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Manual Cutting Mode

1. 17 706008 1 TR2 pcb transformer 18 709007 2 TB1 TB2 terminal block 14 position 19 709086 2 Terminal block marker strip 14 position 20 709058 2 F2 F3 fuse holder 21 709012 1 F2 fuse AGC 3A 22 709059 1 F3 fuse AGC 2A 23 709061 1 Fl fuse holder 24 709063 1 F1 2A fuse 208 220 230 240 VAC systems 709062 F1 1A fuse 380 415 460 575 VAC systems 25 709060 1 Strain relief 26 709001 H P7 receptacle 4 pin 27 709002 1 P8 receptacle 14 pin 28 740015 1 Logic regulator p c board assembly 29 740012 1 I O p c board assembly 30 708012 1 CON1 CON2 contactor 31 708013 1 Contactor auxiliary switch 32 706009 it TR3 control transformer all voltages except 575 V 706016 TR3 control transformer 575 V system 33 740050 1 Fan blade motor assembly 34 740400 1 Chopper assembly 35 740135 1 Diode bridge assembly 1 phase 740134 Diode bridge assembly 3 phase 6 1 Parts List SR 451 User s Manual Item Number Part Number Quantity Description 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 701082 701090 701083 706023 706013 706011 706010 706052 706014 706015 708011 701091 701092 702043 702034 701084 701085 706018 702041 740042 740039 706019 707002 740120 740121 740123 708004 708024 1 1 1 H Ri E a OR MH R R bh EA NR R a R2 pilot arc resistor 1 ohm R2 pilot arc resistor 1 2 ohm R2 mounting hardware TRI main transformer voltages below 208V 60 Hz 1 phas
2. Electric SHOCK Prevention iio 1 2 FREPIEYCNUSM zs k s ata aie sane aes R O gees 1 3 Explosion Prevention ss Seege A ENEE NEEN Sege ete 1 3 Health Support Equipment DRAN ana ia 1 4 Safety Standards Booklet Index sieste SEN dene RZA 1 4 Section 2 Specifications A 2 1 System DESC RAWA AA WZA WAR A AL RAR AAA 2 1 SYSIEMCOMDONE E ee deeg 2 1 Power Supply Specilications Muir A AA A 2 1 Torch Specifications E EA EA a 2 3 Airborne Noise MISSIONS ee 2 4 Operatins EE 2 5 Section 3 Installation 3 1 Mina Inspection EE 3 1 Power Supply Installation EE 3 1 Primary Power e EE 3 1 Power Supply Output Connections eene EE EEN AGAT 3 3 Torch Conde ee eege Ee 3 5 Gas Supply Connections s AAA AAA AAA CNC Machine Interface Connections Kee 3 8 Section 4 Operation 4 1 Power Supply Front Panel Controls aaa eteeeeeaeeeaeeenaes 4 1 Mechanized Cata Node EE 4 2 Manwal Cutting Modena ira AD Grate C ttins Mode ri O Insulation Cutting Mod erena peas ad ities eS eld seer tee ed beatae dees 4 3 Torch Consumables 00 0 0 0 0 E A aaa aaa nana anawa aaaaaa aaa Eee eee rro 4 4 Advanceable Electrodos ina 4 5 SEINE UPA Cb AAA AN 4 6 CU e ees 4 8 A E GE 4 9 SR 451 User s Manual Section 5 Maintenance and Troubleshooting 5 1 Daily POC E 5 1 Monthly Procedures aiii ld cava
3. Grate Cutting Mode The starting sequence is the same as that in the mechanized cutting mode However the pilot arc relay remains closed so no restarting of the arc is required between spaces in the metal The motion signal remains enabled in spaces between the metal and is disabled only when the plasma start signal is removed Insulation Cutting Mode The insulation cutting mode utilizes the pilot arc for cutting insulating type material In this mode the x y machine motion signal is enabled after the pilot arc is established As in the other modes the motion enable signal can be delayed using the motion delay potentiometer The cutting current is automatically set on the logic regulator circuit board and any front panel current setting is ignored This page intentionally left blank Installation SR 451 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 has taken special care in packaging your SR 451 system If your system was damaged during shipment you will have to file a claim with the shipping company Next 1t will be necessary to contact KALIBURN so replacement parts can be ordered If you need additional assistance please contact KALIBURN Power Supply Installation The SR 451 power supply sho
4. check for contact closure between P8 3 and P8 4 or between TB1 7 and TB1 8 Manually jumper P8 3 and P8 4 and see if the STRT LED illuminates 5 If the L1 LED does not illuminate be sure the regulator pressure is adjusted to 65 psi while gas is flowing through the torch If the pressure is adjusted to 65 psi the torch interlock pressure switch PRS2 or associated wiring may be bad PRS2 is normally open 6 If the CON LED illuminates verify that the main contactor CON2 pulls in If it does not 5 8 Maintenance and Troubleshooting Contactor making noise The arc will not transfer to the workpiece No spark between the spark gap electrodes SR 451 User s Manual CON2 or associated wiring may be bad If CON2 pulls in the auxiliary switch or associated wiring may be bad Red D C Power light or associated wiring may be bad Pilot Arc lead has a leak or loose fittings Contactor has accumulated dust inside Take contactor apart and blow out with compressed air Check 24VAC supply for low voltage 24VAC can be measured between TB2 7 and TB2 8 Loose work ground connection 2 Pierce height too high Incorrect damaged or worn consumables Improper spark gap Set the spark gap to 015 38 mm Worn spark gap electrodes Clean electrodes with fine sandpaper and set the gap to 015 38 mm Replace electrodes that have a rounded face Verify that all LED s illuminate
