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Kaliburn SR-100i User Manual

Plasma cutting system without ohmic contact torch
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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 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

    (1) year for the SR-100i torch and leads and three (3) years for the SR-100i power supply. This product is intended for commercial use and is not intended for personal, family, or household purposes.
  • 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 standard for arc welding equipment). Information...

  • 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 ...…………………………………………………………..……… 1-1 Electric Shock Prevention ...……………………………………………………….….…… 1-2 Fire Prevention ...…………………….………………………………….…………………. 1-3 Explosion Prevention ..…….….………….…………………………………..………….. 1-3 Health Support Equipment ...…………………….……………………………….………...
  • Page 6 SR-100i User’s Manual Section 5 Maintenance and Troubleshooting ......5-1 Daily Procedures ....……..................5-1 Monthly Procedures ......................5-2 230/460V 60 Hz Transformer Configurations ..............5-4 220/380V 50 Hz Transformer Configurations ..............5-6 Logic-Regulator Status LED’s ....................5-8 Logic-Regulator Sequence of Operation ................5-8 General Troubleshooting ......................
  • 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 ............5-7 Figure 5-4 380V 50 Hz Three Phase Transformer ............5-7 Figure 6-1 Control Panel ....................
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  • Page 9: Section 1 Safety

    Installation and repairs made to the SR-100i system should only be performed by qualified personnel. The SR-100i system makes use of both A.C. and D.C.

  • Page 10: Electric Shock Prevention

    Remember that the workpiece forms the current path back to the power supply. • Never bypass the safety interlock devices. • Before removing any of the SR-100i covers, switch the system off at the wall disconnect. Wait at least five (5) minutes before removing any cover. This...

  • Page 11: Fire Prevention

    Observe the following guidelines to protect against explosion: • Never operate the SR-100i system in the presence of explosive gases or other explosive materials. • Never cut pressurized cylinders or any closed container.

  • Page 12: Health Support Equipment

    SR-100i system. Observe the following guidelines to minimize exposure to these electric and magnetic fields: • Stay as far away from the SR-100i power supply, torch, torch leads, and remote high frequency console as possible.
  • Page 13 Safety SR-100i User’s Manual AWS Standard ULR, Ultraviolet Reflectance of Paint, obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126. 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.
  • 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 Standards Association, 178 Rexdale Boulevard, Toronto, Ontario M9W lR3, Canada.

  • Page 15: Section 2 Specifications

    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. Two nozzle sizes (50 amp and 100 amp) are available to produce excellent cut quality throughout its range.

  • Page 16: Figure 2-1 Power Supply Dimensions

    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 415 VAC, 3Ø ............27 amps 460 VAC, 3Ø ............25 amps 575 VAC, 3Ø ............20 amps Open Circuit Voltage ..........

  • 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 in (35 mm) Length: Torch main body ..........3.5 in (89 mm) Torch main body / handle assembly ....12.8 in (325 mm) Weight (including handle) ........

  • Page 18: Airborne Noise Emissions

    Proper ear protection should be used as defined by local or national codes. The following chart gives the noise levels generated by the SR-100i when operating at 100 amps, 120 arc volts. The measurements were made with a sound level meter.

  • Page 19: Operating Modes

    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.
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  • Page 21: Section 3 Installation

    If you need additional assistance, please contact KALIBURN. Power Supply Installation The SR-100i power supply should be lifted by a forklift or pallet jack only. 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.

  • Page 22: Figure 3-1 Primary Power Connections

    (amps) (amps) Use a Type SO power cable to connect the primary power to the SR-100i power supply. The power cable should have a 600 volt minimum rating and should be sized according to local and national codes. Route the power cable through the strain relief on the rear of the power supply and connect the hot lines to the input terminals on the safety contactor CON1 as shown in Figure 3-1.

  • Page 23: Power Supply Output Connections

    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 make a gas seal.

  • Page 24: Figure 3-2 Power Supply Output Connections

    Installation SR-100i User’s Manual SR−100i Figure 3-2 Power Supply Output Connections...

  • 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.

  • Page 26: Gas Supply Connections

    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 required if there is moisture, oil, or other contaminants in the gas supply.

  • Page 27: Figure 3-4 Gas Supply Connections

    Installation SR-100i User’s Manual SR−100i Figure 3-4 Gas Supply Connections...

  • Page 28: Cnc Machine Interface Connections

    250VAC or 10A – 30VDC. Arc Hold / IHS Complete Signal • The SR-100i requires a contact closure between P8 pins 6 and 7 to inhibit arc starting even though a plasma start signal has been applied to the unit. When the arc hold/ihs complete contacts are opened, the cutting arc is initiated.

  • Page 29: Section 4 Operation

    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 locations.

  • 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.

  • Page 31: Grate Cutting Mode

    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 used for cutting expanded metal or grate material. The starting sequence is the same as that for mechanized cutting.

  • 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...

  • Page 33: Advanceable Electrode

    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 formed in the electrode material.

  • Page 34: Setting Up A Cut

    5. Thread the retaining cap onto the torch and hand tighten. It is very important that all parts are seated tightly to prevent the torch from arcing internally. 6. Apply primary power to the SR-100i. The white A.C. Power light on the front panel should illuminate, indicating that primary power has been applied;...

  • Page 35: 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-100i system. When the cut quality is not satisfactory, the cutting current, speed, or torch height may need to be adjusted until the proper cutting condition is obtained.

  • 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 quality will affect the cutting speeds and torch height.

