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Kaliburn SR-45i User Manual

Manual is about: Plasma Cutting System

Summary of SR-45i

  • Page 1

    Sr-45i user’s manual sr-45i plasma cutting system revision 11 5/16/07 manual part number 718061 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-45i 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-45i torch and leads and three (3) years for th...

  • Page 4

    Sr-45i user’s manual electromagnetic compatibility (emc) the 220/380v 50hz and 415v 50hz sr-45i 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 s...

  • Page 5: Table of Contents

    Sr-45i 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-45i user’s manual section 5 maintenance and troubleshooting ............................ 5-1 daily procedures ...................……........................................................................................ 5-1 monthly procedures .........................................................

  • Page 7

    Sr-45i user’s manual figure 6-5 right side view ............................................................................................ 6-7 figure 6-6 rear view – outside ..................................................................................... 6-8 figure 6-7 torch and handle assemb...

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  • Page 9: Section 1  Safety

    Safety sr-45i 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 i...

  • Page 10: Electric Shock Prevention

    Safety sr-45i 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 c...

  • Page 11: Fire Prevention

    Safety sr-45i user’s manual • never operate the sr-45i 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-45i system, it is necessary to exercise good judgment. While cutting, the arc produ...

  • Page 12: Health Support Equipment

    Safety sr-45i 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 ot...

  • Page 13

    Safety sr-45i 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-45i 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 standard...

  • Page 15: Section 2  Specifications

    Specifications sr-45i user’s manual section 2 specifications system description the sr-45i is a versatile, 45 amp, 100% duty cycle conventional air plasma cutting system that provides continuous operation, patented long life electrodes, and a true constant current output from 20 to 45 amperes. It ut...

  • Page 16

    Specifications sr-45i user’s manual 240 vac, 3Ø ....................................................... 20 amps 380 vac, 3Ø ....................................................... 11 amps 415 vac, 3Ø ....................................................... 10 amps 460 vac, 3Ø ...........................

  • Page 17: Torch Specifications

    Specifications sr-45i user’s manual torch specifications stock number: torch main body .................................................. 770073 torch handle assembly ........................................ 770075 diameter .................................................................... 1.375 i...

  • Page 18: Airborne Noise Emissions

    Specifications sr-45i user’s manual airborne noise emissions the sr-45i 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 b...

  • Page 19: Operating Modes

    Specifications sr-45i user’s manual operating modes the operating mode of the sr-45i 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: aft...

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  • Page 21: Section 3  Installation

    Installation sr-45i 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, kaliburn...

  • Page 22

    Installation sr-45i user’s manual input voltage (vac) phase input current at maximum output (amps) recommended time-delay fuse size (amps) 200 1 38 50 208 1 37 50 220 1 35 45 208 3 23 30 220 3 22 30 240 3 20 25 380 3 11 15 415 3 10 12 460 3 9 12 575 3 7 9 use a type so power cable to connect the pri...

  • Page 23

    Installation sr-45i 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 make...

  • Page 24

    Installation sr-45i user’s manual sr−45i tighten securely figure 3-2 power supply output connections 3-4.

  • Page 25: Torch Connections

    Installation sr-45i 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 ti...

  • Page 26: Gas Supply Connections

    Installation sr-45i user’s manual gas supply connections the sr-45i requires clean, dry, oil-free compressed air for good cut quality, as well as long consumable life. The sr-45i plasma system is supplied with a regulator-filter to filter the incoming gas supply. Additional filtration may be require...

  • Page 27

    Installation sr-45i user’s manual adjust regulator to 65 psi with gas switch in the set position connect gas supply to this port using 1/4" (6 mm) i.D. Minimum hose size sr−45i figure 3-4 gas supply connections 3-7.

  • Page 28

    Installation sr-45i user’s manual cnc machine interface connections perform the following steps to properly interface the sr-45i system with a cnc cutting machine. See the system schematic for additional information. Plasma start signal • the sr-45i requires a contact closure between p8 pins 3 and 4...

  • Page 29: Section 4  Operation

    Operation sr-45i user’s manual section 4 operation power supply front panel controls the sr-45i controls and status indicator lights are located on the front panel of the system, with the exception of the mode switch which is located on the left side of the power supply. This section describes the f...

  • Page 30: Mechanized Cutting Mode

    Operation sr-45i user’s manual figure 4-1 front panel controls mechanized cutting mode to place the sr-45i 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 initiat...