5. levels generated by the SR 451 when operating at 45 amps 115 arc volts The measurements were made with a sound level meter Distance From Torch A Weighted Sound C Weighted Sound Pressure Level Pressure Level 1 meter horizontal 1 6 meters 91 dB 88 dB above the workpiece The maximum noise level is 117 dB at a distance of 2 inches 50 8 mm from the torch while cutting at 45 amps 115 arc volts Specifications SR 451 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 After receiving a plasma start signal the power supply goes through a gas preflow sequence initiates a pilot arc and then transfers the arc to the workpiece The transferred arc sensor provides an x y machine motion enable signal which can be delayed to allow for piercing time Loss of the cutting arc disables the motion signal and deenergizes the SR 45i system even if the plasma start signal remains enabled Manual Cutting Mode The starting sequence is the same as that in the mechanized cutting mode However if the plasma start signal remains enabled automatic restart of the arc is initiated upon loss of the cutting arc The motion signal will remain enabled during the restart and is disabled only when the plasma start signal is removed
6. 1 Safety SR 451 User s Manual Galvanized metal can produce harmful gases during the cutting process Ensure proper ventilation and use breathing eguipment 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 eguipment Electric Shock Prevention The SR 451 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 451 system Observe the following guidelines to protect against electric shock e 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 e 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 45i system if the power cord is damaged in any way e Make sure the primary power ground wire is connected to the input power ground stud on the SR 451 power supply Make sure the connection is securely tightened e Make sure the positive output work ground of the SR 45i power supply
7. and insulation These features alone provide durability cost effective operation and excellent cut quality In addition the use of air as the plasma and cooling gas enhances the cost effectiveness System Components The SR 45i consists of the following components e Power Supply Torch and Handle Assembly Torch Lead Set Work Ground Lead Air regulator Filter System Manual Consumable Spare Parts Kit Power Supply Specifications Stock Number 200 220 VAC 10 SOHZ ENEE 745002 208 VAC 10 60HZ cool 745000 220 VAC T 00Hz uni idas 745001 208 480 VAC 39 60HZ secsceeseceeeeersreses 745018 220 380 VAC 30 50RZ seeecseesrersrrsreere 745003 415 WNC 0 EE 745004 575 VAC 30 60H eee 745006 Input Current at Maximum Output 200 VACA a EEN 38 amps DOB VNC LO EE 37 amps DORN NCI A EA OKE 23 amps DOO WC EE 35 amps DOO VAC SO cc ie airs tite ict Dion ton lees eee nat ais 22 amps Specifications SR 451 User s Manual DAO VAC BO E 20 amps BOO MIC SO EE 11 amps ANSON AC SBa R z ZE R zd 10 amps AO MAG O A ARA 9 amps IN NCO Aa J ORAZ 7 amps Open Circuit Voltage ssas esodw ada w AAA 230 VDC Output C rrent o Rad Rai 20 45 amps Maximum Output Voltage coooocnnncccnoncccnoncnononacinnnos 175 VDC D ty Cy l rola 100 Maximum Ambient Temperature 104 F 40 C Dimensions Wi Asia 19 in 483 mm HAM oi 32 5 in 826 mm DEO Ee 20 in 508 mm Weight Single PHASE pa GG A dpt 245
8. as far away from the SR 45i power supply torch torch leads and remote high frequency console as possible e Route the torch leads as close as possible to the work ground cable e Never place your body between the torch leads and work ground cable Keep the work ground cable and the torch leads on the same side of your body e Never stand in the center of a coiled up set of torch leads or work ground cable Safety Standards Booklet Index For further information concerning safety practices to be exercised with plasma arc cutting equipment please refer to the following publications 1 AWS Standard AWN Arc Welding and Cutting Noise obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 2 AWS Standard C5 2 Recommended Practices for Plasma Arc Cutting obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 3 AWS Standard FSW Fire Safety in Welding and Cutting obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 4 AWS Standard F4 1 Recommended Safe Practices for Preparation for Welding and Cutting of Containers and Piping obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 1 4 Safety SR 451 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 an
