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Kaliburn SR-45i User Manual

Plasma cutting system
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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 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

    (1) year for the SR-45i torch and leads and three (3) years for the SR-45i power supply. This product is intended for commercial use and is not intended for personal, family, or household purposes.
  • 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 standard for arc welding equipment). Information...

  • 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 ...…………………………………………………………..……… 1-1 Electric Shock Prevention ...……………………………………………………….….…… 1-2 Fire Prevention ...…………………….………………………………….…………………. 1-3 Explosion Prevention ..…….….………….…………………………………..………….. 1-3 Health Support Equipment ...…………………….……………………………….………...
  • Page 6 SR-45i User’s Manual Section 5 Maintenance and Troubleshooting ......5-1 Daily Procedures ....……..................5-1 Monthly Procedures ......................5-2 220/230/240V 60 Hz Transformer Configurations ............... 5-4 220/380V 50 Hz Transformer Configurations ..............5-5 Logic-Regulator Status LED’s ....................5-7 Logic-Regulator Sequence of Operation ................5-7 General Troubleshooting ......................
  • 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 Assembly ................. 6-9 Figure 6-8 Shielded Torch Leads ................... 6-10 Figure 6-9 Logic-Regulator P.C. Board ................. 6-12 Figure 6-10 Chopper P.C.
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  • Page 9: Section 1 Safety

    Installation, as well as repairs, made to the SR-45i system should only be performed by qualified personnel. The SR-45i system makes use of both A.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-45i 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-45i 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-45i system. Observe the following guidelines to minimize exposure to these electric and magnetic fields: • Stay as far away from the SR-45i power supply, torch, torch leads, and remote high frequency console as possible.
  • Page 13 Safety SR-45i 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-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 Standards Association, 178 Rexdale Boulevard, Toronto, Ontario M9W lR3, Canada.

  • Page 15: Section 2 Specifications

    20 to 45 amperes. It utilizes a single gas torch that is capable of cutting gauge to 1/2” thick material. The SR-45i also has 4 modes of operation, which provide the capability for cutting all types of material, including expanded metal and insulation.

  • Page 16: Figure 2-1 Power Supply Dimensions

    Specifications SR-45i User’s Manual 240 VAC, 3Ø ............20 amps 380 VAC, 3Ø ............11 amps 415 VAC, 3Ø ............10 amps 460 VAC, 3Ø ............9 amps 575 VAC, 3Ø ............7 amps Open Circuit Voltage ..........230 VDC Output Current ............

  • 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 in (35 mm) Length: Torch main body ..........3.5 in (118 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-45i when operating at 45 amps, 115 arc volts. The measurements were made with a sound level meter.

  • Page 19: Operating Modes

    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.
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  • Page 21: Section 3 Installation

    If you need additional assistance, please contact KALIBURN. Power Supply Installation The SR-45i 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. The proper location of the power supply will provide dependable service and reduce periodic maintenance time.

  • Page 22: Figure 3-1 Primary Power Connections

    (amps) (amps) Use a Type SO power cable to connect the primary power to the SR-45i 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-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 a gas seal.

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

    Installation SR-45i User’s Manual Tighten Securely SR−45i Figure 3-2 Power Supply Output Connections...

  • 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.

  • Page 26: Gas Supply Connections

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

  • Page 27: Figure 3-4 Gas Supply Connections

    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...

  • Page 28: Cnc Machine Interface Connections

    See the system schematic for additional information. Plasma Start Signal • The SR-45i requires a contact closure between P8 pins 3 and 4 to commence the cutting sequence. The cutting sequence is terminated when the contacts are opened. The contacts should be rated for 24VAC - 10mA.

  • Page 29: Section 4 Operation

    Used to delay the x/y machine motion when piercing thicker materials. The delay can be adjusted from 0 to 3 seconds. Digital Mode Switch Thumbwheel The Mode Switch is located on the left side of the SR-45i and is used to set the operating mode of the system.

  • 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.

  • Page 31: Manual Cutting Mode

    Grate Cutting Mode To place the SR-45i 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-45i User’s Manual Torch Consumables Figure 4-2 shows the different torch consumable configurations for cutting various materials with the SR-45i. TORCH CONSUMABLES WHEN CUTTING MATERIALS GREATER THAN 1/8" (3 mm) THICK RETAINING CAP FLAT NOZZLE SWIRL RING ELECTRODE TORCH BODY...

