Parts List

Power Supply (BK300221 - BK300229) ............................................................ 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
v
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.
vi
Spirit II User’s Manual Section 1: Safety
Section 1: Safety
General Precautions
Whereas plasma cutting has been used safely for years, it does require certain
precautions to ensure the safety of the operator and other people around the
equipment. The following safety information must be provided to each person who will
operate, observe, perform maintenance, or work in close proximity to this piece of
equipment.
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.
1-1
Section 1: Safety Spirit II User’s Manual
Toxic Fume Prevention
Care should be taken to ensure adequate ventilation in the cutting area. Some
materials give off toxic fumes that can be harmful or fatal to people in the vicinity of the
cutting area. 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.
1-2
• 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.
1-3
• 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.
1-4
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.
1-5
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.
1-6
Spirit II User’s Manual Section 2: Specifications
Section 2: Specifications
System Description
The Spirit II 275 is a 275 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 2" 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. Eight nozzle sizes (30, 50,
70, 100, 150, 200, 260, and 275 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.
2-1
Section 2: Specifications Spirit II User’s Manual
System Components
The Spirit II 275 System consists of the following components:
Standard Components
• Power Supply
• 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
2-2
Power Supply Specifications

Input Current at
Power Supply Description Part Number
Maximum Output
208 VAC, 3Ø, 60Hz BK300221 163 amps
220 VAC, 3Ø, 60Hz BK300222 153 amps
240 VAC, 3Ø, 60Hz BK300223 140 amps
380 VAC, 3Ø, 50/60Hz BK300224 88 amps
400 VAC, 3Ø, 50/60Hz BK300225 84 amps
415 VAC, 3Ø, 50/60Hz BK300226 81 amps
440 VAC, 3Ø, 50/60Hz BK300227 76 amps
480 VAC, 3Ø, 60Hz BK300228 70 amps
600 VAC, 3Ø, 60Hz BK300229 56 amps
Open Circuit Voltage ......................................... 325 VDC

Output Current (drooping characteristic) ........... 10 - 275 amps
Maximum Output Voltage ................................. 180 VDC
Duty Cycle ........................................................ 100% @ 44 kW
Maximum Ambient Temperature ....................... 104° F (40° C)
Coolant Discharge Pressure ............................. 150 psi (10.2 bar)
Coolant Flow Rate ............................................ 1 gal/min (3.8 liters/min)
Coolant Fluid ..................................................... Propylene glycol solution
Coolant Tank Capacity...................................... 3.2 gal (12 liters)
Weight (without coolant) ................................... 1270 lb (576 kg)
38.4"
[975]
29.0" [737] 43.2" [1097]
2-3
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 BK500695. For
operating temperatures below -13º C, a 50% solution of industrial grade
propylene glycol can be ordered in one-gallon containers, PN BK500895,
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.
2-4
Manual Gas Console (MGC) Specifications

Part Number .................................................... BK300600
Weight .............................................................. 50 lb (23 kg)
12.4" [315]
12.0" [305] 13.7" [348]
(4) Ø .300 [7.6]
10.9" [277]
7.0" [178]
2-5
Gas Supply Requirements

Plasma gas types:
Mild Steel ..................................................... Oxygen
Stainless Steel ............................................ Air or H17
Aluminum .................................................... Air
Shield gas types:
Mild Steel ..................................................... Oxygen or Air
Stainless Steel ............................................. Air or Nitrogen
Aluminum .................................................... Nitrogen
Preflow gas type ............................................... Oxygen and Nitrogen
Marking gas type............................................... Nitrogen
Plasma gas flow rate (maximum):

Oxygen or Air............................................... 67 scfh (1897 liters/hour)
H17 .............................................................. 75 scfh (2124 liters/hour)
Shield gas flow rate (maximum):
Oxygen ........................................................ 19 scfh (538 liters/hour)
Air or Nitrogen ............................................. 225 scfh (6371 liters/hour)
Preflow gas flow rate (maximum) ...................... 60 scfh (1699 liters/hour)
Marking gas flow rate (maximum) ..................... 79 scfh (2237 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.
2-6
Impulse Start Console (ISC) Specifications

Part Number ..................................................... BK300500
Weight .............................................................. 22 lb (10 kg)

8.00" [203]

(4) Ø.312 [8]

12.75" [324] 
12.00" [305] 
13.50" [343]

10.00" [254]

5.35" [136]
2-7
Torch and 2-Gang Manifold Specifications

Part Number:
2-Gang Manifold Assembly .................................................. BK284214
Torch Handle (standard) ...................................................... BK278001
Torch Handle (short) ............................................................ BK278018
Torch Base........................................................................... BK279000
Torch Head (Copper Electrode) ........................................... BK279100
Torch Head (Silver Electrode) .............................................. BK279060
Max Weight:
Manifold/Bracket, Handle (BK278001), Base and Head ...... 8.3 lbs (3.8 kg)
Manifold

3.38" [86]
Torch Handle

BK278001 = 9.46" [240]

BK278018 = 7.06" [179]
1.99"

[51]
Torch Base
Alignment Indicator

1.87" [47]
(Slot)
Attachment Ring
Alignment Indicator
Torch Head (Circle)
5.08" [129]

2-8
5-Gang Manifold Specifications

Part Number .................................................... BK280022
Weight .............................................................. 6 lb (2.7 kg)

6.18" [157]

0.327" [8.3] 
0.25" [6.4]
(4) 0.187" [4.8] Mounting Holes



1.18" [30]
3.80"

[97]
4.20"

[107]

3.035" [77]

8.35" [212]
2-9
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 275 amps, 145 arc volts. The measurements were made
with a sound level meter.
A-Weighted Sound C-Weighted Sound

Distance From Torch
Pressure Level Pressure Level
1 meter horizontal / 1.6
meters above the 110 dB 107 dB
workpiece
The maximum noise level is 127 dB at a distance of 3 inches (76.2 mm) from the torch
while cutting at 275 amps, 145 arc volts.
2-10
Spirit II User’s Manual Section 3: Installation
Section 3: Installation
Initial Inspection
All systems undergo full testing before being shipped from Kaliburn. In the unlikely
event that one of the components is defective or missing, please contact Kaliburn so a
replacement item can be sent. 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 or pallet jack. In order to prevent
damaging the power supply, the forks should be of adequate length to protrude on the
far side of the power supply. 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. 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.
3-1
Section 3: Installation Spirit II User’s Manual
2-Gang Manifold
The 2-gang manifold assembly must be mounted to the torch. See Section 2 for
mounting dimensions.
Torch
The torch must be installed on the positioner of an arc voltage control (height control)
capable of maintaining the cutting arc voltage within 1 arc volt. 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.
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.
3-2
Figure 1: Spirit II System with Manual Gas Console and Internal Inova System
3-3
Figure 2: Spirit II System with Manual Gas Console and External Inova System
3-4
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:
Input Current Recommended

3 Phase
at Maximum Time-Delay Fuse
Input Voltage (VAC)
Output (amps) Size (amps)
208 VAC, 60Hz 163 200
220 VAC, 60Hz 153 200
240 VAC, 60Hz 140 175
380 VAC, 50/60Hz 88 110
400 VAC, 50/60Hz 84 100
415 VAC, 50/60Hz 81 100
440 VAC, 50/60Hz 76 100
480 VAC, 60Hz 70 90
600 VAC, 60Hz 56 70
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.
3-5
TB5
L1 (U)
L2 (V)
L3 (W)
Ground
Strain Relief Disconnect Box

L1 L2 L3 Gnd Connections
TB5 Connections
Figure 3: Power Supply Primary Connections
3-6
Power Supply Output Connections

Perform the following steps to connect the output of the power supply to the impulse
start console and the work table. See Figure 4 on the next page.
Power Supply Electrode Lead 1

1. Route one end of the #1/0AWG power supply electrode lead through the upper
strain relief on the rear of the power supply and connect it to the electrode terminal.
2. Route the other end of the power supply electrode lead through the strain relief on
the impulse start console and connect it to the cathode manifold.
Power Supply Nozzle Lead 2

1. Route the larger ring terminal end of the #10AWG power supply nozzle lead through
the bushing on the rear of the power supply and connect it to the nozzle terminal.
2. Route the smaller ring terminal end of the power supply nozzle lead through the
strain relief on the impulse start console and connect it to the pilot terminal on the
printed circuit board.
Power Supply CTP Sensor Lead 3

1. Route the ring terminal end of the #14AWG power supply CTP sensor lead through
the bushing on the rear of the power supply and connect it to the CTP terminal.
2. Route the FASTON end of the power supply CTP sensor lead through the strain
relief on the impulse start console and connect it to the CTP sensor lead with
FASTON connector.
Work Ground Lead 4

1. Route one end of the #1/0AWG work ground lead through the bottom strain relief on
the rear of the power supply and connect it to the work terminal.
2. Connect the other end of the work ground lead to the star ground point on the cutting
table.
The star ground point is generally referred to as the common ground point on the
cutting table where all subsystems of the machine are grounded. This point is then
connected to a driven earth ground rod that should be as close as possible to the
star ground. The ground rod should have no other wires connected to it. The
ground rod should be at least 3/4 inches in diameter and should be driven into the
earth’s permanent moisture layer. The length of the ground rod varies from
installation to installation and should be installed according to local and national
codes. Refer to the National Electrical Code, Article 250, Section H, Ground
Electrode System for additional information.
3-7
Strain Relief 4 1
Strain Relief
Figure 4: Power Supply Output Connections
3-8
ISC Control Cable and ISC Ground Connections

Perform the following steps to connect the ISC control cable and ISC ground. See
Figure 5 on the next page.
ISC Control Cable 5
1. Connect the ISC control cable plug labeled P16 to the connector labeled P16 on the
rear of the power supply.
2. Connect the ISC control cable plug labeled P1 to the connector labeled P1 on the
impulse start console.
ISC Ground Cable 6

1. Connect one end of the ISC ground cable to the ground stud on the impulse start
console.
2. Connect the other end of the ISC ground cable to the star ground on the cutting
table. Make sure that good metal-to-metal contact is made.
Cooling System Connections

Perform the following steps to connect the cooling system to the impulse start console.
See Figure 5 on the next page.
Coolant Supply Hose 7
1. Connect one end of the coolant supply hose to the coolant out fitting on the rear of
the power supply. Note that the coolant out fitting has right hand threads.
2. Connect the other end of the coolant supply hose to the coolant in fitting on the
impulse start console. Note that the coolant in fitting has right hand threads.
Coolant Return Hose 8

1. Connect one end of the coolant return hose to the coolant in fitting on the rear of the
power supply. Note that the coolant in fitting has left hand threads.
2. Connect the other end of the coolant return hose to the coolant out fitting on the
impulse start console. Note that the coolant out fitting has left hand threads.
3-9
7 8 5
7 8
Figure 5: Cooling System Connections
3-10
Torch Leads to Impulse Start Console Connections

Perform the following steps to connect the torch leads to the impulse start console.
See Figure 6 on the next page.
Note: When making hose connections, only tighten the brass fittings enough to
make water or gas seals. The fittings are subject to damage if over tightened.
Braided Shield 11
1. Remove the threaded ring from the brass shield connector on the end of the braided
shield. Route the torch leads through the opening in the impulse start console and
push the shield connector through the hole until it is seated against the side of the
console.
2. Slide the threaded ring over the torch leads, thread it onto the brass shield
connector, and tighten firmly. The shield connector should ground the braided
shield to the case of the impulse start console in order to help reduce high frequency
noise emission. Using an ohmmeter, measure for zero ohms between the braided
shield and the ground stud located on the outside of the impulse start console.
Torch Electrode/Coolant Supply Lead 12

• Connect the torch electrode/coolant supply lead to the brass cathode manifold. Note
that the torch electrode/coolant supply lead has right hand threads.
Torch Coolant Return Lead 13

• Connect the torch coolant return lead to the brass cathode manifold. Note that the
torch coolant return lead has left hand threads.
Torch Nozzle Lead 14

• Connect the torch nozzle lead to the angled bracket on the red standoff. Note that
the torch nozzle lead has right hand threads.
Torch CTP Sensor Lead 15

• Connect the #18AWG torch CTP sensor lead to the red standoff as shown.
3-11
11 14 12
15
13
Figure 6: Torch Leads to Impulse Start Console Connections
3-12
Torch Leads to Torch Base Connections

Perform the following steps to connect the torch leads to the torch base.
Note: When making hose connections, only tighten the brass fittings
enough to make water or gas seals. The fittings are subject to damage if
over tightened. Also, use two wrenches when tightening the torch fittings
to avoid damaging the torch base.
Torch Lead through Torch Handle Installation

• Route the torch leads through the torch handle. Note that the threaded end of
the torch handle mates with the torch base.
Torch Electrode/Coolant Supply Lead 16

• Connect the torch electrode/coolant supply lead to the torch base as shown.
Torch Coolant Return Lead 17

• Connect the torch coolant return lead to the torch base as shown. Note that
the torch coolant return lead fitting has left hand threads.
Torch Nozzle Lead 18

• Connect the torch nozzle lead to the torch base as shown.
Torch CTP Sensor Lead 19

• Connect the torch CTP sensor lead to the torch base as shown.
18 19 18 19
17 16 17 16
Figure 7: Torch Leads to Torch Base Connections
3-13
Torch Gas Connections

Perform the following steps to connect the torch gas hoses to the manual gas
console, torch base, and manifold assemblies. See figure 8.
Note: When making hose connections, only tighten the brass fittings
enough to make gas seals. The fittings are subject to damage if over
tightened.
7.5 Foot Shield Gas Hose 20

1. Route one end of the 7.5 foot (2.3 m) shield gas hose through the torch
handle and connect to the shield gas fitting on the torch base.
2. Connect the other end of the 7.5 foot (2.3 m) shield gas hose to the shield
gas outlet on the 5-gang manifold.
17 Inch Plasma Gas Hose 21