9. be rated for 24VAC 10mA Motion Output Signal e The SR 45i provides a maintained contact closure or 24VAC output between P8 pins 12 and 14 as long as a cutting arc is maintained between the torch and the workpiece To configure the motion signal for a contact closure connect a jumper wire between terminal block TB1 positions 11 and 13 To configure the motion signal for 24VAC connect a jumper wire between terminal block TBI positions 10 and 11 and another jumper wire between terminal block TBI positions 12 and 13 TBI is located on the sub panel of the system behind the rear panel The motion contacts are rated for 10A 250VAC or 10A 30VDC 3 8 Operation SR 45i User s Manual Section 4 Operation Power Supply Front Panel Controls The SR 431 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 function of each control and indicator See Figure 4 1 for front panel control and indicator locations Power Off Button Deenergizes the SR 451 system and turns off the cooling fans Power On Button Indicator 2 Energizes the SR 451 system and turns on the cooling fans Illuminates to show that the system is energized AC Power Indicator Illuminates when primary power is applied to the SR 451 system DC Power Indicator Illuminates when then main contactor has been energized a
10. effect on dross formation Operation SR 451 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 Material Grate Cutting Type Travel Speed Galvanized 019 28 Galvanized 022 26 Galvanized 028 24 Galvanized 034 22 Galvanized 040 20 Galvanized 052 18 Galvanized 063 16 Mild Steel 1 16 Mild Steel 1 8 Mild Steel 1 4 Mild Steel 3 8 Mild Steel 1 2 Stainless 015 28 Stainless 018 26 Stainless 024 24 Stainless 030 22 Stainless 036 20 Stainless 048 18 Stainless 1 16 Stainless 1 8 Stainless 1 4 Stainless 3 8 Stainless 1 2 Aluminum Aluminum Aluminum Aluminum Aluminum 1 inch 25 4 mm 1 psi 0689 bar 6 895 KPa With the Gas switch in the Set position adjust the regulator on the rear panel to 65 psi 4 9 This page intentionally left blank Maintenance and Troubleshooting SR 451 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 in mind Be aware that the large blue electrolytic capacitor
11. from the side terminal of the rear panel fuse Fl to TB2 14 380V 50Hz Operation For 380V operation TRI must be connected in a wye configuration Install a 10 AWG jumper wire from OV on the first primary winding to OV on the second primary winding Install a second 10 AWG jumper wire from OV on the second primary winding to OV on the third primary winding Connect the three phase primary power from the main contactor CON2 to the 220V connection on each primary winding See Figure 5 2 When the primary voltage of TRI is changed the control transformer TR3 must also be rewired for the correct service voltage For 380V operation connect the white wire of control transformer TR3 to TB2 13 and the brown wire to TB2 14 Connect the gray wire of control transformer TR3 to the side terminal of the rear panel fuse F1 5 5 Maintenance and Troubleshooting SR 451 User s Manual 220V 3 Phase 0 220 0 220 0 220 Figure 5 2 220V 50 Hz Three Phase Transformer 220 V 3 PHASE 380V 3 Phase 220 0 0 220 0 220 0 220 380 V E 220 3 PHASE 0 E 220 Figure 5 3 380V 50 Hz Three Phase Transformer 5 6 Maintenance and Troubleshooting SR 45i User s Manual Logic Regulator Status LED s If a problem occurs with the SR 451 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
