Lincoln Electric BURNY KALIBURN Spirit II 275 Bedienungsanleitung

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

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to

non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

Revision History

Rev

ECO#

Author

Date

Description of Change

A - CAD 02/04/2013 Initial Release.

B LAD0202 CAD 06/07/2013

Added 100A/150A silver electrodes, replaced RHF with

ISC, corrected system interconnect diagrams, changed

rated inlet gas pressure to 115 psi, added 100 psi

minimum to inlet gas pressure.

C LAD0217 CAD 08/06/2013

Deionization filter cartridge (500510) replaced sediment

filter (300152). Parts list updated.

Expanded notes on System Interconnection diagrams to

clarify cabling requirements for various configurations.

D LAD0228

LAD0223 CAD 08/28/2013

Corrected contact ratings on page 3-19.

Added pinouts to CII, FII, JII cables in Parts List.

Corrected part numbers for coolant/power leads and

work ground in Parts List.

E LAD0260 CAD 03/18/2014

Inductor (707150) replaced by (707155). 10” fan

(500516) replaced by (284031). Added notes about torch

handle vent hole. Updated Chopper Test Procedure.

F LAD0264 CAD 03/31/2014

Added “BK” prefix to all part numbers. Added PCB

Outline Dwgs and corrected electrode tool in Part List.

Corrected Remote On/Off info in Installation section.

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

or reduced to any electronic medium or machine-readable format without

explicit written permission from Kaliburn.

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

Other logos, products and company names mentioned herein

may be trademarks of their respective owners.

Kaliburn Inc.

a Lincoln Electric Company

4130 Carolina Commerce Parkway

Ladson, SC 29456 USA

Spirit II User’s Manual Prologue

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to

non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

iii

Table of Contents

Section 1: Safety

General Precautions .........................................................................................1-1

Ultraviolet Radiation Protection.........................................................................1-1

Noise Protection................................................................................................1-1

Toxic Fume Prevention .....................................................................................1-2

Electric Shock Prevention .................................................................................1-2

Fire Prevention..................................................................................................1-3

Explosion Prevention.........................................................................................1-3

Health Support Equipment................................................................................1-4

Safety Standards Booklet Index........................................................................1-5

Section 2: Specifications

System Description ...........................................................................................2-1

System Components.........................................................................................2-2

Power Supply Specifications.............................................................................2-3

Torch Coolant Specifications.............................................................................2-4

Manual Gas Console (MGC) Specifications......................................................2-5

Gas Supply Requirements ................................................................................2-6

Impulse Start Console (ISC) Specifications.......................................................2-7

Torch and 2-Gang Manifold Specifications........................................................2-8

5-Gang Manifold Specifications.........................................................................2-9

Airborne Noise Emissions.................................................................................2-10

Section 3: Installation

Initial Inspection ................................................................................................3-1

Component Placement......................................................................................3-1

System Interconnection.....................................................................................3-2

Power Supply Primary Power Connections.......................................................3-5

Power Supply Output Connections ...................................................................3-7

ISC Control Cable and ISC Ground Connections..............................................3-9

Cooling System Connections............................................................................3-9

Torch Leads to Impulse Start Console Connections.........................................3-11

Torch Leads to Torch Base Connections..........................................................3-13

Torch Gas Connections.....................................................................................3-14

Gas Supply Connections...................................................................................3-17

CAN Communication Connections....................................................................3-18

CNC Machine Interface Connections................................................................3-19

Filling the Cooling System.................................................................................3-20

Prologue Spirit II User’s Manual

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to

non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

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

Spirit II User’s Manual Prologue

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to

non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

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

Prologue Spirit II User’s Manual

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to

non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

Limited Warranty

KALIBURN expressly warrants that this product shall be free from defects in materials

and workmanship, under proper and normal use for the intended function of such

product, for a period of three (3) years for the Spirit II plasma power supply (includes the

cooling system and internally installed Inova option) and one (1) year for all other Spirit

II system component. This warranty does not apply to torch consumable parts.

The warranty period starts three (3) months after the product ships from the factory.

This product is intended for commercial use and is not intended for personal, family, or

household purposes. There are no warranties that extend beyond the express limited

warranty set forth immediately above. All other warranties, whether expressed, implied,

statutory or made herein or in any other communication, including any implied warranty

of merchantability, fitness for any particular purpose or non-infringement, are expressly

excluded.