1. Route one end of the 17 inch (432 mm) plasma gas hose through the torch
handle and connect to the plasma gas fitting on the torch base.
2. Thread the torch handle onto the torch base, being careful not to twist the
torch leads and gas hoses when tightening the torch handle.
3. Tighten the base to the handle using a pin style adjustable spanner wrench
(fits 2" diameter with ¼" diameter pin).
4. Attach the 2-gang manifold assembly to the torch handle. The top of the
manifold bracket should be flush with the top of the torch handle.
5. Connect the other end of the 17 inch (432 mm) plasma gas hose to the
plasma gas outlet on the 2-gang manifold.
6. Mount the torch handle/base/manifold to the positioner. Note the alignment
indicators on the torch base (slot) and torch head (circle). These aid in
aligning the quick-disconnect torch base and head and should be oriented so
they are clearly visible when the operator is changing heads.
6 Foot Preflow/Postflow/Marking Gas Hose 22

1. Connect one end of the 6 foot (1.8 m) preflow/postflow/marking gas hose to
the preflow/postflow/marking outlet on the 5-gang manifold.
2. Connect the other end of the 6 foot (1.8 m) preflow/postflow/marking gas
hose to the preflow/postflow/marking inlet on the 2-gang manifold.
Marking Gas Hose 23

1. Connect one end of the marking shield gas hose to the marking shield outlet
on the rear of the MGC.
2. Connect the other end of the marking shield gas hose to the marking shield
inlet on the 5-gang manifold.
3-14
Postflow Gas Hose 25

1. Connect one end of the postflow hose to the postflow outlet on the rear of the
MGC. Note that the postflow hose fittings have left hand threads.
2. Connect the other end of the postflow hose to the postflow inlet on the 5-gang
manifold.
Plasma Gas Hose 26

1. Connect on end of the plasma hose to the plasma outlet on the rear of the
MGC.
2. Connect the other end of the plasma hose to the plasma inlet on the 2-gang
manifold.
Shield Gas Hose 27

1. Connect one end of the shield hose to the shield outlet on the rear of the
MGC.
2. Connect the other end of the shield hose to the shield inlet on the 5-gang
manifold.
Preflow Gas Hose 28

1. Connect one end of the preflow hose to the preflow outlet on the rear of the
MGC. Note that the preflow hose fittings have left hand threads.
2. Connect the other end of the preflow hose to the preflow inlet on the 5-gang
manifold.
5-Gang Manifold Control Cable 29

1. Connect the 5-gang manifold control cable plug marked P15 to the 5-gang
manifold as shown.
2. Connect the 5-gang manifold control cable plug labeled P12 to the connector
labeled P12 on the rear of the power supply.
2-Gang Manifold Control Cable 30

1. Connect the 2-gang manifold control cable plug marked P18 to the 2-gang
manifold as shown.
2. Connect the 2-gang manifold control cable plug labeled P13 to the connector
labeled P13 on the rear of the power supply.
3-15
Manual Gas
Console
28
27
26
23
25
RED
26
30
GREEN
22
BLUE
21
GREEN RED REAR
PORT
22
REAR
20 27 23 28 29 25 PORT
BLUE
21 20
Figure 8: Torch Gas Connections
3-16
Gas Supply Connections

Perform the following steps to connect the gas supply lines to the MGC. See Section 2
for gas supply requirements. Mating hose barbs and connectors are supplied with the
system and are sized for 3/8 inch inside diameter hose. Do not change the inlet gas
supply fittings to quick-connect fittings. Using quick-connect fittings to connect
and disconnect pressurized hoses may cause damage to the system.
Note: When making hose connections, only tighten the brass fittings enough to
make gas seals. The fittings are subject to damage if over tightened.
Air Inlet 31 (ISO 3821 hose color - black)

• Air must be supplied to the unit at all times, regardless of the cutting current or
material type.
Oxygen Inlet 32 (ISO 3821 hose color - blue)
• Oxygen must be supplied to the unit at all times, unless stainless steel is being cut
with H17 plasma.
Nitrogen Inlet 33 (ISO 3821 hose color - black)
• Nitrogen must be supplied to the unit at all times, regardless of the cutting current or
material type.
H17 Inlet 34 (ISO 3821 hose color - red)
• H17 must be supplied to the unit when stainless steel is being cut with H17 as the
plasma gas. See cutting charts in Section 5 for more information.
32
34
31
33
3-17
CAN Communication Connections

Perform the following steps to connect the plasma power supply to the MGC.
CAN Cable 35
• Connect the male end of the CAN cable to the connector labeled P4 on the rear of
the plasma power supply.
• Connect the female end of the CAN cable to the top connector on the rear of the
MGC.
CAN Termination Plug 36
• If not already installed, connect the CAN termination plug to the bottom connector on
the rear of the MGC.
35
35
36
3-18
CNC Machine Interface Connections

Perform the following steps to properly interface the Spirit system with a CNC cutting
machine. See the system schematic for additional information.
Plasma Start Input
The power supply requires a contact closure between P8 pins 3 and 4 to commence the
cutting or marking sequence. The sequence is terminated when the contacts are
opened. The contacts should be rated for 24VDC - 7.3mA.
Plasma Cut/Mark Input
The power supply requires a contact closure between P8 pins 1 and 2 to put the system
in plasma marking mode. Opening the contacts puts the system in cutting mode. The
operating mode should be selected prior to applying a start signal. The contacts should
be rated for 24VDC - 7.3mA.
Arc Hold Input
The power supply requires a contact closure between P8 pins 10 and 11 to inhibit arc
starting even though a plasma start signal has been applied to the unit. When the
contacts are opened, the arc is initiated. This feature is used to decrease cycle time by
allowing pre-cut gas and contact sequencing to occur simultaneously with initial torch
height positioning. The contacts should be rated for 24VDC - 7.3mA.
Motion Output
The power supply provides a maintained contact closure output between P8 pins 12
and 14 as long as an arc is maintained between the torch and the workpiece. The
motion contacts are rated for 24VDC – 10mA.
Remote On/Off Input
The power supply requires a maintained contact closure between P8 pins 5 and 6 to
energize the system from a remote location, provided that the OFF Button on the
manual gas console is released. The contacts should be rated for 24VAC – 10mA.
Opening the contacts deenergizes the system. If the remote on/off feature is to be
used, remove the jumper between positions 1 and 2 on the J17 connector on the
microprocessor DSP board.
Power Supply Ready Output
The power supply provides a maintained contact closure output between P8 pins 7 and
8 when the system is ready to cut or mark. The contacts are open during gas purge or
when an error occurs. The contacts are rated for 24VDC – 10mA.
3-19
Filling the Cooling System

WARNING: Do not touch the fans inside the power supply.
Important: Never turn on the system when the coolant reservoir is empty.
Important: When handling coolant, wear nitrile gloves and safety glasses.
Important: Only use Kaliburn approved coolant. Commercially available
antifreeze contains corrosion inhibitors that will damage the cooling
system. See Section 2 for more information.
1. Remove primary power from the Spirit system.

2. Ensure the torch base and torch head (with consumables) are properly installed.
3. Ensure the coolant supply (in and out) hoses are properly installed.
4. Remove the coolant reservoir cap/level gauge and then remove the top, left and
right covers from the power supply.
5. Ensure the coolant filter housing is tightened securely.
6. Ensure the drain petcock on the bottom of the reservoir is tightened securely.
7. Fill the reservoir with approximately 2 ½ gallons of approved coolant.
8. Apply primary power to the Spirit system and enable it by releasing (turn right) the
OFF Button on the MGC.
9. On the MGC main menu, move the pointer to On. Press SELECT to start the
coolant pump circulating coolant through the system. Note: The coolant pump will
turn off automatically if the coolant level drops below the minimum level inside the
reservoir. If this happens, add more coolant.
10. With the coolant pump running, locate the small red push-button on top of the
coolant filter housing (beneath the reservoir). Press and hold the red button until no
air or bubbles are seen inside the filter housing. Dry any coolant that leaks out.
11. Check for coolant leaks at all hose connections, the impulse start console, and at the
torch.
12. Push the OFF Button on the MGC to stop the coolant pump.
14. Fill the reservoir with coolant until the coolant gauge indicates full.
15. Replace the power supply covers and replace the coolant reservoir cap/level gauge.
16. End of procedure.
3-20
Spirit II User’s Manual Section 4: Operation with Manual Gas Console
Section 4: Operation
Operating the Manual Gas Console (MGC)
The Manual Gas Console (MGC) is the interface to the entire Spirit system when the
MGC is used instead of the Automatic Gas Console (AGC).
OFF Button
Push to disable the Spirit system.
Release (turn to the right) to enable
the system, which can then be
energized by choosing ON and then
SELECT.
Up/Down/Select Buttons
Press the up or down button to move
the pointer ( ) accordingly on the
display. These buttons are
represented as UP and DOWN
throughout this manual.
Press the select button to access
menu items or settings identified by
the pointer. This button is shown as
SELECT throughout this manual.
Display
The display turns on automatically
when AC power is applied to the
Spirit system. It displays the menu
tree, which is navigated using the
Up/Down/Select buttons and is used
to control the entire Spirit system.
Pressure Regulator Knobs

Turn to the left or right to adjust the
amount of output gas pressure for
PreFlow, PostFlow, Plasma and
Shield gases.
4-1
Section 4: Operation with Manual Gas Console Spirit II User’s Manual
Setting up to Cut
The following procedure uses the information from the cutting charts in Section 5 to
prepare the system to cut. Press the UP or DOWN button on the MGC to move the
pointer through the menu as described below.
Push the OFF Button on the MGC to disable

the system. On the main menu, move the
pointer to Setup. Press SELECT.
Press SELECT to cycle through the list until

Cutting is displayed.
Move the pointer to Current.

the desired amperage is displayed.
Move the pointer to Select Gas.

Press SELECT.
Press SELECT to choose the Plasma gas.

Move the pointer to Shield and press SELECT
to choose the shield gas. Move the pointer to
Return and press SELECT.
Move the pointer to Adjust Gas.

Press SELECT.
Move the pointer to a gas and then press

SELECT to start the flow of that gas. Turn the
corresponding regulator knob on the MGC to
adjust the displayed pressure to match the
value in the cutting chart. Repeat for all other
gases. Move the pointer to Return and press
SELECT. Repeat to return to the main menu.
The system is now setup to cut.
4-2
Setting up to Mark (Overrides Cut)

The system will automatically switch between cutting and marking based upon
commands in the part program. However, all cutting commands in the part program can
be overridden with marking commands by simply changing the Process to Marking.
Push the OFF Button on the MGC to disable

the system. On the main menu, move the
pointer to Setup. Press SELECT.

Marking is displayed. Move the pointer to
Return and press SELECT.
The system is now setup to mark instead of

cut.
Verifying Input Gas Pressures

For the system to work properly the input gas pressures must be within an acceptable
range. To check the input pressures, follow the steps below.
On the main menu, move the pointer to

Input Gas. Press SELECT.
Verify that all connected gas pressures are at

least 120psi. The maximum input gas pressure
is 145psi.
Press SELECT to return to the main menu.
4-3
Making a Cut or Mark

Once the process type, gas types and gas pressures have been set in the MGC; the
correct torch parts (consumables) installed; and the X/Y controller and torch height
control are properly configured; the system is ready to cut or mark.
Release the OFF Button (turn to the right) on

the MGC. On the main menu, move the
pointer to On. Press SELECT.
The MGC will purge the gas hoses. The purge

icon ( ) is displayed during this process.
Once purging is complete, the ready icon ( )

is displayed. The system is now ready to cut or
mark.
When the system receives a start signal from

the X/Y controller, the following sequence is
initiated:
• Two second gas preflow
• Impulse start circuit energized
• Pilot arc initiation
• Transferred arc (cutting or marking arc)
established
• Motion output relay energized
When the start signal is removed, the arc is

extinguished and the motion output relay is
deenergized.
4-4
Piercing Thick Materials

Care must be taken when piercing thick materials in order to prevent damage to the
shield cap and nozzle. As with all thicknesses, the pierce height must be set high
enough so the metal ejected while piercing does not come into contact with the shield
cap. Also, some of the material ejected during the pierce may adhere to the top side of
the plate and form a ring of solidified material around the pierce point.
Action must be taken so the torch does not move from the pierce height down to the
cutting height and come into contact with this solidified metal. The torch should not
move from the pierce height down to the cutting height until the X/Y controller has
moved the torch away from the pierce point.
One way to accomplish this may be to program the pierce time on the torch height
control system to a value that is longer than the X/Y controller motion delay time.
Moving Pierces and Edge Starts

On very thick materials, an edge start or moving pierce may be required to prevent
damage to the torch consumables.
With a moving pierce, the X/Y machine should begin moving at approximately 5–10
inches/minute (125–250 mm/min) as soon as the arc transfers to the plate. After the arc
completely penetrates the plate, the torch should be positioned at the proper cutting
height and the X/Y machine speed should be increased to the correct level.
With an edge start the torch should be positioned at the edge of the material prior to
starting the arc.
4-5
Cut Quality
Before the optimum cutting condition can be achieved on a particular material type and
thickness, the machine operator must have a thorough understanding of the cutting
characteristics of the Spirit system. When the cut quality is not satisfactory, the cutting
speed, torch height, or gas pressures may need to be adjusted in small increments until
the proper cutting condition is obtained. The following guidelines should be useful in
determining which cutting parameter to adjust.
Note: Before making any parameter changes, verify that the torch is square to
the workpiece. Also, it is essential to have the correct torch parts in place and to
ensure that they are in good condition. Check the electrode for excessive wear
and the nozzle and shield cap orifices for roundness. Also, check the parts for
any dents or distortions. Irregularities in the torch parts can cause cut quality
problems.
1. A positive cut angle (top dimension of piece smaller than the bottom dimension)
usually occurs when the torch standoff distance is too high, when cutting too fast, or
when excessive power is used to cut a given plate thickness.
2. A negative cut angle (top dimension of piece larger than the bottom dimension)
usually occurs when the torch standoff distance is too low or when the cutting speed
is too slow.
3. Top dross usually occurs when the torch standoff distance is too high.
4. Bottom dross usually occurs when the cutting speed is either too slow (slow-speed
dross) or too fast (high-speed dross). Low-speed dross is easily removed, while
high-speed dross usually requires grinding or chipping off. When using oxygen as
the shielding gas, bottom dross can sometimes be removed by increasing the shield
gas pressure. However, increasing the shield pressure too much can cause cut face
irregularities (see below). Bottom dross also occurs more frequently as the metal
heats up. As more pieces are cut out of a particular plate, the more likely they are to
form dross.
5. When using oxygen as a shielding gas, cut face irregularities usually indicate that
the shield gas pressure is too high or the torch standoff distance is too low.
6. A concave cut face usually indicates that the torch standoff distance is too low or the
shield gas pressure is too high. A convex cut face usually indicates that the torch
standoff distance is too high or the shield gas pressure is too low.
7. Note that different material compositions have an effect on dross formation.
8. If the material is not being completely severed, the likely causes are that the cutting
current is too low, the travel speed is too high, the gas pressures are incorrect, the
incorrect gas types are selected, the incorrect consumables are installed in the
torch, or the consumables are worn.
4-6
Checking Errors
The last ten (10) system errors are available through the MGC as described below.
On the main menu, move the pointer to Errors.