  • Page 37: Figure 4-4 Mild Steel Cutting Chart (30-50 Amps)

    Operation SR-100i User’s Manual Figure 4-4 Mild Steel Cutting Chart (30-50 amps)

  • Page 38: Figure 4-5 Mild Steel Cutting Chart (75-100 Amps)

    Operation SR-100i User’s Manual Figure 4-5 Mild Steel Cutting Chart (75-100 amps) 4-10...

  • Page 39: Figure 4-6 Stainless Steel Cutting Chart (30-50 Amps)

    Operation SR-100i User’s Manual Figure 4-6 Stainless Steel Cutting Chart (30-50 amps) 4-11...

  • Page 40: Figure 4-7 Stainless Steel Cutting Chart (75-100 Amps)

    Operation SR-100i User’s Manual Figure 4-7 Stainless Steel Cutting Chart (75-100 amps) 4-12...

  • Page 41: Figure 4-8 Aluminum Cutting Chart (30-50 Amps)

    Operation SR-100i User’s Manual Figure 4-8 Aluminum Cutting Chart (30-50 amps) 4-13...

  • Page 42: Figure 4-9 Aluminum Cutting Chart (75-100 Amps)

    Operation SR-100i User’s Manual Figure 4-9 Aluminum Cutting Chart (75-100 amps) 4-14...

  • Page 43: Section 5 Maintenance And Troubleshooting

    4. With the Gas switch in the Set position, adjust the regulator on the rear panel of the SR-100i to 85 psi. Return the Gas switch to the Run position. 5. Raise the torch 2 inches above the workpiece. Apply a start signal to the SR- 100i using the CNC control.

  • 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 system before performing the following...
  • Page 45 2. Listen for gas leaks in the supply lines and in the internal plumbing system of the SR-100i. Tighten any connections that are leaking. Leaks in the supply can cause poor cut quality, as well as torch overheating.

  • Page 46: 230/460V 60 Hz Transformer Configurations

    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.

  • Page 47: Figure 5-1 230V 60 Hz Three Phase Transformer

    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...

  • Page 48: 220/380V 50 Hz Transformer Configurations

    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.

  • Page 49: Figure 5-3 220V 50 Hz Three Phase Transformer

    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...

  • Page 50: Logic-Regulator Status Led's

    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 any bad fuses.

  • Page 51: General Troubleshooting

    2. Torch retaining cap or consumables not installed correctly. 3. If the SR-100i is given a start signal and the PWR, STRT, G1, and ILK LED’s illuminate, but the CON LED does not, replace the logic- regulator p.c. board.
  • 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.
  • 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 high frequency coupling transformer TR7.

  • Page 54: Chopper Test Procedure

    Note: Unless otherwise noted, leave connectors plugged into the circuit boards while making voltage measurements. Turn off all power to the SR-100i power supply. Disconnect the torch leads from the Torch Electrode and Torch Nozzle connections on the I/O p.c. board.
  • 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 the voltage is correct, the chopper is working properly.
  • 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 logic board.

  • 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 708087 Off actuator, red 708088 Off switch, red 708089 On actuator, green / illuminated 708090 On switch, green...
  • Page 58 Parts List SR-100i User’s Manual Item Number Part Number Quantity Description 701089 R5 Mounting hardware TR1 main transformer (voltages below) 706100 208V, 60 Hz, 3 phase 706104 220/380V, 50 Hz, 3 phase 706107 230/460V, 60 Hz, 3 phase 706105 415V, 50 Hz, 3 phase...

  • Page 59: Figure 6-1 Control Panel

    Parts List SR-100i User’s Manual Figure 6-1 Control Panel...

  • Page 60: Figure 6-2 Rear View - Inside

    Parts List SR-100i User’s Manual SR−100i Figure 6-2 Rear View – Inside...

  • Page 61: Figure 6-3 Base - Top View

    Parts List SR-100i User’s Manual Figure 6-3 Base – Top View...

  • Page 62: Figure 6-4 Left Side View

    Parts List SR-100i User’s Manual Figure 6-4 Left Side View...

  • Page 63: Figure 6-5 Right Side View

    Parts List SR-100i User’s Manual Figure 6-5 Right Side View...

  • Page 64: Figure 6-6 Rear View - Outside

    Parts List SR-100i User’s Manual SR−100i Figure 6-6 Rear View – Outside...

  • Page 65: Torch And Handle Assembly

    Parts List SR-100i User’s Manual Torch and Handle Assembly Item Number Part Number Quantity Description 800280 Torch main body assembly 770059 Torch handle 770060 Torch jacket (brass tube) – with rack 770065 Torch jacket (brass tube) – without rack 770061...

  • 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 711122 35’ Braided shield 770068 Shield connector 770061 Shield connector nut 800072 Torch nozzle lead assembly 800074 Torch electrode lead assembly...

  • 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 50 amp nozzle 810130 50 amp shield cap 810131 100 amp nozzle 810129 100 amp shield cap 800062 100 amp nozzle (tapered) 800063...

  • 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: Appendix A Electromagnetic Compatibility (Emc

    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 for arc welding equipment). The limits used in this standard are based on practical experience. However, the ability of...

  • 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, signaling and telephone cables; above, below and adjacent to the plasma cutting equipment;...
  • 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 cutting installation and adjacent to it should be considered.

  • 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 the input terminals on the safety contactor CON1 as shown in Figure A-1.

  • 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 719003 EMI filter enclosure 702048 EMI filter, 60A 711185 28” 4/4 Type SO power cable...

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