12. in the proper order In mode 0 or 2 if all LED s illuminate but the HF LED does not replace the logic regulator p c board Visually check all terminal connections around the high frequency transformer and spark gap assembly Disconnect the high frequency transformer TR4 and check for 120 VAC across the supply leads after a start signal has been received and the HF LED has illuminated If 120 VAC is present go to step 6 If 120 VAC is not present check the continuity in the lines from P3 18 to TB2 6 from P3 17 to TR4 and from TR4 to TB2 1 If all lines are good give the system a start signal wait for the HF LED to illuminate and check for 120 VAC between P3 18 on the logic regulator p c board and TB2 1 then between P3 17 and TB2 1 If P3 18 reads 120 VAC but P3 17 does not replace the logic regulator p c board Note that P3 must be plugged in to the logic regulator p c board to obtain the correct readings Check the high frequency transformer TR4 primary and secondary windings Replace TR4 if either winding is open Remove the wire from the high frequency capacitor C9 and check the capacitor for a short circuit Replace if necessary Check the primary and secondary windings of the high frequency coupling transformer TRS Replace TRS if either winding is open 5 9 Maintenance and Troubleshooting SR 45i User s Manual Torch will not ignite Replace torch consumables Check all LE
13. 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 e Inspect the torch leads frequently Never use the system if the leads are damaged in any way e Do not stand in wet damp areas when operating or performing maintenance on the system e Wear insulated gloves and shoes while operating or performing maintenance on the system e Make sure the SR 45i system is switched off at the wall disconnect before servicing the power supply or torch e Never change torch consumable parts unless the SR 431 system is switched off at the wall disconnect e 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 e Never bypass the safety interlock devices e Before removing any of the SR 451 covers switch the system off at the wall disconnect Wait at least five 5 minutes before removing any cover This 1 2 Safety SR 451 User s Manual e Never operate the SR 431 system without all of the covers in place e Preventive maintenance should be performed daily to avoid possible safety hazards Fire Prevention When using the SR 431 system it is necessary to exercise good judgment While cutting the arc produces sparks that could cause a fire should they fal
14. plastic is in good condition and has no signs of arcing 2 Check all consumables and discard any damaged items Verify that the electrode seat is clean to insure proper electrical contact 4 Check the o ring on the torch for signs of damage Apply a thin film of o ring lubricant to the o ring gt 5 1 Maintenance and Troubleshooting 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 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 procedures SR 45i Power Supply 1 2 REU OO ON En 11 0 Remove the rear panel of the power supply Verify that all torch lead connections and work ground connections are secure Only tighten the gas fittings enough to make a gas seal The fittings are subject to damage if over tightened Verify that the primary AC connections are tight Remove the left and right side panels and blow out the power supply cabinet with clean dry compressed air Be sure to blow off all circuit bards Verify that all p c board connectors are installed securely Verify that the rear panel Amp connectors are installed securely Check the pilot arc r
15. to either the three 220V taps 220 240 220 240 220 or to the three 240V taps For 230V units connect the primary wires to the 240V taps LA A Figure 5 1 220 230 240V 60 Hz Three Phase Transformer 5 4 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 TRI 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 220V 50Hz Operation For 220V operation TR1 must be connected in a delta configuration Install a 10 AWG jumper wire from 220V on the first primary winding to OV on the second primary winding Install a second 10 AWG jumper wire from 220V on the second primary winding to OV on the third primary winding Install a third 10 AWG jumper wire from 220V on the third primary winding to OV on the first primary winding Connect the three phase primary power from the main contactor CON2 to the 220V connection on each primary winding See Figure 5 2 When the primary voltage of TR1 is changed the control transformer TR3 must also be rewired for the correct service voltage For 220V operation connect the white wire of control transformer TR3 to TB2 13 and the brown wire to TB2 14 Also connect a wire 20 AWG minimum
16. 2 6 710103 50 1 1 1 1 1 SS ZX b Figure 6 8 Shielded Torch Leads 6 10 SR 45i User s Manual Parts List SR 451 User s Manual Consumable Spare Parts Kit Part Number 770020 Part Number 770000 770104 770030 770015 770017 770012 770098 770023 770072 716008 Quantity ka LA ba Fa ra Li LN Yu ULU Description Flat metal cutting nozzle Tapered metal cutting nozzle Insulation cutting nozzle Electrode advanceable Electrode non advanceable Swirl ring Retaining cap Electrode advancing tool assembly Torch o ring O ring lubricant Parts List SR 451 User s Manual Logic Regulator P C Board Assembly 740015 o Sm en an zi 0e OBY ce Den d Sack ech a 3 quo pgo K gt K c In IN lO a T N N cza R9 _R28 EE P18 l Ces C41 u20 Figure 6 9 Logic Regulator P C Board 6 12 Parts List SR 451 User s Manual Chopper P C Board C25 9 E EJ R8 c20C_ 16 Q1 Ut Q Q CH R2 EJ R R10 SE L R13 cie cz2 _ O c O 2 Ow O LG O W c c WP1 WP2 Figure 6 10 Chopper P C Board 6 13 This page intentionally left blank Electromagnetic Compatibility EMC SR 451 User s Manual Appendix A Electromagnetic Compatibility EMC Backgro