Press SELECT.
Press SELECT to cycle through the last ten

(10) error codes.
See Section 6 in this manual for details on the

error codes.
Simultaneously pressing DOWN and SELECT

will erase all ten error codes.
Move the pointer to Return and press

SELECT to return to the main menu.
Checking the Version and Serial Number

The hardware version, software version and serial number for the Power Supply and
Gas Console can be displayed as described below.

Version. Press SELECT.
Move the pointer to either Power Supply or

Gas Console. Press SELECT.
Review the necessary information.
Press SELECT to return to the previous

screen.
Move the pointer to Return and press

SELECT to return to the main menu.
4-7
Changing the Language

The language displayed on the MGC can be changed as described below.

Configure. Press SELECT.
Press SELECT on Languages.
Move the pointer to the desired language and

then press SELECT. The display changes
immediately to the selected language.
Move the pointer to Return and press SELECT

to return to the previous screen. Repeat to
return to the main menu.
Adjusting the Screen Contrast

The contrast of the display on the MGC can be adjusted as described below.

Configure. Press SELECT.
Move the pointer to Contrast.

Press SELECT to cycle through the list of
contrast settings.
Move the pointer to Return and press SELECT

to return to the main menu.
4-8
Spirit II User’s Manual Section 5: Torch Consumables and Cutting Charts
Section 5: Torch Consumables and

Cutting Charts
Installing / Removing the Torch Head
WARNING: Remove primary power from the Spirit system!
1. Each time the torch head is connected to the torch base, use a cotton swab to apply
a small amount of o-ring lubricant on each of the seven o-rings on the top of the
torch head. Reminder: do not use an excessive amount of o-ring lubricant.
2. Align the indicator on the torch head (circle) with the one on the torch base (slot).
3. Apply enough upward force to engage the threads while tightening the attachment
ring. Turn the attachment ring to the RIGHT to tighten.
4. Keep tightening the attachment ring until it stops. There should be no gap between
the attachment ring and the o-ring on the torch base.
During this process, a small amount of coolant will collect in the torch head.
It is normal for this coolant to discharge between the o-ring on the torch base and
the attachment ring while the system is being pressurized. If coolant continues to
discharge after the system is pressurized, turn off the plasma power supply, remove
the torch head and inspect the o-rings for damage.
YES NO!
O-ring O-ring
Torch Base
Torch Head
There is no Gap is visible
gap between between
o-ring and o-ring and
attachment attachment
ring ring
To remove the torch head, turn the attachment ring to the LEFT.
5-1
Section 5: Torch Consumables and Cutting Charts Spirit II User’s Manual
Installing / Replacing Consumables

WARNING: Remove primary power from the Spirit system!
Note: When installing the consumables, do not use an excessive amount
of o-ring lubricant. Also ensure that the lubricant is placed only on the
o-rings. Excess lubricant can interfere with gas flow, which can cause
starting problems, poor cut quality, and short consumable life.
1. Unthread the torch head from the torch base by turning the attachment ring to
the LEFT. Verify the torch base doesn't unthread from the torch handle.
2. Remove the outer retaining cap from the torch head.
3. Remove the inner retaining cap from the torch head.
4. Separate the shield cap from either the inner retaining cap or the outer
retaining cap.
5. Use the nozzle removal tool (P/N BK277056) to remove the nozzle from the
torch head. To do this, insert the tool into the groove on the nozzle and hold
the tool/nozzle in the palm of your hand. Pull both hands apart using a linear
motion as shown in the left image below. Do not use a prying or bending
motion as shown in the right image below.
YES NO!
PULL OR
PULL
6. Use the swirl ring removal tool (P/N BK260105) to remove the swirl ring from
the nozzle.
7. Remove the electrode from the torch head using the appropriate tool:
• All copper electrodes use socket P/N BK277087 & driver P/N BK277086.
• All silver electrodes use P/N BK279061.
8. Inspect all consumables and o-rings for damage and excess wear. Replace
with new consumables as necessary.
9. Inspect the cooling tube in the torch head for damage. See Section 6
Maintenance and Troubleshooting if replacement is necessary.
5-2
Maximizing Consumable Life

Use the following guidelines to maximize consumable parts life:
1. The Spirit system utilizes the latest advancement in technology for extending the life
of the torch consumable parts. To maximize the life of the consumable parts, it is
imperative that the shutdown procedure of the arc is carried out properly. The arc
must be extinguished while it is still attached to the workpiece. A popping
noise may be heard if the arc extinguishes abnormally. Note that holes are usually
programmed without lead-outs to prevent loss of the arc during shutdown. There is
a time delay between the reception of a stop signal and when the arc is
extinguished. During this time, the gases and cutting current are changed to
optimum values for extinguishing the arc. Ideally, the x/y machine controller should
provide a plasma stop signal prior to the end of the cut path so the gases and
current reach the shut off values at the same time that the part has been completely
cut. The shut down times are different for each current and are given below.
Arc Shutdown Times
Current (A) Time (ms)
30 490
50 390
70 300
100 300
150 175
200 195
260 175
275 175
2. Use the recommended pierce height given in the cutting charts. A pierce height that
is too low will allow molten metal that is ejected during the piercing process to
damage the shield cap and nozzle. A pierce height that is too high will cause the
pilot arc time to be excessively long and will cause nozzle damage. See “Piercing
Thick Materials” in Section 4.
3. Never fire the torch in the air. Nozzle damage will occur.
4. Make sure the torch does not touch the plate while cutting. Shield cap and nozzle
damage will result.
5. Use a chain cut when possible. Starting and stopping the torch is more detrimental
to the consumables than making a continuous cut.
6. Always use error tracking on the plasma console to keep track of cut errors. See
Section 4 for information on error tracking.
5-3
Inspecting for Damage

When the cut quality is not satisfactory, use the following guidelines for
determining which consumable parts need to be changed. Inspect all parts for
dirt, debris, and excess o-ring lubricant and clean as necessary.
Part Inspect For Corrective Action

Outer Cap
Dents, cracks Replace outer cap
Center hole out of round Replace shield cap

Shield Cap
Dents, Scratches Replace shield cap
Dry o-ring Apply a thin film of o-ring lubricant
Damaged o-ring Replace shield cap

Center hole out of round Replace retaining cap
Retaining Cap
Dents, cracks Replace retaining cap
Dry o-ring Apply a thin film of o-ring lubricant
Damage o-ring Replace retaining cap

Center hole out of round Replace nozzle
Nozzle Erosion or arcing Replace nozzle
Dry o-rings Apply a thin film of o-ring lubricant
Damaged o-rings Replace nozzle

Damage Replace swirl ring
Clogged holes Blow out with compressed air. Replace

Swirl Ring swirl ring if clogs can’t be removed.
Damaged o-rings Replace swirl ring

Pit depth Replace electrode if center pit depth is
greater than 0.040” (1 mm) for copper
Electrode electrode or 0.098" (2.5mm) for silver.
Erosion or arcing Replace electrode

or
Damaged o-rings Replace electrode
5-4
Selecting Consumables
Mild Steel
Copper Electrode
Outer Shield Inner Swirl Copper Torch
Nozzle
Retaining Cap Cap Retaining Cap Ring Electrode Head
BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100
30A
BK277140/
BK284150 BK277115 BK277153 BK277122 BK277142 BK277131 BK279100
50A
BK284150 BK277150 BK277153 BK277125 BK277142 BK277131 BK279100
70A
BK284150 BK277286 BK277151 BK277284 BK277283 BK277282 BK279100
100A
BK277151/
BK284150 BK277117 BK277152 BK277293 BK277139 BK277292 BK279100
150A
BK284150 BK277274 BK277266 BK277289 BK277143 BK277291 BK279100
200A
BK284150 BK277263 BK277266 BK277269 BK277258 BK277270 BK279100
275A
5-5
Mild Steel
Silver Electrode
Outer Shield Inner Swirl Silver Torch
Nozzle
BK279410
BK284150 BK277286 BK277151 BK279484 BK279483 (brown o-ring) BK279060
100A
BK277151/ BK279420
BK284150 BK277117 BK277152 BK279493 BK279439 (green o-ring) BK279060
150A
BK279440
BK284150 BK277274 BK277266 BK279489 BK279443 (yellow o-ring) BK279060
200A
BK279450
BK284150 BK277263 BK277266 BK279469 BK279458 (red o-ring) BK279060
275A
5-6
Stainless Steel - H17 Plasma

Copper Electrode
Nozzle
BK284150 BK277150 BK277113 BK277124 BK277140 BK277132 BK279100
70A
BK284150 BK277146 BK277113 BK277126 BK277141 BK277133 BK279100
100A
BK284150 BK277298 BK277266 BK277297 BK277139 BK277135 BK279100
150A
BK284150 BK277274 BK277266 BK277287 BK277259 BK277135 BK279100
200A
BK284150 BK277211 BK277280 BK277118 BK277139 BK277135 BK279100
260A
5-7
Stainless Steel - Air or Nitrogen Plasma

Copper Electrode
Nozzle
BK284150 BK277144 BK277110 BK277121 BK277138 BK277137 BK279100
30A
BK284150 BK277149 BK277110 BK277123 BK277142 BK277137 BK279100
50A
BK284150 BK277150 BK277153 BK277125 BK277142 BK277131 BK279100
70A
BK284150 BK277286 BK277151 BK277284 BK277283 BK277282 BK279100
100A
BK284150 BK277117 BK277152 BK277293 BK277139 BK277292 BK279100
150A
BK284150 BK277274 BK277266 BK277289 BK277143 BK277291 BK279100
200A
BK284150 BK277263 BK277266 BK277276 BK277258 BK277270 BK279100
275A
5-8
Stainless Steel - Air or Nitrogen Plasma

Silver Electrode
Nozzle
BK279410
100A
BK279420
150A
BK279440
200A
5-9
Aluminum
Copper Electrode
Nozzle
BK284150 BK277145 BK277153 BK277120 BK277140 BK277130 BK279100
30A
BK284150 BK277150 BK277153 BK277122 BK277142 BK277131 BK279100
50A
BK284150 BK277150 BK277153 BK277125 BK277142 BK277131 BK279100
70A
BK284150 BK277286 BK277151 BK277284 BK277283 BK277282 BK279100
100A
BK284150 BK277117 BK277152 BK277293 BK277139 BK277292 BK279100
150A
BK284150 BK277274 BK277266 BK277289 BK277143 BK277291 BK279100
200A
BK284150 BK277263 BK277266 BK277276 BK277258 BK277270 BK279100
275A
5-10
Aluminum
Silver Electrode
Nozzle
BK279410
100A
BK279420
150A
BK279440
200A
BK279450
BK284150 BK277263 BK277266 BK279469 BK279458 (red o-ring) BK279060
275A
5-11
Cutting Charts
The cutting charts shown on the following pages are intended to give the
operator the best starting point to use when making a cut on a particular material
type and thickness. Small adjustments may have to be made to achieve the best
cut. Also, remember that the arc voltage must be increased as the electrode
wears in order to maintain the correct cutting height.
Cutting Chart Index

Copper Silver
Material Current Plasma Gas Shield Gas
Electrode Electrode
Mild Steel 30 Amps Oxygen Oxygen Page 5-13
Mild Steel 50 Amps Oxygen Oxygen or Air Page 5-14
Mild Steel 70 Amps Oxygen Air Page 5-15
Mild Steel 100 Amps Oxygen Air Page 5-16 Page 5-39
Stainless Steel 30 Amps Air Air Page 5-20

Stainless Steel 50 Amps Air Nitrogen Page 5-21
Stainless Steel 70 Amps H17 Nitrogen Page 5-22
Stainless Steel 100 Amps Air Nitrogen Page 5-25 Page 5-43
Aluminum 30 Amps Air Nitrogen Page 5-32

Aluminum 100 Amps Air Nitrogen Page 5-35 Page 5-46
5-12
Mild Steel - 30 Amps - Oxygen Plasma / Oxygen Shield

Copper Electrode
Shield Cap Nozzle Electrode
BK277145 BK277120 BK277130
Outer Cap Retaining Cap Swirl Ring Torch Head

BK284150 BK277153 BK277140 BK279100
Imperial*
Material Arc Travel Cutting Pierce Pierce Kerf
Preflow Plasma Shield Postflow
Thickness Voltage Speed Height Height Time Width
(ga) (in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)
20 .036 120 105 .080
100 .062
18 .048 121 97 .090
16 .060 125 78 .110
.065
14 .075 35 77 6 75 126 65 .105 200
12 .105 127 55
11 .120 129 50 .070
.120 .125 300
10 .135 131 40
Metric*
(mm) (psi) (psi) (psi) (psi) (volts) (mm/m) (mm) (mm) (msec) (mm)
1 120 2615 2.0 100 1.6
1.5 124 2020 2.6
2.8 1.7
2 35 77 6 75 1615 200
126 2.7
2.5 1455
1.8
3 128 1285 2.9 3.1 300
Marking* – For All Material Thicknesses

