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Kaliburn SR-100i User manual

Manual is about: Plasma Cutting System Without Ohmic Contact Torch

Summary of SR-100i

  • Page 1

    Sr-100i user’s manual sr-100i plasma cutting system without ohmic contact torch revision 10 5/17/07 manual part number 718048 455 fleming road charleston, sc 29412 usa (800) 252-2850 – toll free (843) 795-4286 – phone (843) 795-8931 – fax www.Kaliburn.Net.

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  • Page 3: Limited Warranty

    Sr-100i user’s manual limited warranty kaliburn expressly warrants that this product shall be free from defects in materials and workmanship, under proper and normal use for the intended function of such equipment, for a period of one (1) year for the sr-100i torch and leads and three (3) years for ...

  • Page 4

    Sr-100i user’s manual electromagnetic compatibility (emc) the 220/380v 50hz and 415v 50hz sr-100i plasma cutting systems are manufactured to comply with the european standards en 60974 (arc welding equipment – part 1: welding power sources) and en 50199 (electromagnetic compatibility (emc) – product...

  • Page 5: Table of Contents

    Sr-100i user’s manual table of contents section 1 safety ..……………………………………..……………………………. 1-1 general precautions .…………………………………………………..……….…..……… 1-1 ultraviolet radiation protection ..…………………………………………………………. 1-1 noise protection .……………………………………………………..……………………. 1-1 toxic fume prevention ...………………………...

  • Page 6: Section 6  Parts List

    Sr-100i user’s manual section 5 maintenance and troubleshooting ............................ 5-1 daily procedures ...................……........................................................................................ 5-1 monthly procedures ........................................................

  • Page 7

    Sr-100i user’s manual figure 5-1 230v 60 hz three phase transformer ......................................................... 5-5 figure 5-2 460v 60 hz three phase transformer ......................................................... 5-5 figure 5-3 220v 50 hz three phase transformer ...................

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  • Page 9: Section 1  Safety

    Safety sr-100i user’s manual 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. It is management’s responsibility to see that the following safety ...

  • Page 10: Electric Shock Prevention

    Safety sr-100i user’s manual 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 ...

  • Page 11: Fire Prevention

    Safety sr-100i user’s manual will give the capacitors inside the unit time to discharge. • never operate the sr-100i system without all of the covers in place. • preventive maintenance should be performed daily to avoid possible safety hazards. Fire prevention when using the sr-100i system, it is ne...

  • Page 12: Health Support Equipment

    Safety sr-100i user’s manual 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 o...

  • Page 13

    Safety sr-100i user’s manual 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...

  • Page 14

    Safety sr-100i user’s manual 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 standar...

  • Page 15: Section 2  Specifications

    Specifications sr-100i user’s manual section 2 specifications system description the sr-100i is a versatile, 100 amp, 100% duty cycle conventional air plasma cutting system that provides continuous operation, patented long life electrodes, and a true constant current output from 25 to 100 amperes. T...

  • Page 16

    Specifications sr-100i user’s manual input current at maximum output: 208 vac, 3Ø ....................................................... 54 amps 230 vac, 3Ø ....................................................... 49 amps 380 vac, 3Ø ....................................................... 30 amps 41...

  • Page 17: Torch Specifications

    Specifications sr-100i user’s manual torch specifications stock number: torch main body .................................................. 800280 torch handle assembly ........................................ 770075 diameter .................................................................... 1.375 ...

  • Page 18: Airborne Noise Emissions

    Specifications sr-100i user’s manual airborne noise emissions the sr-100i 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...

  • Page 19: Operating Modes

    Specifications sr-100i user’s manual operating modes the operating mode of the sr-100i is switch selectable and can either be mechanized, manual, grate, or insulation. The mode switch is located on the left side of the power supply. The operating modes are described below. Mechanized cutting mode: a...

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  • Page 21: Section 3  Installation

    Installation sr-100i user’s manual section 3 installation initial inspection all systems undergo full testing before being shipped from kaliburn. In the unlikely event that one of your components is defective or missing, please contact kaliburn so a replacement item can be sent to you. Also, kalibur...