  • Page 33: Advanceable Electrode

    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 formed in the electrode material.

  • 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 770072 on the torch body.
  • 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.

  • Page 36: 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 cutting current, speed, or torch height may need to be adjusted until the proper cutting condition is obtained.

  • 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 quality will affect the cutting speeds and torch height.
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  • Page 39: Section 5 Maintenance And Troubleshooting

    4. With the Gas switch in the Set position, adjust the regulator on the rear panel of the SR-45i to 65 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- 45i using the CNC control.

  • 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 monthly basis.
  • Page 41 2. Listen for gas leaks in the supply lines and in the internal plumbing system of the SR-45i. Tighten any connections that are leaking. Leaks in the supply can cause poor cut quality, as well as torch overheating.

  • Page 42: 220/230/240V 60 Hz Transformer 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 the operating voltage for these systems, perform the following procedures.

  • Page 43: 220/380V 50 Hz Transformer Configurations

    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 primary voltage of TR1 is changed, the control transformer TR3 must also be rewired for the correct service voltage.

  • Page 44: Figure 5-2 220V 50 Hz Three Phase Transformer

    Maintenance and Troubleshooting SR-45i User’s Manual 220V 3 Phase 220 V 3 PHASE Figure 5-2 220V 50 Hz Three Phase Transformer 380V 3 Phase 380 V 3 PHASE Figure 5-3 380V 50 Hz Three Phase Transformer...

  • Page 45: Logic-Regulator Status Led's

    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 bad fuses.

  • 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 support for any issues not covered in this section.
  • 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.
  • 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 6.

  • Page 49: 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-45i power supply. Disconnect the torch leads from the Torch Minus and Pilot Arc connections on the I/O p.c. board.
  • 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 the voltage is correct, the chopper is working properly.
  • 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 VDC.
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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 708087 Off actuator, red 708088 Off switch, red 708089 On actuator, green / illuminated 708090 On switch, green...
  • Page 54 Parts List SR-45i User’s Manual Item Number Part Number Quantity Description 701082 R2 pilot arc resistor, 1 ohm 701090 R2 pilot arc resistor, 1/2 ohm 701083 R2 mounting hardware TR1 main transformer (voltages below) 706023 208V, 60 Hz, 1 phase...

  • Page 55: Figure 6-1 Control Panel

    Parts List SR-45i User’s Manual Figure 6-1 Control Panel...

  • Page 56: Figure 6-2 Rear View - Inside

    Parts List SR-45i User’s Manual SR−45i Figure 6-2 Rear View – Inside...

  • Page 57: Figure 6-3 Base - Top View

    Parts List SR-45i User’s Manual Figure 6-3 Base – Top View...

  • Page 58: Figure 6-4 Left Side View

    Parts List SR-45i User’s Manual Figure 6-4 Left Side View...

  • Page 59: Figure 6-5 Right Side View

    Parts List SR-45i User’s Manual Figure 6-5 Right Side View...

  • Page 60: Figure 6-6 Rear View - Outside

    Parts List SR-45i User’s Manual SR−45i Figure 6-6 Rear View – Outside...

  • Page 61: Torch And Handle Assembly

    Parts List SR-45i User’s Manual Torch and Handle Assembly Item Number Part Number Quantity Description 770073 Torch main body assembly 770059 Torch handle 770060 Torch jacket (brass tube) – with rack 770065 Torch jacket (brass tube) – without rack 770061...

  • 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 711021 25’ Braided shield 770068 Shield connector 770061 Shield connector nut 770006 Pilot arc lead assembly 770005 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 Flat metal cutting nozzle 770104 Tapered metal cutting nozzle 770030 Insulation cutting nozzle 770015 Electrode, advanceable 770017 Electrode, non-advanceable 770012 Swirl ring 770098...

  • 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: Appendix A Electromagnetic Compatibility (Emc

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

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

  • Page 70: Primary Power Connection

    CON1 as shown in Figure A-1. Connect the green ground wire to the ground stud on the sub-panel of the SR-45i. Use a type SO power cable to connect the primary power to the EMI filter. Route the power cable through the strain relief on the EMI filter enclosure and connect the hot lines to the A, B, and C terminals on the line side of the filter.

  • 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 719002 EMI filter enclosure 702047 EMI filter, 30A 711183 28” 10/4 Type SO power cable...

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