Arc Travel Marking Initial Pierce
Type of Gas Preflow Plasma Shield Postflow
Voltage Speed Height Height Time
(Plasma) (Shield) (psi) (psi) (psi) (psi) (volts) (ipm) (mm/min) (in) (mm) (in) (mm) (msec)
Nitrogen Nitrogen N/A 25 25 N/A 145 250 6350 .177 4.5 .100 2.5 0
Argon** Air** N/A 50 25 N/A 66 100 2540 .100 2.5 .100 2.5 0
* Use an arc transfer height (ignition height) of .100” (2.5 mm) for cutting and marking.
** Only available on systems with the Automatic Gas Console.
(Revised 04/26/2013)
5-13
Mild Steel - 50 amps - Oxygen Plasma / Oxygen or Air Shield

Copper Electrode
BK277115 BK277122 BK277131

BK284150 BK277153 BK277140/BK277142 BK279100
Imperial*
Cold-Rolled Steel – Oxygen Shield – Swirl Ring BK277140

12 .105 123 70 .120 100 .075
11 .120 25 74 12 72 126 60 .125 .135
200 .078
10 .135 128 50 .135
Hot-Rolled Steel – Air Shield – Swirl Ring BK277142
14 .075 200
100 .075
12 .105 106 190 .100
.135
.125 180
25 74 19 72 200 .080
10 .135 110 170 .110
3/16 113 105 .200 300 .085
.140
1/4 117 75 .225 400 .087
Metric*
Cold-Rolled Steel – Oxygen Shield – Swirl Ring BK277140

2.5 121 1895 2.9 100 1.9
25 74 12 72 3.4
3 125 1555 3.1 200 2.0
Hot-Rolled Steel – Air Shield – Swirl Ring BK277142
2.5 4885 100 1.9
106 2.5 3.4
3 4660 200 2.0
25 74 19 72
5 113 2555 5.1
3.6 400 2.2
6 116 2075 5.5

Argon** Air** N/A 50 25 N/A 71 100 2540 .100 2.5 .100 2.5 0
* Use an arc transfer height (ignition height) of .135” (3.4 mm) for cutting and .100” (2.5 mm) for marking.
(Revised 04/26/2013)
5-14
Mild Steel - 70 Amps - Oxygen Plasma / Air Shield

Copper Electrode
BK277150 BK277125 BK277131

BK284150 BK277153 BK277142 BK279100
Imperial*
(in) (psi) (psi) (psi) (psi) (volts) (ipm) (in) (in) (msec) (in)
1/8 35 110 190 .150 100
.100 .080
3/16 113 130 .200 200
25 76 74
1/4 40 116 120 .110 .225 300
.085
3/8 122 75 .140 .250 400
Metric*
3 35 109 4995 3.6 100
2.5 2.0
5 25 76 74 113 3265 5.1
40 300
6 115 3105 2.7 5.5 2.2

Argon** Air** N/A 50 25 N/A 62 100 2540 .100 2.5 .100 2.5 0
(Revised 04/26/2013)
5-15

Copper Electrode
BK277286 BK277284 BK277282

BK284150 BK277151 BK277283 BK279100
Imperial*
1/4 125 150 .090 .200 300
3/8 100 .130 .250 400 .090
130
1/2 25 83 26 81 65 .155 .300 500
5/8 143 47 .325 800
.185 .095
3/4 145 35 .350 1000
Metric*
6 124 3950 2.1 4.9 300
10 2405 3.3 6.5 2.3
130 500
12 25 83 26 81 1850 3.7 7.3
16 143 1180 8.3
4.7 1000 2.4
20 145 800 9.0

Argon** Air** N/A 50 25 N/A 60 100 2540 .100 2.5 .100 2.5 0
(Revised 04/26/2013)
5-16

Copper Electrode
BK277117 BK277293 BK277292

BK284150 BK277151/BK277152 BK277139 BK279100
Imperial*
Retaining Cap BK277151
1/4 118 165 .105 .200 300
.125
3/8 20 71 30 69 123 125 .135 .250 400
1/2 125 90 .140 .300 500 .130
5/8 127 70 .325 600 .130
.140
3/4 130 55 .350 1000 .135
1 20 71 45 69 134 40 .150 .400
1.25 *** 145 25 .200 .350 1500 .140
1.50 *** 155 15 .225 .350
Metric*
6 117 4305 2.6 4.9 300
3.2
10 20 71 30 69 123 3040 3.4 6.5
500
12 124 2485 3.5 7.3 3.3
16 127 1760 8.3 1000 3.3
3.6
20 130 1340 9.0 3.4
25 20 71 45 69 133 1040 3.7 10.1
1500
32 *** 145 625 5.1 8.9 3.6
38 *** 154 385 5.6 8.9

Argon** Air** N/A 50 25 N/A 61 100 2540 .100 2.5 .100 2.5 0
*** Edge start recommended.
(Revised 04/26/2013)
5-17

Copper Electrode
BK277274 BK277289 BK277291

BK284150 BK277266 BK277143 BK279100
Imperial*
1/4 125 230 .040 .200 300
3/8 130 140 .090 .250 400 .150
1/2 133 120 .115 .300 500
5/8 137 100 .130 .350 600 .152
3/4 140 75 .150 .400 800 .153
20 74 58 72
1 147 50 .175 .450 1000
.155
1.25 155 25 .240 .500
1.50 *** 165 17 .300
.350 1500 158
1.75 *** 175 12 .350
2.00 *** 185 7 .500 .500 .160
Metric*
6 124 6100 .8 4.9 300
10 130 3480 2.3 6.5 3.8
500
12 132 3160 2.7 7.3
16 137 2515 3.3 8.9 800
20 141 1810 3.8 10.3
20 74 58 72 1000 3.9
25 146 1310 4.3 11.3
32 155 610 6.1 12.7
38 *** 164 435 7.5 8.9
1500 4.0
45 *** 175 295 9.2 9.2
50 *** 183 195 12.2 12.2 4.1

Argon** Air** N/A 50 25 N/A 62 100 2540 .100 2.5 .100 2.5 0
(Revised 04/26/2013)
5-18

Copper Electrode
BK277263 BK277269 BK277270

BK284150 BK277266 BK277258 BK279100
Imperial*
1/2 125 .140 .300 500
139 .165
5/8 105 .135 .325 600
3/4 138 90 .120 .350 800 .170
1 144 65 .160 .400 1000
.185
1.25 150 45 .175 .500
20 81 70 79
1.50 *** 163 25 .235
1.75 *** 170 20 .290 .350 .190
1500
2.00 *** 180 15 .350
2.25 *** 185 13 .375 .375 .260
2.50 *** 190 9 .385 .385 .275
Metric*
12 139 3290 3.6 7.4 500
4.2
16 2650 3.3 8.3 800
138
20 2190 3.1 9.0 4.3
1000
25 143 1690 4.0 10.1
4.7
32 150 1120 4.4 12.8
20 81 70 79
38 *** 162 645 5.9
45 *** 170 495 7.5 8.9 4.8
1500
50 *** 178 395 8.7
55 *** 183 345 9.2 9.2 6.6
60 *** 187 285 9.6 9.6 6.9

Argon** Air** N/A 50 25 N/A 54 100 2540 .120 3.0 .100 2.5 0
(Revised 04/26/2013)
5-19
Stainless Steel - 30 Amps - Air Plasma / Air Shield

Copper Electrode
BK277144 BK277121 BK277137

BK284150 BK277110 BK277138 BK279100
Imperial*
20 .036 200 .020
71 100 .065
18 .048 165
35 81 30 85 .035 .050
16 .060 74 125 .068
200
14 .075 75 90 .025 .070
Metric*
1 71 4855 0.6 100
35 81 30 85 1.3 1.7
1.5 73 3260 0.9 200

Argon** Nitrogen** N/A 50 25 N/A 55 100 2540 .140 3.6 .100 2.5 0
(Revised 04/26/2013)
5-20
Stainless Steel - 50 Amps - Air Plasma / Nitrogen Shield

Copper Electrode
BK277149 BK277123 BK277137

BK284150 BK277110 BK277142 BK279100
Imperial*
14 .075 87 105
100
12 .105 88 75 .105
.035 .070
11 .120 89 65
25 66 40 67 200
10 .135 90 55
.110
3/16 94 50 .040 .080 300
1/4 100 40 .060 .125 400 .115
Metric*
2 2565
87 100
2.5 2080 .9 1.8 2.7
3 25 66 40 67 88 1685 200
5 94 1235 1.0 2.1 2.8
400
6 98 1075 1.3 2.9 2.9

(Revised 04/26/2013)
5-21
Stainless Steel - 70 Amps - H17 Plasma / Nitrogen Shield

Copper Electrode
(H17 = 17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)
This gas combination gives the best cut quality and minimum dross levels
BK277150 BK277124 BK277132

BK284150 BK277113 BK277140 BK279100
Imperial*
3/16 35 65 30 60 135 80 .100 .200 300 .090
Metric*
5 35 65 30 60 135 2030 2.5 5.1 300 2.3

(Revised 04/26/2013)
5-22

Copper Electrode
This gas combination gives medium cut quality and minimum dross levels
BK277150 BK277125 BK277131

BK284150 BK277153 BK277142 BK279100
Imperial*
10 .135 132 120 .060 .150 200
.085
3/16 134 100 .070 .200 300
25 76 25 76
1/4 140 75 .090 .225 400
.090
3/8 148 50 .120 .250 500
Metric*
3 131 3210 1.4 3.3 200
2.2
5 25 76 25 76 134 2445 1.8 5.1
400
6 138 2050 2.1 5.5 2.3

(Revised 04/26/2013)
5-23

Copper Electrode
BK277146 BK277126 BK277133

BK284150 BK277113 BK277141 BK279100
Imperial*
3/16 138 115 .105 .200 300 .100
1/4 28 72 40 67 140 100 .125 .225 400
.105
3/8 152 65 .180 .250 500
Metric*
5 138 2865 2.7 5.1 2.5
28 72 40 67 400
6 139 2625 3.0 5.5 2.7

(Revised 04/26/2013)
5-24

Copper Electrode
BK277286 BK277284 BK277282

BK284150 BK277151 BK277283 BK279100
Imperial*
1/4 141 100 .135 .225 400 .092
3/8 25 80 35 80 147 80 .170 .250 500
.095
1/2 154 55 .210 .300 600
Metric*
6 140 2595 3.2 5.6 400 2.3
10 25 80 35 80 148 1935 4.4 6.5
600 2.4
12 152 1540 5.0 7.3

(Revised 04/26/2013)
5-25

Copper Electrode
BK277298 BK277297 BK277135

BK284150 BK277266 BK277139 BK279100
Imperial*
1/4 95 .250 .250 400
.135
3/8 75 .150 .275 500
1/2 25 77 75 81 165 60 .165 .300 600
.140
5/8 50 .185 .325 800
3/4 40 .250 .350 1200 .145
Metric*
10 1845 3.8 7.0 3.4
600
12 155 1610 4.1 7.4
25 77 75 81 3.6
16 1260 4.7 8.3 800
20 167 940 6.9 9.0 1200 3.7

(Revised 04/26/2013)
5-26

Copper Electrode
BK277117 BK277293 BK277292

BK284150 BK277152 BK277139 BK279100
Imperial*
1/4 145 150 .160 .250 400
.125
3/8 150 115 .180 .275 500
1/2 20 71 70 69 155 85 .210 .300 600
.130
5/8 160 60 .220 .325 800
3/4 168 45 .240 .350 1200 .135
Metric*
6 144 3910 4.0 6.3 400
3.2
10 150 2805 4.7 7.0
600
12 20 71 70 69 153 2330 5.1 7.4
3.3
16 160 1510 5.6 8.3 800
20 170 1030 6.2 9.0 1200 3.4

(Revised 04/26/2013)
5-27

Copper Electrode
This gas combination gives the good cut quality and minimum dross levels
BK277274 BK277287 BK277135

BK284150 BK277266 BK277259 BK279100
Imperial*
3/8 156 80 .195 .250 500
.150
1/2 148 75 .130 .300 600
5/8 37 72 79 68 155 60 .190 .350 800
.155
3/4 160 50 .200 .400 1200
1.0 170 35 .240 .450 1500 .160
Metric*
10 154 2010 4.7 6.5
600 3.8
12 149 1935 3.6 7.3
16 37 72 79 68 155 1515 4.8 8.9 800
3.9
20 161 1215 5.2 10.3
1500
25 169 915 6.0 11.3 4.1

(Revised 04/26/2013)
5-28

Copper Electrode
BK277274 BK277289 BK277291

BK284150 BK277266 BK277143 BK279100
Imperial*
1/4 130 200 .200 400
.070 .150
3/8 133 150 .250 500
1/2 140 110 .115 .300 600 .152
5/8 146 75 .150 .350 800
20 74 58 72 .155
3/4 153 60 .190 .400 1200
1.0 158 40 .210 .450 .160
1.25 *** 170 20 .250 .350 1500 .165
1.50 *** 180 10 .275 .350 .175
Metric*
6 129 5220 1.8 4.9 400
3.8
10 134 3655 1.9 6.5
600
12 138 3020 2.6 7.3
16 146 1890 3.8 8.9 800 3.9
20 74 58 72
20 153 1450 4.8 10.3
25 157 1050 5.2 11.3 4.1
1500
32 *** 170 495 6.4 8.9 4.2
38 *** 179 260 6.9 8.9 4.4

(Revised 04/26/2013)
5-29

Copper Electrode
BK277211 BK277118 BK277135

BK284150 BK277280 BK277139 BK279100
Imperial*
3/8 145 85 .160 .250 500
.190
1/2 142 80 .140 .300 600
5/8 145 65 .185 .350 800
40 63 64 63 .195
3/4 150 55 .225 .400 1200
1.0 160 33 .250 .450 .200
1500
1.25 *** 170 26 .280 .350 .205
Metric*
10 144 2140 4.0 6.5
600 4.8
12 142 2060 3.7 7.3
16 145 1640 4.7 8.9 800
40 63 64 63 5.0
20 151 1315 5.8 10.3
25 159 875 6.3 11.3 1500 5.1
32 *** 170 650 7.1 8.7 5.2