  • Page 22

    Installation sr-100i user’s manual input voltage (vac) phase input current at maximum output (amps) recommended time-delay fuse size (amps) 208 3 54 70 230 3 49 70 380 3 30 40 415 3 27 35 460 3 25 30 575 3 20 25 use a type so power cable to connect the primary power to the sr-100i power supply. The ...

  • Page 23

    Installation sr-100i user’s manual power supply output connections perform the following steps to connect the output of the power supply to the torch leads and the work table. See figure 3-2 for additional information. Note: when making hose connections, only tighten the brass fittings enough to mak...

  • Page 24

    Installation sr-100i user’s manual sr−100i figure 3-2 power supply output connections 3-4.

  • Page 25: Torch Connections

    Installation sr-100i user’s manual torch connections perform the following steps to connect the torch leads to the torch. Note: when making hose connections, only tighten the brass fittings enough to make a gas seal. The fittings are subject to damage if over tightened. Also, use two wrenches when t...

  • Page 26: Gas Supply Connections

    Installation sr-100i user’s manual gas supply connections the sr-100i requires clean, dry, oil-free compressed gas for good cut quality, as well as long consumable life. The sr-100i plasma system is supplied with a regulator-filter to filter the incoming gas supply. Additional filtration may be requ...

  • Page 27

    Installation sr-100i user’s manual sr−100i figure 3-4 gas supply connections 3-7.

  • Page 28

    Installation sr-100i user’s manual cnc machine interface connections perform the following steps to properly interface the sr-100i system with a cnc cutting machine. See the system schematic for additional information. Plasma start signal • the sr-100i requires a contact closure between p8 pins 3 an...

  • Page 29: Section 4  Operation

    Operation sr-100i user’s manual section 4 operation power supply front panel controls the sr-100i controls and status indicator lights are located on the front panel of the system. This section describes the function of each control and indicator. See figure 4-1 for front panel control and indicator...

  • Page 30: Mechanized Cutting Mode

    Operation sr-100i user’s manual figure 4-1 front panel controls mechanized cutting mode to place the sr-100i in the mechanized cutting mode, set the mode switch thumbwheel to position number 2. The start signal initiates the following sequence of events: 1. Two-second gas preflow. 2. Pilot arc initi...

  • Page 31: Grate Cutting Mode

    Operation sr-100i user’s manual enabled during restarting of the cutting arc. The cutting sequence is terminated when the plasma start signal is disabled. Grate cutting mode to place the sr-100i in the grate cutting mode, set the mode switch thumbwheel to position number 5. The grate cutting mode is...

  • Page 32: Torch Consumables

    Operation sr-100i user’s manual torch consumables figure 4-2 shows the different torch consumable configurations for cutting various materials with the sr-100i. Figure 4-2 torch consumables 4-4.

  • Page 33: Advanceable Electrode

    Operation sr-100i user’s manual advanceable electrode the sr-100i torch uses a patented advanceable electrode pn 800275. This means on an average, an electrode can be used four different times. The length of time a particular electrode can be used is determined by the depth of the crater that is for...

  • Page 34: Setting Up A Cut

    Operation sr-100i user’s manual setting up a cut use the following procedure to make a cut with the sr-100i. 1. Using the charts in this section, determine the proper torch parts and cutting conditions for the material being cut. 2. Install the proper shield cap onto the retaining cap. Note that the...

  • Page 35: Cut Quality

    Operation sr-100i user’s manual 10. Set the current thumbwheel according to the cutting chart in this section. 11. Set the mode switch to the proper mode, as previously described. 12. The cutting operation is initiated after a start signal is received. The arc should establish after approximately 2 ...

  • Page 36: Cutting Charts

    Operation sr-100i user’s manual cutting charts the following conditions are intended to give the operator the best starting point to use when making a cut on a particular material type and thickness and may not reflect optimum conditions. Different metal compositions, consumable parts wear, and air ...

  • Page 37

    Operation sr-100i user’s manual figure 4-4 mild steel cutting chart (30-50 amps) 4-9.

  • Page 38

    Operation sr-100i user’s manual figure 4-5 mild steel cutting chart (75-100 amps) 4-10

  • Page 39

    Operation sr-100i user’s manual figure 4-6 stainless steel cutting chart (30-50 amps) 4-11.