17. 220V 50 Hz Three Phase Transformer ococonocccnoncccnonccononcnonnnanonananononacnnnnnnnns 5 6 Figure 5 3 380V 50 Hz Three Phase Transformer sg seeseess ees tes 5 6 Figure 6 1 Control EE 6 3 Figure 6 2 Rear Views Inside eege Eege 6 4 Figure 6 3 Base POP TEE 6 5 Figure 6 4 Left Side VIEW w od ENEE as 6 6 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 6 9 Figure 6 10 Figure A 1 Figure A 2 SR 45i User s Manual E 16 Wy rl O EET dune 6 7 Rear View WEE 6 8 Torch and Handle Assembly sea i IAA 6 9 Shielded Torch LejdS tac E A OO eau 6 10 Logic Regulator PA E 6 12 Chopper PC Board siii aires ala RAR ASA 6 13 Primary Power Connection misa ida A OT liner A 4 ENTE ii A 5 This page intentionally left blank Safety SR 451 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 as well as repairs made to the SR 45i system should only be performed by qualified personnel The SR 431 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 R
18. 770030 770012 770072 716008 770023 770025 770028 M M M M dl M M Torch main body assembly Torch handle Torch jacket brass tube with rack Torch jacket brass tube without rack Torch jacket retainer Retaining cap Electrode advanceable Electrode non advanceable Flat metal cutting nozzle Tapered metal cutting nozzle Insulation cutting nozzle Swirl ring Torch o ring O ring lubricant Electrode advancing tool assembly Advancing tool body Advancing tool screw Figure 6 7 Torch and Handle Assembly 6 9 Parts List Shielded Torch Leads 770002 Shielded Torch Leads Assembly 25 Item Number Part Number Quantity Description 711021 770068 770061 770006 770005 710103 NNBWN ra 257 1 MK A pi Braided shield Shield connector Shield connector nut Pilot arc lead assembly Torch power lead assembly Hose clamp 770004 Shielded Torch Leads Assembly 35 Item Number Part Number Quantity Description 1 711021 2 770068 3 770061 4 770010 5 770008 6 710103 357 1 M A M Braided shield Shield connector Shield connector nut Pilot arc lead assembly Torch power lead assembly Hose clamp 770080 Shielded Torch Leads Assembly 50 Item Number Part Number Quantity Description Braided shield Shield connector Shield connector nut Pilot arc lead assembly Torch power lead assembly Hose clamp 1 711021 2 770068 3 770061 4 770081 5 77008
19. ATIONS 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 TRI are labeled with their corresponding voltages 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 220V 60Hz Operation For 220V operation connect the three phase primary power from the main contactor CON2 to the 220V connection on each primary winding When the primary voltage of TR1 is changed the control transformer TR3 must also be rewired for the correct service voltage For 220V operation connect the white wire of control transformer TR3 to TB2 13 and the brown wire to TB2 14 Also connect a wire 20 AWG minimum from the side terminal of the rear panel fuse F1 to TB2 14 230 240V 60Hz Operation For 230V and 240V operation connect the three phase primary power from the main contactor CON to the 240V connection on each primary winding When the primary voltage of TR1 is changed the control transformer TR3 must also be rewired for the correct service voltage For 230V and 240V operation connect the white wire of control transformer TR3 to TB2 13 and the brown wire TB2 14 Connect the red white wire of control transformer TR3 to the side terminal of the rear panel fuse F1 Connect the primary wires from H E H H H CON2