(Revised 04/26/2013)
5-30

Copper Electrode
BK277263 BK277276 BK277270

BK284150 BK277266 BK277258 BK279100
Imperial*
1/2 143 120 .125 .300 600
.165
5/8 148 90 .140 .350 800
3/4 152 80 .180 .400 1200
20 73 70 75 .170
1.0 165 55 .210 .450
1.25 *** 175 35 .250 .350 1500
.180
1.50 *** 185 25 .300 .350
Metric*
12 141 3220 3.1 7.3 600
4.2
16 148 2275 3.6 8.9 800
20 153 1940 4.7 10.3
20 73 70 75 4.3
25 164 1435 5.2 11.3
1500
32 *** 175 880 6.4 8.9
4.6
38 *** 184 640 7.5 8.9

** Edge start recommended.
(Revised 04/26/2013)
5-31
Aluminum - 30 Amps - Air Plasma / Nitrogen Shield

Copper Electrode
BK277145 BK277120 BK277130

BK284150 BK277153 BK277140 BK279100
Imperial*
.040 150
.100 100 .065
.050 35 81 20 85 135 120 .030
.063 90 .150 200 .070
Metric*
1 3885 2.5 100 1.7
35 81 20 85 135 0.8
1.5 2520 3.4 200 1.8

Argon** Air** N/A 50 25 N/A 75 100 2540 .120 3.0 .100 2.5 0
(Revised 04/26/2013)
5-32

Copper Electrode
BK277150 BK277122 BK277131

BK284150 BK277153 BK277142 BK279100
Imperial*
.050 135 180 .050 100 .080
.100
.063 25 66 19 67 138 140 .065 150 .082
.080 143 90 .075 .150 200 .085
Metric*
1.5 137 3870 1.5 2.5 150 2.1
25 66 19 67
2.0 142 2360 1.8 3.7 200 2.2

Argon** Air** N/A 50 25 N/A 77 100 2540 .120 3.0 .100 2.5 0
(Revised 04/26/2013)
5-33

Copper Electrode
BK277150 BK277125 BK277131

BK284150 BK277153 BK277142 BK279100
Imperial*
.080 130 250 .050 .150
100 .080
1/8 135 160 .070 .175
3/16 145 80 .100 .200 200
25 76 25 76 .085
1/4 150 50 .060 .250 300
3/8 155 40 .075 .275 400
.090
1/2 162 30 .115 .300 500
Metric*
2 129 6400 1.2 3.7
100 2.0
3 134 4420 1.7 4.3
5 145 1920 2.3 5.2
25 76 25 76 300 2.2
6 148 1440 1.7 6.1
10 156 975 2.0 7.0
500 2.3
12 160 820 2.6 7.4

Argon** Air** N/A 50 25 N/A 69 100 2540 .120 3.0 .100 2.5 0
(Revised 04/26/2013)
5-34

Copper Electrode
BK277286 BK277284 BK277282

BK284150 BK277151 BK277283 BK279100
Imperial*
1/4 158 105 .155 .250 300 .095
3/8 25 80 26 80 162 90 .180 .275 400 .098
1/2 165 70 .195 .300 500 .100
Metric*
6 158 2710 3.8 6.3 300 2.4
10 25 80 26 80 162 2210 4.6 7.0
500 2.5
12 165 1890 4.9 7.4

Argon** Air** N/A 50 25 N/A 71 100 2540 .120 3.0 .100 2.5 0
(Revised 04/26/2013)
5-35

Copper Electrode
BK277117 BK277293 BK277292

BK284150 BK277152 BK277139 BK279100
Imperial*
1/4 145 145 .130 .250 400
.125
3/8 155 115 .185 .275 500
1/2 20 71 50 69 165 90 .230 .300 600 .130
5/8 65 .325 800 .135
170 .250
3/4 45 .350 1200 .140
Metric*
6 143 3770 3.1 6.3 400
3.2
10 156 2825 4.8 7.0
600
12 20 71 50 69 162 2430 5.5 7.4 3.3
16 170 1630 8.3 3.4
6.4 1200
20 170 990 9.0 3.6

Argon** Air** N/A 50 25 N/A 69 100 2540 .100 2.5 .100 2.5 0
(Revised 04/26/2013)
5-36

Copper Electrode
BK277274 BK277289 BK277291

BK284150 BK277266 BK277143 BK279100
Imperial*
1/4 150 190 .135 .250 300
.150
3/8 145 .140 .275 400
155
1/2 110 .300 500
20 74 58 72 .135 .155
5/8 95 .350 600
160
3/4 65 .150 800 .160
.400
1.0 *** 175 35 .200 1000 .170
Metric*
6 149 4955 3.3 6.3 300
3.8
10 3545 3.5 7.0
155 500
12 2995 7.4
20 74 58 72 3.4 3.9
16 160 2380 8.9 800
20 162 1575 3.9 4.1
10.2 1000
25 *** 174 940 5.0 4.3

Argon** Air** N/A 50 25 N/A 71 100 2540 .100 2.5 .100 2.5 0
(Revised 04/26/2013)
5-37

Copper Electrode
BK277263 BK277276 BK277270

BK284150 BK277266 BK277258 BK279100
Imperial*
3/8 160 160 .160 .275 400
.160
1/2 165 125 .180 .300 500
5/8 168 105 .190 .350 600
.165
3/4 20 73 65 75 172 85 .200 800
1.00 *** 180 60 .240
.400 .170
1.25 *** 185 45 .260 1000
1.50 *** 190 25 .270 .180
Metric*
10 160 3930 4.1 7.1
500 4.1
12 163 3375 4.4 7.4
16 168 2645 4.8 8.9
800 4.2
20 20 73 65 75 173 2055 5.3
25 *** 179 1565 6.0
10.2 4.3
32 *** 185 1120 6.6 1000
38 *** 189 645 6.8 4.6

Argon** Air** N/A 50 25 N/A 56 100 2540 .120 3.0 .100 2.5 0
(Revised 04/26/2013)
5-38

Silver Electrode
BK277286 BK279484 BK279410
(brown o-ring)

BK284150 BK277151 BK279483 BK279060
Imperial*
1/4 125 150 .090 .200 300
3/8 100 .130 .250 400 .090
130
1/2 25 83 26 81 65 .155 .300 500
5/8 143 47 .325 800
.185 .095
3/4 145 35 .350 1000
Metric*
6 124 3950 2.1 4.9 300
10 2405 3.3 6.5 2.3
130 500
12 25 83 26 81 1850 3.7 7.3
16 143 1180 8.3
4.7 1000 2.4
20 145 800 9.0

Argon** Air** N/A 50 25 N/A 60 100 2540 .100 2.5 .100 2.5 0
(Revised 04/26/2013)
5-39

Silver Electrode
BK277117 BK279493 BK279420
(green o-ring)

BK284150 BK277151/BK277152 BK279439 BK279060
Imperial*
1/4 118 165 .105 .200 300
.125
3/8 20 71 30 69 123 125 .135 .250 400
1/2 125 90 .140 .300 500 .130
5/8 127 70 .325 600 .130
.140
3/4 130 55 .350 1000 .135
1 20 71 45 69 134 40 .150 .400
1.25 *** 145 25 .200 .350 1500 .140
1.50 *** 155 15 .225 .350
Metric*
6 117 4305 2.6 4.9 300
3.2
10 20 71 30 69 123 3040 3.4 6.5
500
12 124 2485 3.5 7.3 3.3
16 127 1760 8.3 1000 3.3
3.6
20 130 1340 9.0 3.4
25 20 71 45 69 133 1040 3.7 10.1
1500
32 *** 145 625 5.1 8.9 3.6
38 *** 154 385 5.6 8.9

Argon** Air** N/A 50 25 N/A 61 100 2540 .100 2.5 .100 2.5 0
(Revised 04/26/2013)
5-40

Silver Electrode
BK277274 BK279489 BK279440
(yellow o-ring)

BK284150 BK277266 BK279443 BK279060
Imperial*
1/4 125 230 .040 .200 300
3/8 130 140 .090 .250 400 .150
1/2 133 120 .115 .300 500
5/8 137 100 .130 .350 600 .152
3/4 140 75 .150 .400 800 .153
20 74 58 72
1 147 50 .175 .450 1000
.155
1.25 155 25 .240 .500
1.50 *** 165 17 .300
.350 1500 158
1.75 *** 175 12 .350
2.00 *** 185 7 .500 .500 .160
Metric*
6 124 6100 .8 4.9 300
10 130 3480 2.3 6.5 3.8
500
12 132 3160 2.7 7.3
16 137 2515 3.3 8.9 800
20 141 1810 3.8 10.3
20 74 58 72 1000 3.9
25 146 1310 4.3 11.3
32 155 610 6.1 12.7
38 *** 164 435 7.5 8.9
1500 4.0
45 *** 175 295 9.2 9.2
50 *** 183 195 12.2 12.2 4.1

Argon** Air** N/A 50 25 N/A 62 100 2540 .100 2.5 .100 2.5 0
(Revised 04/26/2013)
5-41

Silver Electrode
BK277263 BK279469 BK279450
(red o-ring)

BK284150 BK277266 BK279458 BK279060
Imperial*
1/2 125 .140 .300 500
139 .165
5/8 105 .135 .325 600
3/4 138 90 .120 .350 800 .170
1 144 65 .160 .400 1000
.185
1.25 150 45 .175 .500
20 81 70 79
1.50 *** 163 25 .235
1.75 *** 170 20 .290 .350 .190
1500
2.00 *** 180 15 .350
2.25 *** 185 13 .375 .375 .260
2.50 *** 190 9 .385 .385 .275
Metric*
12 139 3290 3.6 7.4 500
4.2
16 2650 3.3 8.3 800
138
20 2190 3.1 9.0 4.3
1000
25 143 1690 4.0 10.1
4.7
32 150 1120 4.4 12.8
20 81 70 79
38 *** 162 645 5.9
45 *** 170 495 7.5 8.9 4.8
1500
50 *** 178 395 8.7
55 *** 183 345 9.2 9.2 6.6
60 *** 187 285 9.6 9.6 6.9

Argon** Air** N/A 50 25 N/A 54 100 2540 .120 3.0 .100 2.5 0
(Revised 04/26/2013)
5-42

Silver Electrode
BK277286 BK279484 BK279410
(brown o-ring)

BK284150 BK277151 BK279483 BK279060
Imperial*
1/4 141 100 .135 .225 400 .092
3/8 25 80 35 80 147 80 .170 .250 500
.095
1/2 154 55 .210 .300 600
Metric*
6 140 2595 3.2 5.6 400 2.3
10 25 80 35 80 148 1935 4.4 6.5
600 2.4
12 152 1540 5.0 7.3

(Revised 04/26/2013)
5-43

Silver Electrode
BK277117 BK279493 BK279420
(green o-ring)

BK284150 BK277152 BK279439 BK279060
Imperial*
1/4 145 150 .160 .250 400
.125
3/8 150 115 .180 .275 500
1/2 20 71 70 69 155 85 .210 .300 600
.130
5/8 160 60 .220 .325 800
3/4 168 45 .240 .350 1200 .135
Metric*
6 144 3910 4.0 6.3 400
3.2
10 150 2805 4.7 7.0
600
12 20 71 70 69 153 2330 5.1 7.4
3.3
16 160 1510 5.6 8.3 800
20 170 1030 6.2 9.0 1200 3.4

(Revised 04/26/2013)
5-44

Silver Electrode
BK277274 BK279489 BK279440
(yellow o-ring)

BK284150 BK277266 BK279443 BK279060
Imperial*
1/4 130 200 .200 400
.070 .150
3/8 133 150 .250 500
1/2 140 110 .115 .300 600 .152
5/8 146 75 .150 .350 800
20 74 58 72 .155
3/4 153 60 .190 .400 1200
1.0 158 40 .210 .450 .160
1.25 *** 170 20 .250 .350 1500 .165
1.50 *** 180 10 .275 .350 .175
Metric*
6 129 5220 1.8 4.9 400
3.8
10 134 3655 1.9 6.5
600
12 138 3020 2.6 7.3
16 146 1890 3.8 8.9 800 3.9
20 74 58 72
20 153 1450 4.8 10.3
25 157 1050 5.2 11.3 4.1
1500
32 *** 170 495 6.4 8.9 4.2
38 *** 179 260 6.9 8.9 4.4

(Revised 04/26/2013)
5-45

Silver Electrode
BK277286 BK279484 BK279410
(brown o-ring)

BK284150 BK277151 BK279483 BK279060
Imperial*
1/4 158 105 .155 .250 300 .095
3/8 25 80 26 80 162 90 .180 .275 400 .098
1/2 165 70 .195 .300 500 .100
Metric*
6 158 2710 3.8 6.3 300 2.4
10 25 80 26 80 162 2210 4.6 7.0
500 2.5
12 165 1890 4.9 7.4

Argon** Air** N/A 50 25 N/A 71 100 2540 .120 3.0 .100 2.5 0
(Revised 04/26/2013)
5-46

Silver Electrode
BK277117 BK279493 BK279420
(green o-ring)

BK284150 BK277152 BK279439 BK279060
Imperial*
1/4 145 145 .130 .250 400
.125
3/8 155 115 .185 .275 500
1/2 20 71 50 69 165 90 .230 .300 600 .130
5/8 65 .325 800 .135
170 .250
3/4 45 .350 1200 .140
Metric*
6 143 3770 3.1 6.3 400
3.2
10 156 2825 4.8 7.0
600
12 20 71 50 69 162 2430 5.5 7.4 3.3
16 170 1630 8.3 3.4
6.4 1200
20 170 990 9.0 3.6

Argon** Air** N/A 50 25 N/A 69 100 2540 .100 2.5 .100 2.5 0
(Revised 04/26/2013)
5-47

Silver Electrode
BK277274 BK279489 BK279440
(yellow o-ring)