  • Page 40

    Operation sr-100i user’s manual figure 4-7 stainless steel cutting chart (75-100 amps) 4-12.

  • Page 41

    Operation sr-100i user’s manual figure 4-8 aluminum cutting chart (30-50 amps) 4-13.

  • Page 42

    Operation sr-100i user’s manual figure 4-9 aluminum cutting chart (75-100 amps) 4-14.

  • Page 43: Daily Procedures

    Maintenance and troubleshooting sr-100i user’s manual section 5 maintenance and troubleshooting warning: only qualified maintenance personnel should perform maintenance on the sr-100i system. The system utilizes potentially fatal a.C. And d.C. Voltages. All maintenance should be performed with safet...

  • Page 44: Monthly Procedures

    Maintenance and troubleshooting sr-100i user’s manual monthly procedures 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. ** warning ** remove primary power from the ...

  • Page 45

    Maintenance and troubleshooting sr-100i user’s manual damage. Replace the torch leads if damage is found. Torch 1. Remove all consumables from the torch and verify that the anode-cathode insulator (brown plastic) is in good condition, with no signs of arcing. 2. Check all consumables and discard any...

  • Page 46

    Maintenance and troubleshooting sr-100i user’s manual 230/460v 60 hz transformer configurations 230v 60 hz and 460v 60 hz power supplies are shipped with a dual voltage main transformer tr1. The primary taps on tr1 are labeled with their corresponding voltages. To change the operating voltage for th...

  • Page 47

    Maintenance and troubleshooting sr-100i user’s manual figure 5-1 230v 60 hz three phase transformer figure 5-2 460v 60 hz three phase transformer 5-5.

  • Page 48

    Maintenance and troubleshooting sr-100i user’s manual 220/380v 50 hz transformer configurations 220v 50 hz and 380v 50 hz power supplies are shipped with a dual voltage main transformer tr1. The primary taps on tr1 are labeled with their corresponding voltages. To change the operating voltage for th...

  • Page 49

    Maintenance and troubleshooting sr-100i user’s manual figure 5-3 220v 50 hz three phase transformer figure 5-4 380v 50 hz three phase transformer 5-7.

  • Page 50

    Maintenance and troubleshooting sr-100i user’s manual logic-regulator status led’s if a problem occurs with the sr-100i system, check all of the primary disconnect fuses before proceeding. Also, check fuses f1, f2, and f3 in the power supply. Be sure to check all fuses with an ohmmeter and replace a...

  • Page 51: General Troubleshooting

    Maintenance and troubleshooting sr-100i user’s manual after a transferred cutting arc is established, the following led’s will go out: • h.F. • par (par will remain illuminated in modes 5 and 9) general troubleshooting the following chart lists general troubleshooting guidelines for the sr-100i syst...

  • Page 52

    Maintenance and troubleshooting sr-100i user’s manual regulator pressure is adjusted to 85 psi while gas is flowing through the torch. If the pressure is adjusted to 85 psi, the torch interlock pressure switch (prs1) or associated wiring may be bad. Prs1 is normally open. 6. If the con led illuminat...

  • Page 53

    Maintenance and troubleshooting sr-100i user’s manual primary and secondary windings. Replace tr5 if either winding is open. 8. Remove the wire from the high frequency capacitor c8 and check the capacitor for a short circuit. Replace if necessary. 9. Check the primary and secondary windings of the h...

  • Page 54: Chopper Test Procedure

    Maintenance and troubleshooting sr-100i user’s manual chopper test procedure the following test should be performed when all functions appear to be working correctly but there is no output current. Before performing this procedure, check all torch lead connections, torch consumables, pilot arc relay...

  • Page 55

    Maintenance and troubleshooting sr-100i user’s manual output busbar (wire #9). Leave the negative voltmeter lead connected to the negative side of c1. 13. Turn on the power supply and give the system a start command. When the red d.C. Power light illuminates, the voltmeter should read +250 vdc. If t...

  • Page 56

    Maintenance and troubleshooting sr-100i user’s manual test). C. Give the system a start signal. When the red d.C. Power light illuminates, the voltage on pin 10 should increase to approximately 5.8 vdc. If pin 10 does not read 5.8 vdc, check the continuity in the lines between the chopper and the lo...

