Kaliburn SR-100i User manual

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
[phone] – Toll free
[phone] – Phone
[phone] – Fax
www.kaliburn.net

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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 the SR-100i power supply. 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 description on the face
hereof. All other warranties, either expressed or implied, including any
implied warranty of merchantability or fitness for any particular purpose,
are expressly excluded.
If this product or any component thereof is determined to be defective in
manufacture, 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 non-conforming 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. Beyond this remedy,
KALIBURN will not 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.
This warranty will be considered void if torches or torch
consumables manufactured by anyone other than
KALIBURN are incorporated into this product.
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 stock 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.

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
about the EMC standard EN 50199 can be found in Appendix A.

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 ...…………………….……………………………….………...1-4
Safety Standards Booklet Index ...…………………….……………………………….…...1-4
Section 2 Specifications...….……...………………………………………………2-1
System Description ...………………………………………………………………………2-1
System Components ………………………………………………………………………. 2-1
Power Supply Specifications ……………………………………………………………… 2-1
Torch Specifications ...…………………………………………………………………….. 2-3
Airborne Noise Emissions ..……………………………………………………………….. 2-4
Operating Modes .........……………………………………………………………………..2-5
Section 3 Installation.....…………………………………………………………3-1
Initial Inspection .......……………………………………………………………………… 3-1
Power Supply Installation .…………………………………………………………………3-1
Primary Power Connection ...………………………………………………………………3-1
Power Supply Output Connections .......……………………………………………………3-3
Torch Connections ....………………………………………………………………………3-5
Gas Supply Connections ...............................………………………………………………3-6
CNC Machine Interface Connections ...……………………………………………………3-8
Section 4 Operation………………………………………………………………4-1
Power Supply Front Panel Controls ..………………………………………………………4-1
Mechanized Cutting Mode ............…………………………………………………………4-2
Manual Cutting Mode ...........................……………………………………………………4-2
Grate Cutting Mode ..............................…………………………………………………… 4-3
Insulation Cutting Mode ...…………………………………………………………………4-3
Torch Consumables ......…………………………………………………………………… 4-4
Advanceable Electrode .…………………………………………………………………… 4-5
Setting up a Cut .........………………………………………………………………………4-6
Cut Quality ................………………………………………………………………………4-7
Cutting Charts ...........………………………………………………………………………4-8

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 ...................................................................................................... 5-9
Chopper Test Procedure ........................................................................................................5-12
Section 6 Parts List...........................................................................................6-1
Power Supply ........................................................................................................................6-1
Torch and Handle Assembly .................................................................................................6-9
Shielded Torch Leads ........................................................................................................... 6-10
Consumable Spare Parts Kit ................................................................................................. 6-11
Logic-Regulator P.C. Board ................................................................................................. 6-12
Chopper P.C. Board ..............................................................................................................6-13
Appendix A Electromagnetic Compatibility (EMC)..........A-1
Background ...........................................................................................................................A-1
Installation and Use ...............................................................................................................A-1
Assessment of Area ...............................................................................................................A-2
Methods of Reducing Emissions .......................................................................................... A-2
Primary Power Connection ...................................................................................................A-4
EMI Filter Parts List ............................................................................................................. A-5
Illustrations
Figure 2-1 Power Supply Dimensions ............................................................................2-2
Figure 2-2 Torch Dimensions .........................................................................................2-3
Figure 3-1 Primary Power Connections ......................................................................... 3-2
Figure 3-2 Power Supply Output Connections ...............................................................3-4
Figure 3-3 Torch Connections ........................................................................................3-5
Figure 3-4 Gas Supply Connections ...............................................................................3-7
Figure 4-1 Front Panel Controls .....................................................................................4-2
Figure 4-2 Torch Consumables ...................................................................................... 4-4
Figure 4-3 Electrode Advancing Tool ............................................................................4-5
Figure 4-4 Mild Steel Cutting Chart (30-50 amps) ........................................................ 4-9
Figure 4-5 Mild Steel Cutting Chart (75-100 amps) ...................................................... 4-10
Figure 4-6 Stainless Steel Cutting Chart (30-50 amps) ..................................................4-11
Figure 4-7 Stainless Steel Cutting Chart (75-100 amps) ................................................4-12
Figure 4-8 Aluminum Cutting Chart (30-50 amps) ........................................................4-13
Figure 4-9 Aluminum Cutting Chart (75-100 amps) ......................................................4-14

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 ................................................................................................ 6-3
Figure 6-2 Rear View - Inside ........................................................................................6-4
Figure 6-3 Base – Top View ...........................................................................................6-5
Figure 6-4 Left Side View ..............................................................................................6-6
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. Board ......................................................................................6-13
Figure A-1 Primary Power Connection ...........................................................................A-4
Figure A-2 EMI Filter ......................................................................................................A-5

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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
information is provided to each person who will operate, observe, perform
maintenance, or work in close proximity to this piece of equipment.
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.
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. 8 shade or ISO 4850 No. 11 shade,
which provides protection up to 100 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 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 be
used as defined by local or national codes. See Section 2 for noise emission
levels.
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.
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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 cut these metals unless all people
subjected to the fumes wear proper air breathing equipment.
Electric Shock Prevention
The SR-100i 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 SR-100i system. Observe the
following guidelines to protect against electric shock:
•A wall-mounted disconnect should be installed and fused according to local
and national electrical codes. The disconnect 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 SR-100i 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 SR-100i power supply. Make sure the connection is
securely tightened.
•Make sure the positive output (work ground) of the SR-100i 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 SR-100i system is switched off at the wall disconnect before
servicing the power supply or torch.
•Never change torch consumable parts unless the SR-100i 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 SR-100i covers, switch the system off at the wall
disconnect. Wait at least five (5) minutes before removing any cover. This
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