BK284150 BK277266 BK279443 BK279060
Imperial*
1/4 150 190 .135 .250 300
.150
3/8 145 .140 .275 400
155
1/2 110 .300 500
20 74 58 72 .135 .155
5/8 95 .350 600
160
3/4 65 .150 800 .160
.400
1.0 *** 175 35 .200 1000 .170
Metric*
6 149 4955 3.3 6.3 300
3.8
10 3545 3.5 7.0
155 500
12 2995 7.4
20 74 58 72 3.4 3.9
16 160 2380 8.9 800
20 162 1575 3.9 4.1
10.2 1000
25 *** 174 940 5.0 4.3

Argon** Air** N/A 50 25 N/A 71 100 2540 .100 2.5 .100 2.5 0
(Revised 04/26/2013)
5-48

Silver Electrode
BK277263 BK279469 BK279450
(red o-ring)

BK284150 BK277266 BK279458 BK279060
Imperial*
3/8 160 160 .160 .275 400
.160
1/2 165 125 .180 .300 500
5/8 168 105 .190 .350 600
.165
3/4 20 73 65 75 172 85 .200 800
1.00 *** 180 60 .240
.400 .170
1.25 *** 185 45 .260 1000
1.50 *** 190 25 .270 .180
Metric*
10 160 3930 4.1 7.1
500 4.1
12 163 3375 4.4 7.4
16 168 2645 4.8 8.9
800 4.2
20 20 73 65 75 173 2055 5.3
25 *** 179 1565 6.0
10.2 4.3
32 *** 185 1120 6.6 1000
38 *** 189 645 6.8 4.6

Argon** Air** N/A 50 25 N/A 56 100 2540 .120 3.0 .100 2.5 0
(Revised 04/26/2013)
5-49
BLANK
5-50
Spirit II User’s Manual Section 6: Maintenance &Troubleshooting
Section 6: Maintenance & Troubleshooting

WARNING: Only qualified maintenance personnel should perform
maintenance on the Spirit system.
The system utilizes potentially fatal A.C. and D.C. voltages. All maintenance
should be performed with safety in mind.
Use extreme caution when working near the power conversion module (i.e.,
chopper). The large electrolytic capacitors store large amounts of energy
even after power has been removed from the system. Wait at least five
minutes after turning off power, and then use a voltmeter to verify that the
capacitors are fully discharged before touching the power conversion module.
Capacitor failure can injure and/or cause property damage.
If troubleshooting requires the system to be powered with the enclosure
panels removed, remain clear of the capacitors. Failure of a capacitor can
result in a sudden release of stored energy causing rupture of the capacitor
case.
Routine Maintenance
Note: At minimum, these checks should be performed on a monthly basis. In
excessively dirty environments or in heavy usage situations, the checks
should be performed more frequently.
Power Supply
1. Remove the left, right, and top covers on the power supply.
2. Using clean, dry, compressed air, blow out all accumulated dust, including dust on
PC boards and fans. Be sure to blow out the fan and heat exchanger at the rear of
the unit. In an excessively dirty environment, blow out the unit on a weekly basis.
3. Verify the ground and primary three phase A.C. voltage connections are tight.
4. Verify all PC board connectors are installed securely.
5. Verify all rear cable connectors are installed securely.
6. Verify the electrode lead and work ground lead are secure and free from corrosion.
7. Check the torch coolant filter / deionization cartridge at the rear of the power supply
and replace if dirty.
8. Flush the cooling system every six months and replace the coolant and coolant filter
/ deionization cartridge.
6-1
Section 6: Maintenance &Troubleshooting Spirit II User’s Manual
Manual Gas Console (MGC)

1. Remove the cover of the manual gas console. Using clean, dry, compressed air,
blow out all accumulated dust inside the unit. In an excessively dirty environment,
blow out the unit on a weekly basis.
2. Verify that all PC board connectors are installed securely.
3. Verify that all gas hose connectors are tight and that there are no leaks. Only
tighten the gas fittings enough to make a gas seal. The fittings are subject to
damage if over tightened.
4. Inspect all gas hoses to ensure no damage exists. Immediately replace any
damaged gas hoses.
Torch, Torch Leads, and Gas Hoses

1. Verify that all torch lead and gas hose connections are tight and that there are no
gas or water leaks. Only tighten the fittings enough to make a water or gas
seal. The fittings are subject to damage if over tightened.
2. Verify that the braided shield of the torch leads is fastened securely to the brass
shield adapter that connects to the impulse start console. Also, make sure the
shield adapter is secured tightly to the impulse start console enclosure.
3. Inspect the braided shield for nicks or cuts and replace if necessary.
4. Remove the torch handle and verify that the connections at the torch base are
tightened securely. Only tighten the fittings enough to make a water or gas
seal. The fittings are subject to damage if over tightened. Coolant leaking from
the drain hole in the torch handle indicates damaged or loose torch leads.
5. Make sure the torch lead insulating sleeves are positioned to properly cover the
brass torch fittings at the torch base.
6. Inspect the outer sleeve on the torch base's electrode/coolant supply lead. If
nicks, cuts or holes are found, replace the torch base.
7. Remove the torch consumables from the torch head and inspect all o-rings.
Replace any o-rings with cuts, nicks, abrasions, or any other signs of wear.
Faulty o-rings may cause gas or water leaks, which will affect cut quality.
8. With the electrode removed, inspect the cooling tube in the torch head for
damage.
If using the copper electrode, the torch head uses cooling tube P/N BK277007. If
replacement is required, use tool P/N BK200109.
If using the silver electrode, the torch head uses cooling tube holder assembly
P/N BK279216. Remove this using the tool (socket P/N BK277087 & driver P/N
BK277086) and inspect the o-rings for damage. Apply a small amount of o-ring
lubricant before re-installing in the torch head.
9. Wipe any excess o-ring lubricant off of the torch base and head.
6-2
Impulse Start Console (ISC)

1. Open the cover (door) of the impulse start console and verify that all leads and
hoses are tightened securely. Only tighten the fittings enough to make a water
or gas seal. The fittings are subject to damage if over tightened.
Work Ground
1. Verify that the work ground lead is securely fastened to the star ground on the
cutting table, and that the connection point is free from corrosion. Use a wire brush
to clean the connection point if necessary.
6-3
Replacing the Torch Coolant and Filter

WARNING: Do not touch the fans inside the power supply.
Important: Never turn on the system when the coolant reservoir is empty.
Important: When handling coolant, wear nitrile gloves and safety glasses.
Important: Only use Kaliburn approved coolant. Commercially available
antifreeze contains corrosion inhibitors that will damage the cooling
system. See Section 2 for more information.
The torch coolant should be flushed out of the system every six months and replaced
with new coolant. Replace the coolant filter / deionization cartridge at the same time.

2. Ensure the torch base and torch head (with consumables) are properly installed.
3. Ensure the coolant supply (in and out) hoses are properly installed.
4. Remove the coolant reservoir cap/level gauge.
5. Remove the top, left and right covers from the power supply.
6. Connect a 3/8" ID hose and bucket to the drain petcock on the bottom of the
reservoir. Unscrew the petcock to drain the reservoir. Leave the hose and bucket in
place after the coolant drains out.
7. Remove the coolant supply hose (coolant out) from the rear of the power supply.
Note that the coolant supply hose has right hand threads. Be prepared for some
coolant to escape from the fitting on the power supply and from the supply hose.
8. Blow compressed air (100 psi maximum) into the coolant supply hose. This will force
the remaining coolant from the torch, torch leads, and supply hose into the reservoir
and out of the drain petcock. Continue until coolant stops flowing into the bucket.
9. Tighten the drain petcock and remove the hose and bucket.
10. Protect the area beneath the coolant filter housing as coolant will leak during this
step. Unscrew the coolant filter housing and remove it from the power supply. Use
caution as the housing will be full of coolant. Install a new coolant filter / deionization
cartridge and replace the coolant filter housing. Remove the protective material and
dry any leaked coolant.
11. Reconnect the coolant supply hose on the rear of the power supply.
12. Follow all of the steps in "Filling the Cooling System" in Section 3 of this manual to
complete this procedure.
6-4
Microprocessor (DSP) Status Indicators

The microprocessor DSP board controls all of the functions of the Spirit power
supply. It contains diagnostic LEDs and OPTO LEDs which aid in
troubleshooting the system. These indicators illuminate when a particular event
occurs. Illuminated LEDs indicate the following:
LED Indication
D7 – RS232 OUT Isolated Serial transmission

D10 – RS232 T1 OUT Serial transmission
D11 – CAN RXD CAN transmission
D12 – CAN TXD CAN transmission
D24 – PWM Chopper(s) energized
D33 – COOLANT LEVEL Coolant reservoir level is sufficient
D36 – PLASMA START Plasma start signal applied to Spirit
D37 – ARC HOLD Arc hold input enabled
D38 – MARKING Marking input enabled
D39 – CORNER Corner current input enabled
D40 – EOFF Off button disengaged
D41 – MOTION Motion output signal activated
D42 – PLASMA READY Power supply ready output signal activated
D43 – PAT Pilot arc transistor energized
D48 – RMT ON/OFF Remote On/Off input enabled
D50 – ISC DOOR ISC door is closed
D77 – 3.3V uP PWR 3.3V Microprocessor power
D78 – 1.8V uP PWR 1.8V Microprocessor power
OPTO U21 – MTR/SOL Coolant pump relay CR5 energized (Pump On)
OPTO U22 – PAR Pilot arc relay energized
OPTO U23 – CON DC power output (main contactor energized)
OPTO U24 – SURGE CR3 and K1 (I/O PCB) relays energized
OPTO U26 – FAN Fans energized
OPTO U27 – PREFLOW Preflow gas valve 1 energized
OPTO U28 – PLASMA Plasma gas valve 2 energized
OPTO U29 – SHIELD Shield gas valve 3 energized
OPTO U30 – VENT Vent gas valve 4 energized
OPTO U31 – POSTFLOW Postflow gas valve 5 energized
OPTO U32 – MARKING Marking gas valves 6 and 7 energized
OPTO U34 – IMPULSE START Impulse start circuit energized
OPTO U37 – RHF HF transformer energized
6-5
Microprocessor (DSP) Sequence of Operation

The following DSP Indicators should illuminate after primary power is applied:
 D77 3.3V Supply
 D78 1.8V Supply
 D50 ISC (Door)
 D33 Coolant Level
 D37 Arc Hold (if INOVA is being used)
 D10 RS232 T1 Out (Blinking)
 D11 CAN RXD (Dim Flashing)
 D12 CAN TXD (Dim Flashing)
The following DSP Indicators should illuminate when the OFF Button is released:
 D40 OFF Button
The following DSP Indicators should illuminate when the ON Button is activated:
 U21 Opto Motor / Solenoid
 U19 Opto Solenoid (not used)
 U26 Opto Fan
 D42 Plasma Ready
The following DSP Indicators should illuminate when a START signal is applied (begin
cut cycle):
 D36 Start
 U27 Opto Preflow
 U29 Opto Shield
 U24 Opto Surge (only over 100 amps)
 U23 Opto Contactor
 D24 PWM (Chopper ON)
 U22 Opto Pilot Arc Relay ON
 D43 PAT ON (Blinks during a START)
 U34 Opto ISC (Blinks during a START)
The following DSP Indicators should illuminate with an arc transfer:

 U31 Opto Postflow
 U28 Opto Plasma
 D41 Motion
The following LEDs should turn OFF after the Motion Indicator turns ON:
 U34 Opto ISC
 U27 Opto Preflow
 D43 PAT
When the START signal is removed, OPTO U30 (Vent) will illuminate. It will then go out
with the rest of the cut cycle indicators.
6-6
Error Codes
The following is a comprehensive list of error codes for the Spirit system. When the system
uses a Manual Gas Console, only the numeric error code is displayed. When an Automatic
Gas Console is used, the text description is also displayed.
Power Supply
Code Short Description Long Description
10121 ISC Door ISC Door is open
10138 Stop Pressed (Off Button) OFF Button on Plasma Console or Manual Gas
Console is pressed.
10140 Phase R Transformer Secondary phase voltage is low
10150 Phase Y Transformer Secondary phase voltage is low
10160 Phase B Transformer Secondary phase voltage is low
10161 CON1 Main Contactor failed to open
10170 Coolant Level Coolant Level is low
10180 Coolant Flow Low Coolant flow is low
10190 Coolant Flow High Coolant flow is high
10220 Coolant Temperature High The coolant temperature is high
10290 GC Quiet Lost CAN communication with Gas Console
10300 PC Quiet Lost CAN communication with Plasma Console
10320 FCC Invalid Final Cut Current invalid
10330 PAC Invalid Pilot Arc Current invalid
10340 AH IHS Timeout Arc Hold for Initial Height Sense has timed out
10350 PAT Not Established Pilot Arc Current not established within 2 seconds
10360 TAC Not Established Transferred Arc Current not established within 2
seconds
10370 Current Unbalanced Current is not balanced between chopper
assemblies (275A and 400A systems)
10380 TAC Lost 1 Transferred Arc lost during TAC hold time
10390 TAC Lost 2 Transferred Arc lost during Upslope
10400 TAC Lost 3 Transferred Arc lost during Cutting
10410 TAC Lost 4 Transferred Arc lost during Downslope
10420 FCC Unreached Did not achieve final cut current
10430 Output Over Current Chopper has exceeded its maximum rated current
10432 Output Over Current TZ Instantaneous Over Current detected
10440 Output Over Voltage Maximum Cutting Voltage has been exceeded.
10450 Start Premature Removal Start Signal removed prior to completion of upslope
10461 Chopper1 Temp Chopper 1 maximum operating temperature
exceeded
exceeded
exceeded
6-7
Gas Console
Code Short Description Long Description
20100 Plasma Adjust Could not adjust Plasma Gas
20110 Shield Adjust Could not adjust Shield Gas
20120 Preflow Adjust Could not adjust Preflow Gas
20130 Postflow Adjust Could not adjust Postflow Gas
20140 Marking Adjust Could not adjust Marking Gas (Automatic Gas Console)
20160 N2 Mix Adjust Could not adjust N2 Mix Gas
20170 O2 Mix Adjust Could not adjust O2 Mix Gas
20200 O2 Low O2 Input Pressure is low
20210 N2 Low N2 Input Pressure is low
20220 Argon Low Argon Input Pressure is low
20230 O2N2 Low Air Input Pressure is low
20240 H17 Low H17 Input Pressure is low
20250 O2 High O2 Input Pressure is high
20260 N2 High N2 Input Pressure is high
20270 Argon High Argon Input Pressure is high
20280 O2N2 High Air Input Pressure is high
20290 H17 High H17 Input Pressure is high
20300 PS Quiet Lost CAN communication with Power Supply
20310 PC Quiet Lost CAN communication with Plasma Controller
6-8
General Troubleshooting
The following contains general troubleshooting guidelines for the Spirit system. Please
contact KALIBURN technical support for any issues not covered in this section. Before
any tests are performed, make sure that all system fuses are good; remove top cover of
power supply to check these fuses.
Problem Possible Cause
Power supply indicator 1. Primary disconnect fuse blown.