  • Page 57: Section 6  Parts List

    Parts list sr-100i user’s manual section 6 parts list power supply note: see figures 6-1 to 6-6. Item number part number quantity description 1 708087 1 off actuator, red 2 708088 1 off switch, red 3 708089 1 on actuator, green / illuminated 4 708090 1 on switch, green 5 740107 2 light housing 6 740...

  • Page 58

    Parts list sr-100i user’s manual item number part number quantity description 38 701089 1 r5 mounting hardware 39 706100 706104 706107 706105 706106 1 tr1 main transformer (voltages below) 208v, 60 hz, 3 phase 220/380v, 50 hz, 3 phase 230/460v, 60 hz, 3 phase 415v, 50 hz, 3 phase 575v, 60 hz, 3 phas...

  • Page 59

    Parts list sr-100i user’s manual figure 6-1 control panel 6-3.

  • Page 60

    Parts list sr-100i user’s manual sr−100i figure 6-2 rear view – inside 6-4.

  • Page 61

    Parts list sr-100i user’s manual figure 6-3 base – top view 6-5.

  • Page 62

    Parts list sr-100i user’s manual figure 6-4 left side view 6-6.

  • Page 63

    Parts list sr-100i user’s manual figure 6-5 right side view 6-7.

  • Page 64

    Parts list sr-100i user’s manual sr−100i figure 6-6 rear view – outside 6-8.

  • Page 65: Torch and Handle Assembly

    Parts list sr-100i user’s manual torch and handle assembly item number part number quantity description 1 800280 1 torch main body assembly 2 770059 1 torch handle 3 770060 770065 1 torch jacket (brass tube) – with rack torch jacket (brass tube) – without rack 4 770061 1 torch jacket retainer 5 8000...

  • Page 66: Shielded Torch Leads

    Parts list sr-100i user’s manual shielded torch leads 800077 shielded torch leads assembly – 35’ item number part number quantity description 1 711122 35’ braided shield 2 770068 1 shield connector 3 770061 1 shield connector nut 4 800072 1 torch nozzle lead assembly 5 800074 1 torch electrode lead ...

  • Page 67: Consumable Spare Parts Kit

    Parts list sr-100i user’s manual consumable spare parts kit (part number 800098) part number quantity description 810132 5 50 amp nozzle 810130 1 50 amp shield cap 810131 5 100 amp nozzle 810129 1 100 amp shield cap 800062 5 100 amp nozzle (tapered) 800063 1 100 amp shield cap (tapered) 800083 1 ope...

  • Page 68: Logic-Regulator P.C. Board

    Parts list sr-100i user’s manual logic-regulator p.C. Board (assembly 800400) figure 6-9 logic-regulator p.C. Board 6-12.

  • Page 69: Chopper P.C. Board

    Parts list sr-100i user’s manual chopper p.C. Board figure 6-10 chopper p.C. Board 6-13.

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  • Page 71: (Emc)

    Electromagnetic compatibility (emc) sr-100i user’s manual appendix a electromagnetic compatibility (emc) background the 220/380v 50hz and 415v 50hz sr-100i plasma cutting systems are manufactured to comply with the european standard en 50199 (electromagnetic compatibility (emc) – product standard fo...

  • Page 72: Assessment of Area

    Electromagnetic compatibility (emc) sr-100i 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,...

  • Page 73

    Electromagnetic compatibility (emc) sr-100i user’s manual 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. Equipotential bonding bonding of all metallic components in the plasma cuttin...

  • Page 74: Primary Power Connection

    Electromagnetic compatibility (emc) sr-100i user’s manual primary power connection note: see section 3 for additional information. Route the power cable supplied with the emi filter through the strain relief on the rear of the power supply and connect the hot lines (red, white, and black wires) to t...

  • Page 75: Emi Filter Parts List

    Electromagnetic compatibility (emc) sr-100i user’s manual emi filter parts list emi filter assembly – 220/380 vac 50hz (assembly 800108) item number part number quantity description 1 719003 1 emi filter enclosure 2 702048 1 emi filter, 60a 3 711185 28” 4/4 type so power cable 4 709105 2 strain reli...