This warranty will be considered void if the Spirit II system is operated with non-genuine

KALIBURN torch consumables, or if the equipment has been subjected to improper

installation, improper care or abnormal operation.

If this product or any component thereof is determined to be defective in materials or

workmanship, KALIBURN will repair or replace the defective component or product.

The buyer’s remedies are limited to the return of the product for repair or replacement of

any defective product or part at the sole discretion of KALIBURN. No freight charges of

any kind are covered under this warranty. All returned goods shall be at the buyer’s risk

and expense. In no event will KALIBURN be responsible for any special, incidental or

consequential damages or injury to the person or property of anyone by reason of any

defect in any equipment sold hereunder.

Returned Goods Procedure

KALIBURN utilizes a returned goods procedure that must be followed before returning

any items for repair, replacement, or restocking. This means that a returned goods

authorization number must be obtained prior to shipment to KALIBURN. It will be

necessary for the customer to provide a description, along with the part number and

serial number, if applicable, of the item to be returned. In no case will KALIBURN

accept a returned shipment without the proper returned goods authorization number.

For shipments inside the U.S., parts must be returned to KALIBURN within 30 days of

the invoice date to be considered for credit. For shipments outside the U.S., parts must

be returned within 60 days of the invoice date to be considered for credit.

Electromagnetic Compatibility (EMC)

The 380V 50/60Hz and 415V 50/60Hz CE marked Spirit II plasma cutting systems are

manufactured to comply with the European standard EN 60974-10 (Electromagnetic

compatibility (EMC) – Product standard for arc welding equipment). Information about

the EMC standard EN 60974-10 can be found in Appendix A.

Spirit II User’s Manual Section 1: Safety

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to

non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

1-1

Section 1: Safety

General Precautions

Whereas plasma cutting has been used safely for years, it does require certain

precautions to ensure the safety of the operator and other people around the

equipment. The following safety information must be provided to each person who will

operate, observe, perform maintenance, or work in close proximity to this piece of

equipment.

Installation, operation, and repairs made to the Spirit system should only be performed

by qualified personnel. The system makes use of both A.C. and D.C. circuitry for

operation. Fatal shock hazard does exist. Exercise extreme caution while working

on the system.

Ultraviolet Radiation Protection

Plasma cutting produces ultraviolet radiation similar to a welding arc. This ultraviolet

radiation can cause skin and eye burns. For this reason, it is essential that proper

protection be worn. The eyes are best protected by using safety glasses or a welding

helmet with an AWS No. 12 shade or ISO 4850 No. 13 shade, which provides protection

up to 400 amperes. All exposed skin areas should be covered with flame-retardant

clothing. The cutting area should also be prepared in such a way that ultraviolet light

does not reflect. Walls and other surfaces should be painted with dark colors to reduce

reflected light. Protective screens or curtains should be installed to protect additional

workers in the area from ultraviolet radiation.

Noise Protection

The system generates high noise levels while cutting. Depending on the size of the

cutting area, distance from the cutting torch, and arc current cutting level, acceptable

noise levels may be exceeded. Proper ear protection should be used as defined by

local or national codes. See Section 2 for noise emission levels.

Section 1: Safety Spirit II User’s Manual

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to

non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

1-2

Toxic Fume Prevention

Care should be taken to ensure adequate ventilation in the cutting area. Some

materials give off toxic fumes that can be harmful or fatal to people in the vicinity of the

cutting area. Also, some solvents decompose and form harmful gases when exposed

to ultraviolet radiation. These solvents should be removed from the area prior to cutting.

Galvanized metal can produce harmful gases during the cutting process. Ensure proper

ventilation and use breathing equipment when cutting these materials.

Certain metals coated with or containing lead, cadmium, zinc, beryllium, and mercury

produce harmful toxins. Do not cut these metals unless all people subjected to the

fumes wear proper air breathing equipment.

Electric Shock Prevention

The Spirit system uses high open circuit voltages that can be fatal. Extreme care

should be used when operating or performing maintenance on the system. Only

qualified personnel should service the system. Observe the following guidelines to

protect against electric shock:

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

and national electrical codes. The disconnect switch should be located as close as

possible to the power supply so it can be turned off in case of an emergency.

•The primary power cord should have a 600 volt minimum rating in order to protect

the operator. In addition, it should be sized according to local and national electrical

codes. Inspect the primary power cord frequently. Never operate the system if the

power cord is damaged in any way.