(white light) will not 2. Internal power supply fuse is blown (F1A, F1B).
illuminate 3. Power supply indicator light is burned out or the
associated wiring is bad.
4. Control Transformer or associated wiring bad.
Power Supply will not 1. ISC door open.

energize after choosing ON 2. Low coolant level.
and then SELECT on the 3. Fuse is blown (F1-F6).
MGC. 4. Faulty OFF Button or associated wiring.
5. Off Relay faulty.
Power supply will not stay on 1. Faulty DSP board.

after choosing ON and then 2. Off Relay faulty.
SELECT on the MGC.
No arc at the torch 1. Incorrect torch consumables installed.

2. Incorrect gas pressure settings.
3. Pilot arc transistor (PAT) is not operating properly.
Check the PAT LED (D43) on the DSP
microprocessor board.
4. Damaged or loose torch lead connections.
5. Shorted torch or torch leads. Check the continuity
between the Electrode lead and the Nozzle lead to
make sure they are not shorted.
6. Open torch or torch leads. Check the continuity
from the Electrode lead to the torch electrode and
the Nozzle lead to the large brass body of the
torch.
The arc will not transfer to 1. Loose work ground connection.

the workpiece 2. Pierce height too high.
3. Incorrect, damaged, or worn consumables.
6-9
Problem Possible Cause

Primary power has been 1. Check power/communications CAN cable
applied to the system, but connection on back of manual gas console.
the manual gas console 2. Check for blown DIN rail fuse.
screen is blank 3. Check for 120v on pins of power/communications
CAN cable at back of the manual gas console.
The manual gas console 1. Cycle primary power to the Spirit system.
screen is on, but the screen 2. Check the connection of the ribbon cable that
doesn't work connects the keypad to the DSP PCB in the
manual gas console.
Gas pressures will not adjust 1. Wrong consumables installed in torch.

properly 2. Loose pressure transducer cable on PC board in
the MGC.
3. Check connectors on the MGC valve associated
with the malfunction.
Low pressure error 1. Supply gas pressure(s) less than 120 psi.
Pressure error during cut 1. Supply gas pressure(s) fluctuating during cut.
Liquid or torch coolant Infrequent dripping from the drain hole may be
leaking from drain hole in condensation; no action is required.
torch handle. Noticeable flow from the drain hole indicates a
problem with the torch leads and/or connections.
1. Check for damaged or loose torch lead
connections within the torch handle.
6-10
Chopper Test Procedure

WARNING: Only qualified maintenance personnel should perform the chopper
test procedure. The system utilizes potentially fatal A.C. and D.C. voltages. All
maintenance should be performed with safety in mind.
Use extreme caution when working near the power conversion module (i.e.,
chopper). The large electrolytic capacitors store large amounts of energy even
after power has been removed from the system. Wait at least five minutes after
turning off power, and then use a voltmeter to verify that the capacitors are fully
discharged before touching the power conversion module.
Capacitor failure can injure and/or cause property damage. If troubleshooting
requires the system to be powered with the enclosure panels removed, remain
clear of the capacitors. Failure of a capacitor can result in a sudden release of
stored energy causing rupture of the capacitor case.
IMPORTANT: Depending upon the system, there are one, two or three chopper
assemblies in the power supply. The following steps must be performed on each
chopper with the other chopper(s) disabled. To disable a chopper, remove the
plug from J1 on the chopper PCB (see drawing on next page).
2. Open the impulse start console door and disconnect the Green P1 Plug from the
impulse start PCB. Close the impulse start console door to activate the door
interlock switch.
3. Remove the top, left, right and front covers from the power supply to expose the
DSP PCB, input and output terminal blocks and chopper(s).
4. Remove the Electrode, Work and Nozzle leads from the output terminal block, which
is located on the left side of the unit.
5. Ensure the torch head (with a full set of consumables) is properly installed onto the
torch base.
6. Apply primary power to the Spirit system.
7. Release the OFF Button on the Plasma Controller or Manual Gas Console to enable
the system. Press or SELECT the ON Button to energize the system. After the
gases set, prepare to apply a start signal to the unit.
6-11
8. With a start signal applied, check the three phase voltage input to each chopper at
the diode bridge terminals (three screws on the left side of each chopper). Refer to
TABLE 1 for the proper three phase AC voltage.
Note that the system will only energize for approximately two seconds each
time a start signal is applied.
If the voltage is not present, check for primary voltage on the main contactor
(CON 1) and on the primary side of the power transformer.
Diode Bridge Terminals
Chopper PCB
J1 Plug D2 (Green LED) is
under J1 Plug
Top View of Chopper
9. With a start signal applied, check for the proper DC voltage (refer to TABLE 1) at the
output terminal block between Electrode and Work, which is located on the left side
of the unit.
If the proper DC voltage is present, the chopper is working properly.
TABLE 1
Chopper 1 Chopper 2 Chopper 3
3 Phase OCV 3 Phase OCV 3 Phase OCV
AC (DC) AC (DC) AC (DC)
Spirit II
255 370 255 370 255 370
400 Amp
Spirit II
225 325 225 325 N/A N/A
275 Amp
Spirit II
208 300 N/A N/A N/A N/A
150 Amp
6-12
10. If the proper DC voltage is not present at the output terminal block, check the 200
amp fuse F9 (chopper 1), fuse F10 (chopper 2) or fuse F11 (chopper 3) located on
the bottom right of the output bus bars.
If the fuse is open, replace chopper and fuse.
11. If the fuse(s) is good, check if the chopper PWM LED illuminates when a start signal
is applied:
a) check D24 on the DSP PCB – If D24 doesn’t illuminate, replace DSP PCB.
b) check D2 on the chopper PCB – If D2 doesn’t illuminate green, go to step 12.
12. Check PCB power to the chopper from the DSP:

a) Push the OFF Button.
b) Disconnect the J1 plug from the chopper PCB.
c) Leave the OFF Button pushed in.
d) With a digital voltmeter, measure the following voltages on the J1 plug:
J1-5 (ground) to J1-1 +15vdc Supply
J1-5 (ground) to J1-2 +5vdc Supply
J1-5 (ground) to J1-3 +5vdc (PWM Signal)
If ALL of the voltages are present, replace chopper. If any of the voltages are not
present, go to step 13:
13. Remove primary power from the Spirit system. Check cable continuity between the
chopper PCB and DSP PCB. Use a digital voltmeter set up to read resistance
(ohms) and make the following measurements:
Chopper (1) J1-1 to DSP J7-1


If ALL of the continuity readings are good, replace DSP PCB.
6-13
BLANK
6-14
Spirit II User’s Manual Section 7: Parts List
Section 7: Parts List

Power Supply (BK300221 - BK300229)
Right Side View
Item Part Number Quantity Description
4 BK707155 2 L1/L2 Inductor
5 BK706409 1 T2 Control Transformer, 200-480 V / 60 Hz
BK706410 T2 Control Transformer, 600 V / 60 Hz
6 BK706405 1 T1 Main Transformer, 200-480 V / 60 Hz / 3Ø
BK706502 T1 Main Transformer, 600 V / 60 Hz / 3Ø
15 BK709105 1 Strain Relief
30 BK708121 1 CON 1 Main Contactor
31 BK702076 1 EMI Filter, 380/415 V units only
35 BK709167 1 TB5 3 Phase Input Power Terminal Block
38 BK300250 2 Chopper Assembly
44 BK200204 2 Fan (4.7")
38
44
35
15
4 31 6 30
7-1
Section 7: Parts List Spirit II User’s Manual

Left Side View
12 BK300101 1 Printed Circuit Board (PCB), Microprocessor (DSP)
16 BK300112 1 Printed Circuit Board (PCB), A.C. Detect
32 BK708118 2 CR3/PAR Relay
33 BK705011 1 PAT IGBT
34 BK702075 2 PAT IGBT Filter Capacitor
36 BK300108 1 Printed Circuit Board (PCB), Power Supply Output (I/O)
37 BK301200 1 (Optional) Printed Circuit Board (PCB), Voltage Divider
39 BK709117 1 I/O Terminal Block (small)
40 BK280003 2 Power Supply, 24VDC
43 BK708105 2 Relay Hold Down Clip
44 BK200204 1 Fan (4.7")
46 BK709252 1 I/O Terminal Block (large)
50 BK284029 2 Current Sensor
51 BK300130 2 F9/F10 Fuse, 200A
52 BK300129 2 F9/F10 Fuse Holder
53 BK300153 1 Off Relay
54 BK300156 1 Off Relay Socket
58 BK701165 2 R1/R2 Resistor, 300W, 3 Ohm
59 BK701141 1 R3 Resistor, 300W, 2 Ohm
60 BK701083 3 Resistor Mounting Hardware
53 54 43 12 16 40 40
BEHIND 44 33 34
PANEL
60 58
37 60 58
CS2
60 59 PAR CR3 CS1 50

32
32
36 51 52
47
F10 F9
51 52
CS4
47
39 46 50
7-2

Top View
1 BK501163 1 Light Housing
2 BK501164 1 Bulb
3 BK501162 1 White Lens
5 BK706409 1 T2 Control Transformer, 200-480 V / 60 Hz
BK706410 T2 Control Transformer, 600 V / 60 Hz
7 BK709359 1 F3 Fuse, 5A, Slow Blow
8 BK709358 1 F4 Fuse, 5A, Medium Blow
9 BK709358 1 F5 Fuse, 5A, Medium Blow
10 BK709360 1 F6 Fuse, 6.3A
13 BK709061 2 F1A/F1B Fuse Holder
14 BK709128 2 F1A/F1B Fuse, FNM 6.25A
18 BK500518 1 Coolant Reservoir Cap/Level Gauge
38 BK300250 2 Chopper Assembly
41 BK708103 2 Fan/CR5 Relay
42 BK708104 2 Relay Socket
43 BK708105 4 Relay Hold Down Clip
1 2 3
38 18
5
CA1
14 13
38 F1A F1B
CA2
FANS CR5
43 42 41 7 8 9 10 41 42 43
F3 F4 F5 F6
(pos 1) (pos 4) (pos 12) (pos 17)
7-3

Cooling Section View
17 BK200092 1 Coolant Reservoir, without Fittings or Cap
18 BK500518 1 Coolant Reservoir Cap/Level Gauge
19 BK300135 1 Coolant Level Switch
20 BK505024 1 Coolant Temperature Switch
21 BK500052 1 Coolant Pump Motor, 1/3hp-230V-50/60 Hz
22 BK500513 1 V-Band Clamp
23 BK500511 1 Coolant Pump, 70 gph
24 BK708061 1 Solenoid Valve, 220/240VAC
25 BK715118 1 Check Valve, Coolant Return
26 BK300134 1 Coolant Flow Sensor
27 BK260250 1 Heat Exchanger
28 BK500509 1 Coolant Filter Housing
29 BK500510 1 Coolant Filter / Deionization Cartridge
45 BK500526 3 Fan Guard (Mounted Outside)
49 BK500525 2 Fan (6")
61 BK284031 1 Fan (10")
18 17
19
20 49 45
27
49 45
26
29 28
61 45
24
15
25
21
23 22
7-4
Manual Gas Console (BK300600)

Right Side View
1 BK300412 1 Power Supply, 24VDC, 8.3A
2 BK300301 1 Printed Circuit Board (PCB), Gas Console DSP
3 BK280030 1 Fan, 24VDC
4 BK300602 1 Keypad
5 BK300603 1 LCD Display
6 BK708111 1 Switch, Pushbutton (OFF Button)
8 BK280032 1 Marking Regulator, 0-60 PSI, 145 PSI Max Input
9 BK500570 2 Plasma/Shield Regulator, 0-125 PSI
10 BK300605 1 Manifold Block, Gas Outputs
3 1
6
5
2
4
8 10
7-5
Manual Gas Console (BK300600)

Left Side View
1 BK300412 1 Power Supply, 24VDC, 8.3A
2 BK300301 1 Printed Circuit Board (PCB), Gas Console DSP
3 BK280030 1 Fan, 24VDC
6 BK708111 1 Switch, Pushbutton (OFF Button)
7 BK500562 1 Preflow Regulator, 0-60 PSI
8 BK280032 1 Marking Regulator, 0-60 PSI, 145 PSI Max Input
9 BK500570 1 Postflow Regulator, 0-125 PSI
11 BK300414 1 Manifold Block, Gas Inputs
1 3
8
11
7-6
Impulse Start Console (BK300500)

1 BK715051 2 Coolant Return Fitting (left hand)
2 BK715050 1 Coolant Supply Fitting (right hand)
3 BK715021 1 Coolant Supply Fitting (right hand)
4 BK709001 1 4 Pin Receptacle
5 BK708057 1 Door Interlock Switch
6 BK500503 1 Cathode Manifold
7 BK980200 1 Printed Circuit Board (PCB), Impulse Start
8 BK980201 1 Impulse Start Manifold
9 BK707300 1 Inductor
6 7
2 9 1 4
7-7
Torch and Manifold Assemblies

1 BK284214 1 2-Gang Manifold (includes Bracket)
2 BK277195 1 2-Gang Manifold Bracket
3 BK278001 1 Torch Handle – Standard
BK278018 Torch Handle – Short
4 BK279000 1 Torch Base
5 BK279100 1 Torch Head (Copper Electrode)
BK279060 Torch Head (Silver Electrode)
6 BK820209 1 O-ring (red)
7 BK500024 1 O-ring (blue)
8 BK500018 1 O-ring (red)
9 BK279013 1 O-ring (red) - indicator only, not a seal
10 BK279112 1 O-ring (red)
11 BK279113 6 O-ring (red)
12 BK284039 1 (17") Torch Solenoid Plasma Hose
13 BK280022 1 5-Gang Manifold for Manual Gas Console
Not shown BK716012 1 O-ring Lubricant
Not shown BK277056 1 Nozzle Removal Tool
Not shown BK277086 1 Electrode Removal Tool Driver
Not shown BK277087 1 Copper Electrode Removal Tool
Not shown BK279061 1 Silver Electrode Removal Tool
12
13
2
3
10
11
4
11
9 11
5
7-8
Shielded Torch Leads

Part Number Length
BK284304-XX Where -XX is the length in feet. Available
in 5 foot increments up to 40 feet.
CAN Communication Cable and Termination Plug

Item Part Number Length
CAN Termination Plug BK300408 N/A
CAN Cable BK300177-XX Where -XX is the length in feet.
Available in 5 foot increments.
Manifold Control Cables

Item Part Number Length
2-Gang Manifold BK280312-XX Where -XX is the length in feet.
5-Gang Manifold BK280321-XX Available in 5 foot increments.