  • Page 31: Manual Cutting Mode

    Operation sr-45i user’s manual manual cutting mode to place the sr-45i in the manual cutting mode, set the mode switch thumbwheel to position number 0. The manual cutting mode is used when it is necessary to automatically reestablish a lost cutting arc. For example, if the torch is going to cross a ...

  • Page 32: Torch Consumables

    Operation sr-45i user’s manual torch consumables figure 4-2 shows the different torch consumable configurations for cutting various materials with the sr-45i. Retaining cap 770098 flat nozzle 770000 swirl ring 770012 electrode 770015 or 770017 torch body 770073 swirl ring 770012 retaining cap 770098...

  • Page 33: Advanceable Electrode

    Operation sr-45i user’s manual advanceable electrode the sr-45i torch uses a patented advanceable electrode pn 770015. 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 forme...

  • Page 34: Setting Up A Cut

    Operation sr-45i user’s manual setting up a cut use the following procedure to make a cut with the sr-45i. 1. Using the charts in this section, determine the proper torch parts and cutting conditions for the material being cut. 2. Apply a small amount of o-ring lubricant pn 716008 to the o-ring pn 7...

  • Page 35

    Operation sr-45i user’s manual 7. Apply primary power to the sr-45i. The a.C. Power light on the front panel should illuminate, indicating that primary power has been applied; however, never assume the power is disconnected when the white light is out. 8. Depress the green on button to energize the ...

  • Page 36: Cut Quality

    Operation sr-45i user’s manual 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 sr-45i system. When the cut quality is not satisfactory, the cutt...

  • Page 37: Cutting Chart

    Operation sr-45i user’s manual cutting chart 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 qu...

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  • Page 39: Daily Procedures

    Maintenance and troubleshooting sr-45i user’s manual section 5 maintenance and troubleshooting warning: only qualified maintenance personnel should perform maintenance on the sr-45i system. The system utilizes potentially fatal a.C. And d.C. Voltages. All maintenance should be performed with safety ...

  • Page 40: Monthly Procedures

    Maintenance and troubleshooting sr-45i user’s manual 5. Reassemble the electrode, swirl ring, and nozzle and install them in the torch. 6. Make sure that the retaining cap is hand tight and all parts are seated properly. Monthly procedures note: at minimum, these checks should be performed on a mont...

  • Page 41

    Maintenance and troubleshooting sr-45i user’s manual tightly to the power supply enclosure. Using an ohmmeter, measure zero ohms between the braided shield and the ground stud on the power supply sub-panel. 6. Inspect the braided shield and torch lead hoses for cuts or other signs of damage. Replace...

  • Page 42: Configurations

    Maintenance and troubleshooting sr-45i user’s manual 220/230/240v 60 hz transformer configurations 220v 60 hz, 230v 60 hz, and 240v 60 hz three phase power supplies are equipped with a dual voltage main transformer tr1. The primary taps on tr1 are labeled with their corresponding voltages. To change...

  • Page 43

    Maintenance and troubleshooting sr-45i user’s manual 220/380v 50 hz transformer configurations 220v 50 hz and 380v 50 hz three phase power supplies are equipped with a dual voltage main transformer tr1. To change the operating voltage for these systems, perform the following procedures. When the pri...

  • Page 44

    Maintenance and troubleshooting sr-45i user’s manual 0 220 0 220 0 220 220v 3 phase 220 220 220 0 0 0 220 v 3 phase figure 5-2 220v 50 hz three phase transformer 0 220 0 220 0 220 380v 3 phase 220 220 220 0 0 0 380 v 3 phase figure 5-3 380v 50 hz three phase transformer 5-6.

  • Page 45

    Maintenance and troubleshooting sr-45i user’s manual logic-regulator status led’s if a problem occurs with the sr-45i 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 any...

  • Page 46: General Troubleshooting

    Maintenance and troubleshooting sr-45i user’s manual general troubleshooting the following chart lists general troubleshooting guidelines for the sr-45i system when the logic-regulator status led’s do not give any insight to the particular problem being experienced. Please contact kaliburn technical...

  • Page 47

    Maintenance and troubleshooting sr-45i user’s manual con2 or associated wiring may be bad. If con2 pulls in, the auxiliary switch or associated wiring may be bad. 7. Red d.C. Power light or associated wiring may be bad. 8. Pilot arc lead has a leak or loose fittings. Contactor making noise 1. Contac...