•Make sure the primary power ground wire is connected to the input power ground

stud on the power supply. Make sure the connection is securely tightened.

•Make sure the positive output (work ground) of the power supply is connected to a

bare metal area on the cutting table. A driven ground rod should be placed no

further than five feet from this connection. Make sure this ground point on the

cutting table is used as the star ground point for all other ground connections.

•Inspect the torch leads frequently. Never use the system if the leads are damaged

in any way.

•Do not stand in wet, damp areas when operating or performing maintenance on the

system.

•Wear insulated gloves and shoes while operating or performing maintenance on the

system.

•Make sure the system is switched off at the wall disconnect before servicing the

power supply or torch.

Spirit II User’s Manual Section 1: Safety

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to

non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

1-3

•Never change torch consumable parts unless the system is switched off at the wall

disconnect.

•Do not attempt to remove any parts from beneath the torch when cutting.

Remember that the workpiece forms the current path back to the power supply.

•Never bypass the safety interlock devices.

•Before removing any of the covers, switch the system off at the wall disconnect.

Wait at least five (5) minutes before removing any cover. This will give the

capacitors inside the unit time to discharge. See Section 6 for additional safety

precautions.

•Never operate the system without all of the covers in place. See Section 6 for

additional safety precautions.

•Preventive maintenance should be performed daily to avoid possible safety hazards.

Fire Prevention

When using the Spirit system, it is necessary to exercise good judgment. While cutting,

the arc produces sparks that could cause a fire if they fall on flammable materials.

Make sure that all flammable materials are a suitable distance away from the cutting

area. All flammable liquids should be at least 40 feet away from the cutting area,

preferably stored in a metal cabinet. Plasma cutting should never be attempted on

containers that contain flammable materials. Make sure that fire extinguishers are

readily accessible in the cutting area.

Make sure that the cutting area is properly ventilated when using oxygen as a cutting

gas.

Explosion Prevention

The Spirit system uses compressed gases. Use proper techniques when handling

compressed gas cylinders and other compressed gas equipment. Observe the

following guidelines to protect against explosion:

•Never operate the system in the presence of explosive gases or other explosive

materials.

•Never cut pressurized cylinders or any closed container.

•When using a water table and cutting aluminum under water or with water touching

the underside of the aluminum plate, hydrogen gas is produced. This hydrogen gas

may collect under the plate and explode during the cutting process. Make sure the

water table is properly aerated to help prevent the accumulation of hydrogen gas.

•Handle all gas cylinders in accordance with safety standards published by the U.S.

Compressed Gas Association (CGA), American Welding Society (AWS), Canadian

Standards Association (CSA), or other local or national codes.

Section 1: Safety Spirit II User’s Manual

This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to

non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.

1-4

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

cylinder that is leaking, cracked, or has other signs of physical damage.

•All gas cylinders should be secured to a wall or rack to prevent accidental knock

over.

•If a compressed gas cylinder is not being used, replace the protective valve cover.

•Never attempt to repair compressed gas cylinders.

•Keep compressed gas cylinders away from intense heat, sparks, or flames.

•Clear the compressed gas cylinder connection point by opening the valve

momentarily prior to installing a regulator.

•Never lubricate compressed gas cylinder valves or pressure regulators with any type

of oil or grease.

•Never use a compressed gas cylinder or pressure regulator for any purpose other

than which it is intended.

•Never use a pressure regulator for any gas other than which it is intended.

•Never use a pressure regulator that is leaking or has other signs of physical

damage.

•Never use oxygen hoses and pressure regulators for any gas other than oxygen.

•Never use any gas hose that is leaking or has other signs of physical damage.

Health Support Equipment

The Spirit system creates electric and magnetic fields that may interfere with certain

types of health support equipment, such as pacemakers. Any person who uses a

pacemaker or similar item should consult a doctor before operating, observing,

maintaining, or servicing the system. Observe the following guidelines to minimize

exposure to these electric and magnetic fields:

•Stay as far away from the power supply, torch, torch leads, and impulse start

console as possible.

•Route the torch leads as close as possible to the work ground cable.

•Never place your body between the torch leads and work ground cable. Keep the

work ground cable and the torch leads on the same side of your body.

•Never stand in the center of a coiled up set of torch leads or work ground cable.

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