 

 
7-9
Gas Hose Package with MGC

Part Number Length*
BK300085-20 20 ft. (6.1m)
BK300085-30 30 ft. (9.1m)
BK300085-40 40 ft. (12.2m)
BK300085-50 50 ft. (15.2m)
BK300085-60 60 ft. (18.3m)
*Custom lengths are available. Contact factory.

 

 

  

 

 

  

  
7-10
Coolant and Power Leads

Part Number Part Number
Length
(Non-CSA Systems) (CSA Systems)
BK280306-XX BK288306-XX Where -XX is the length in feet.

 

 

 

 

 

 
Work Ground Lead

Part Number Part Number
Length
(Non-CSA Systems) (CSA Systems)
BK280318-XX BK288318-XX Where -XX is the length in feet.
 
7-11
Oxygen Supply Gas Hose (Optional)

Part Number Length
BK200362-25 25 ft. (7.6 m)
BK200362-50 50 ft. (15.2 m)
BLUE BLUE
Nitrogen Supply Gas Hose (Optional)

Part Number Length
BK200365-25 25 ft. (7.6 m)
BK200365-50 50 ft. (15.2 m)
BLACK BLACK
Air Supply Gas Hose (Optional)

Part Number Length
BK200364-25 25 ft. (7.6 m)
BK200364-50 50 ft. (15.2 m)
BLACK BLACK
H17 Supply Gas Hose (Optional)

Part Number Length
BK200363-25 25 ft. (7.6 m)
BK200363-50 50 ft. (15.2 m)
RED RED
7-12
“CII” Cable (for Optional External Inova)

Part Number Length
BK300902-XX Where -XX is the length in feet.
STRAIN RELIEF BK709015
CABLE BK711001
PLUG BK709016 PLUG BK709364

BK709018 SOCKET BK709365 PIN
BK709365 PIN
BK709018 SOCKET
BK709019 KEY
7-13
“FII” Cable (for Optional Internal Inova)

Part Number Length
CABLE BK711002

BK709365 PINS BK709018 SOCKET
BK709018 SOCKET
BK709365 PINS
BK709018 SOCKET
BK711005 BK709018 SOCKET
7-14
“JII” Cable (for Optional Internal Inova)

Part Number Length

CABLE BK711049
BK709018 SOCKET BK709365 PIN
BK709365 PIN
BK709018 SOCKET
BK709019 KEY
7-15
PCB Assemblies – Component Reference Locations

Power Supply, Microprocessor DSP (BK300101) – Quadrant 1
1 3
2 4
PCB Quadrant Map
J17 J13
U37 - RHF
U36
J20
U35
U34 – Impulse Start

J22
U32 - Marking
U31 – Postflow
U30 - Vent
J19
U29 - Shield
7-16
1 3
2 4
PCB Quadrant Map
U28 - Plasma
U27 - Preflow
U19 – Solenoid (not used)

J12
U21 – Mtr / Sol
U22 - PAR
U24 - Surge
J16
U26 - Fan
J15 J14 J1
U23 - Con
7-17
1 3
2 4
PCB Quadrant Map
J18 J11
J3
7-18
1 3
2 4
PCB Quadrant Map
J21
J7
J4-1
J8
J4-2 J10
J3
J9
7-19
Power Supply, Output (BK300108)
7-20
Power Supply, A.C. Detect (BK300112)
7-21
Gas Supply, Microprocessor DSP (BK300301) – Quadrant 1
1 3
2 4
PCB Quadrant Map
J25 J19
J4
7-22
1 3
2 4
PCB Quadrant Map
J6
J5
J31 J28
7-23
1 3
2 4
PCB Quadrant Map
J19 J20 J21
J17
J13
7-24
1 3
2 4
PCB Quadrant Map
J13
J9
J18
7-25
Chopper, Gate Driver (BK300106)
7-26
Spirit II User’s Manual Section 8: Internal Inova Console Option
Section 8: Internal Inova Console Option

Overview
This optional Inova system is designed to provide arc voltage control to any plasma
cutting system, however, combining it with the Spirit II provides the added convenience
of having Inova console built directly into the plasma power supply.
This section only covers topics unique to the Spirit II system with the internally installed
Inova console. See the standard Inova manual for all other Inova information.
Plug Identification
Connections for the internal Inova console option are distinguished from other
connections on the back of the power supply by the addition of the letter "I" before the
plug number. The function of each plug (e.g., IP1) is the same as the corresponding
plug found on the external Inova console (e.g., P1).
POSITIONER POSITIONER
CONSOLE #2 CONSOLE #2
REMOTE REMOTE
X/Y MACHINE
RS-422 RS-422 X/Y

RS-422 IN OUT IN MACHINE
RS-422 OUT
Spirit II 150/275 Spirit II 400
Unique Interconnect Cables

Two unique interconnect cables are required for this option with the Spirit II system.
The FII cable is used to connect the Spirit II internal Inova console (IP4) to the X/Y
Machine (CNC controller). The JII cable is used to connect multiple Spirit II internal
Inova consoles (IP8). See the parts list in Section 7 for more details on these cables.
8-1
Section 8: Internal Inova Console Option Spirit II User’s Manual
Grounding
The internal Inova console must be connected to the same protective earth ground as
the plasma power supply and in accordance with national or local codes. The figures
below describe two methods. Use a minimum of #8AWG (10 mm2) wire.
Note: the customer must supply the ground cable.
Direct to star ground:
Ground Ground
Point Point
Jumper to the work ground lead:
Ground Ground
Point Point
8-2
Parts List
1 BK110200 1 Printed Circuit Board (PCB), Microprocessor
2 BK110705 1 Printed Circuit Board (PCB), Power Distribution
3 BK110900 1 Printed Circuit Board (PCB), H-Bridge
4 BK706003 1 Transformer
5 BK709360 1 F7 Fuse, 6.3A
6 BK709370 1 F8 Fuse, 3A
7 BK301200 1 Printed Circuit Board (PCB), Voltage Divider
8 BK709276 1 Power Distribution Block,1 Pole
Location in Spirit II 150 & 275
4 3 2
5 6
F7 F8
(pos A) (pos B)
8-3
Location in Spirit II 150 & 275 - Continued
8-4
Location in Spirit II 400
4 3 2
5 6
F7 F8
(pos A) (pos B)
8-5
Location in Spirit II 400 - Continued
8-6
Spirit II User’s Manual Appendix A: Electromagnetic Compatibility (EMC)
Appendix A:
Electromagnetic Compatibility (EMC)
Background
The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit plasma cutting systems are
manufactured to comply with the European standard EN 60974-10 (Electromagnetic
compatibility (EMC) – Product standard for arc welding equipment). The system has
been tested in accordance with CISPR 11, EMC classification – Group 2 ISM (Class A).
The limits used in this standard are based on practical experience. However, the ability
of plasma cutting equipment to work in a compatible manner with other radio and
electronic systems is greatly influenced by the manner in which it is installed and used.
For this reason, it is important that the plasma cutting equipment be installed and used
in accordance with the information below if electromagnetic compatibility is to be
achieved.
Plasma cutting equipment is primarily intended for use in an industrial environment.

There may be potential difficulties in ensuring electromagnetic compatibility in other
environments.
Installation and Use

The user is responsible for installing and using the plasma cutting equipment according
to the manufacturer’s instructions. If electromagnetic disturbances are detected then it
shall be the responsibility of the user of the plasma cutting equipment to resolve the
situation with the technical assistance of the manufacturer. In some cases this remedial
action may be as simple as earthing the plasma cutting circuit, see Note. In other cases
it could involve constructing an electromagnetic screen enclosing the plasma power
source and the work, complete with associated input filters. In all cases,
electromagnetic disturbances shall be reduced to the point where they are no longer
troublesome.
Note: The plasma cutting circuit may or may not be earthed for safety reasons.
Changing the earthing arrangements should only be authorized by a person who is
competent to assess whether the changes will increase the risk of injury, e.g. by
allowing parallel plasma cutting current return paths which may damage the earth
circuits of other equipment. Further guidance is given in IEC 974-13 Arc welding
equipment – Installation and use.
A-1
Appendix A: Electromagnetic Compatibility (EMC) Spirit II User’s Manual
Assessment of Area
Before installing plasma cutting equipment, the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The following shall be
taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below
and adjacent to the plasma cutting equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g. guarding of industrial equipment;
e) the health of the people around, e.g. the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement;
g) the immunity of other equipment in the environment; the user shall ensure that other
equipment being used in the environment is compatible; this may require additional
protection measures;
h) the time of day that plasma cutting or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the structure of the
building and other activities that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
Methods of Reducing Emissions

Mains Supply
Plasma cutting equipment should be connected to the mains supply according to the
manufacturer’s recommendations. If interference occurs, it may be necessary to take
additional precautions such as filtering of the mains supply. Consideration should be
given to shielding the supply cable of permanently installed plasma cutting equipment in
metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the plasma power source so that good
electrical contact is maintained between the conduit and the plasma power source
enclosure.
Maintenance of the Plasma Cutting Equipment

The plasma cutting equipment should be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and covers should be
closed and properly fastened when the plasma cutting equipment is in operation. The
plasma cutting equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturer’s instructions. In particular, the spark
gaps of arc striking and stabilizing devices should be adjusted and maintained
according to the manufacturer’s recommendations.
Plasma Cutting Cables

The plasma cutting cables should be kept as short as possible and should be positioned
close together, running at or close to the floor level.
A-2
Spirit II User’s Manual Appendix A: Electromagnetic Compatibility (EMC)
Equipotential Bonding
Bonding of all metallic components in the plasma cutting installation and adjacent to it
should be considered. However, metallic components bonded to the workpiece will
increase the risk that the operator could receive a shock by touching these metallic
components and the electrode at the same time. The operator should be insulated from
all such bonded metallic components.
Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth
because of its size and position, e.g. ship’s hull or building steelwork, a connection
bonding the workpiece to earth may reduce emissions in some, but not all instances.
Care should be taken to prevent the earthing of the workpiece increasing the risk of
injury to users, or damage to other electrical equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct connection to the
workpiece, but in some countries where direct connection is not permitted, the bonding
should be achieved by suitable capacitance, selected according to national regulations.
Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding
area may alleviate problems of interference. Screening of the entire welding installation
may be considered for special applications.
A-3
Appendix A: Electromagnetic Compatibility (EMC) Spirit II User’s Manual
BLANK
A-4

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User's Manual

This documentation may not be copied, photocopied, reproduced, translated,

FASTON is a trademark of the TE Connectivity Ltd family of companies.

Other logos, products and company names mentioned herein

© Copyright 2013-2014 Lincoln Global, Inc.

Section 5: Torch Consumables and Cutting Charts

Section 6: Maintenance and Troubleshooting

Section 7: Parts List

Section 8: Internal Inova Console Option

Appendix A: Electromagnetic Compatibility (EMC)

Returned Goods Procedure

Electromagnetic Compatibility (EMC)

Ultraviolet Radiation Protection

Toxic Fume Prevention

Electric Shock Prevention

• A wall-mounted disconnect switch should be installed and fused according to local

• Compressed gas cylinders should be maintained properly. Never attempt to use a

Health Support Equipment

Safety Standards Booklet Index

16. CGA booklet P-14, Accident Prevention in Oxygen-Rich and Oxygen-Deficient

Power Supply Specifications

Open Circuit Voltage ......................................... 325 VDC

29.0" [737] 43.2" [1097]

Torch Coolant Specifications

Manual Gas Console (MGC) Specifications

12.0" [305] 13.7" [348]

(4) Ø .300 [7.6]

Gas Supply Requirements

Plasma gas flow rate (maximum):

Rated Inlet gas pressure ................................... 115 psi (7.9 bar)

Oxygen and nitrogen should be supplied with a purity of at least 99.5%.

Impulse Start Console (ISC) Specifications

Torch and 2-Gang Manifold Specifications

BK278001 = 9.46" [240]

5-Gang Manifold Specifications

(4) 0.187" [4.8] Mounting Holes

Airborne Noise Emissions

A-Weighted Sound C-Weighted Sound

Manual Gas Console (MGC)

Impulse Start Console (ISC)

Power Supply Primary Power Connections

A primary disconnect switch, switching all ungrounded supply conductors, should be

Input Current Recommended

Strain Relief Disconnect Box

Figure 3: Power Supply Primary Connections

Power Supply Output Connections

Power Supply Electrode Lead 1

Power Supply Nozzle Lead 2

Power Supply CTP Sensor Lead 3

Work Ground Lead 4

Figure 4: Power Supply Output Connections

ISC Control Cable and ISC Ground Connections

ISC Ground Cable 6

Cooling System Connections

Coolant Return Hose 8

Figure 5: Cooling System Connections

Torch Leads to Impulse Start Console Connections

Torch Electrode/Coolant Supply Lead 12

Torch Coolant Return Lead 13