  • Page 48

    Maintenance and troubleshooting sr-45i user’s manual torch will not ignite 1. Replace torch consumables. 2. Check all led’s for proper operation. 3. Check all primary disconnect fuses. 4. Check for a spark at the spark gap oscillator. 5. Verify that the main contactor con2 is pulling in. 6. Verify t...

  • Page 49: Chopper Test Procedure

    Maintenance and troubleshooting sr-45i 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 50

    Maintenance and troubleshooting sr-45i user’s manual output busbar (wire #9). Leave the positive voltmeter lead connected to the positive side of c7. 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 +230 vdc. If th...

  • Page 51

    Maintenance and troubleshooting sr-45i user’s manual chopper. If the lines are good and no lines are shorted together, replace the chopper (skip the rest of this test). C. Give the system a start command. When the red d.C. Power light illuminates, the voltage on p1-2 should drop to approximately 0 v...

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  • Page 53: Section 6   Parts List

    Parts list sr-45i 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 7401...

  • Page 54

    Parts list sr-45i user’s manual 6-2 item number part number quantity description 36 701082 701090 1 1 r2 pilot arc resistor, 1 ohm r2 pilot arc resistor, 1/2 ohm 37 701083 1 r2 mounting hardware 38 706023 706013 706011 706010 706052 706014 706015 1 tr1 main transformer (voltages below) 208v, 60 hz, ...

  • Page 55

    Parts list sr-45i user’s manual figure 6-1 control panel 6-3.

  • Page 56

    Parts list sr-45i user’s manual sr−45i figure 6-2 rear view – inside 6-4.

  • Page 57

    Parts list sr-45i user’s manual figure 6-3 base – top view 6-5.

  • Page 58

    Parts list sr-45i user’s manual figure 6-4 left side view 6-6.

  • Page 59

    Parts list sr-45i user’s manual figure 6-5 right side view 6-7.

  • Page 60

    Parts list sr-45i user’s manual sr−45i figure 6-6 rear view – outside 6-8.

  • Page 61: Torch and Handle Assembly

    Parts list sr-45i user’s manual torch and handle assembly item number part number quantity description 1 770073 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 77009...

  • Page 62: Shielded Torch Leads

    Parts list sr-45i user’s manual shielded torch leads 770002 shielded torch leads assembly – 25’ item number part number quantity description 1 711021 25’ braided shield 2 770068 1 shield connector 3 770061 1 shield connector nut 4 770006 1 pilot arc lead assembly 5 770005 1 torch power lead assembly...

  • Page 63: Consumable Spare Parts Kit

    Parts list sr-45i user’s manual consumable spare parts kit (part number 770020) part number quantity description 770000 5 flat metal cutting nozzle 770104 5 tapered metal cutting nozzle 770030 5 insulation cutting nozzle 770015 5 electrode, advanceable 770017 5 electrode, non-advanceable 770012 1 sw...

  • Page 64: Logic-Regulator P.C. Board

    Parts list sr-45i user’s manual logic-regulator p.C. Board (assembly 740015) figure 6-9 logic-regulator p.C. Board 6-12.

  • Page 65: Chopper P.C. Board

    Parts list sr-45i user’s manual chopper p.C. Board figure 6-10 chopper p.C. Board 6-13.

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  • Page 67: (Emc)

    Electromagnetic compatibility (emc) sr-45i user’s manual appendix a electromagnetic compatibility (emc) background the 220/380v 50hz and 415v 50hz sr-45i plasma cutting systems are manufactured to comply with the european standard en 50199 (electromagnetic compatibility (emc) – product standard for ...

  • Page 68: Assessment of Area

    Electromagnetic compatibility (emc) sr-45i 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 69

    Electromagnetic compatibility (emc) sr-45i 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 cutting...

  • Page 70: Primary Power Connection

    Electromagnetic compatibility (emc) sr-45i 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 th...

  • Page 71: Emi Filter Parts List

    Electromagnetic compatibility (emc) sr-45i user’s manual emi filter parts list emi filter assembly – 220/380 vac 50hz (assembly 740133) item number part number quantity description 1 719002 1 emi filter enclosure 2 702047 1 emi filter, 30a 3 711183 28” 10/4 type so power cable 4 709060 2 strain reli...