20. D s for proper operation Check all primary disconnect fuses Check for a spark at the spark gap oscillator Verify that the main contactor CON2 is pulling in Verify that the pilot arc relay PAR is pulling in 7 Check the continuity of the torch leads and verify that all torch lead fittings are secure Replace the torch leads if there are any visible signs of damage 8 Verify that the Torch Minus lead and Pilot Arc lead are not shorted together Check the torch and the torch leads separately 9 Check the torch for any visible signs of damage Replace if necessary 10 Check the surge injection capacitors C3 on the I O p c board and the surge injection resistor R5 which is mounted just above the I O p c board Replace if necessary Proceed to chopper test E een a 1 Poor cut quality 1 Consumables worn Replace as necessary 2 Gas pressure not adjusted to 65 psi 3 Incorrect cutting conditions current speed torch height etc See Section 4 for cutting conditions 4 Wrong mode of operation See Section 4 for operating modes 5 Arc not transferring to workpiece Check all connections on the work ground lead Verify that the connections are tight and free from corrosion If necessary use a wire brush to clean the connections 6 Workpiece not grounded to the cutting table Replace the table slats if necessary 7 Gas supply contaminated Install replace filters as necessary 5 10
21. IRL RING ELECTRODE TORCH BODY 770098 770104 770012 770015 or 770017 710073 TORCH CONSUMABLES WHEN CUTTING INSULATING MATERIAL RETAINING CAP INSULATION NOZZLE SWIRL RING ELECTRODE TORCH BODY 770098 770030 770012 770015 or 770017 710073 Oo Figure 4 2 Torch Consumables 4 4 Operation SR 451 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 Typically the electrode should be advanced after an hour of use which will eliminate the copper electrode casing from being eroded Using the electrode advancing tool provided in the spare parts kit the electrode should be pushed out of the copper casing a distance equal to the depth of the crater Then while still in the electrode tool the cratered electrode material should be ground away until it is flush with the original copper casing This can be accomplished by using a common bench grinder Care should be taken so that none of the copper material is removed in the grinding process Note that a non advanceable electrode PN 770017 is available K IY NU Figure 4 3 Electrode Advancing Tool Operation SR 45i User s Manual Setting up a Cut Use the following procedure to make a cut wi
22. Ib 111 kg oi A OO 265 lb 120 kg Gas Supply Requirements Quality o A O A Clean dry oil free air Flow Rate waw OO aoe lh ieee 250 scfh 7075 liters hour Inlet Pressure EEE E E EE 65 psi 4 5 bar ggg e 32 5 826 pace z 19 483 20 508 Figure 2 1 Power Supply Dimensions Specifications SR 451 User s Manual Torch Specifications Stock Number Torch main body A w w ii ia 770073 Torch handle assembly 770075 Diamet r EEN 1 375 in 35 mm Length Torch main body eneen SR Z en 3 5 in 118 mm Torch main body handle assembly 12 8 in 325 mm Weight including handle 1 33 lb 6 kg 1 375 35 HF peer Clamping Section 12 8 325 5 127 JY Figure 2 2 Torch Dimensions 2 3 Specifications SR 451 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 be used as defined by local or national codes The following chart gives the noise
23. 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 spark at the spark gap assembly and primary disconnect fuses Warning Only qualified maintenance personnel should perform the chopper test procedure The system utilizes potentially fatal A C and D C voltages All maintenance should be performed with safety in mind Be aware that the large blue electrolytic capacitors beside the chopper assembly store large amounts of energy even after power has been removed from the system Wait at least five minutes after turning off power and then use a voltmeter to verify that the capacitors are fully discharged before touching the chopper Note Unless otherwise noted leave connectors plugged into the circuit boards while making voltage measurements 1 Turn off all power to the SR 45i power supply 2 Disconnect the torch leads from the Torch Minus and Pilot Arc connections on the I O p c board 3 Turn off the gas supply 4 Disconnect the primary wires of the high frequency transformer TR4 5 Turn the mode switch to position number 9 6 Install a jumper wire across the terminals of pressure switch PRSI and another jumper wire across the terminals of pressure switch PRS2 7 Connect the
24. SR 451 User s Manual Apply primary power to the SR 451 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 Depress the green On button to energize the power supply Place the Gas switch in the set position and adjust the regulator pressure to 65 psi while gas is flowing through the torch Return the Gas switch to the Run position Set the Motion Delay potentiometer to minimum for material thicknesses up to 1 87 Thicker materials will reguire longer motion delays to allow the arc to fully penetrate the material Set the Current potentiometer according to the cutting chart in this section Set the Mode Switch to the proper mode as previously described The cutting operation is initiated after a start signal is received The arc should establish after approximately 2 seconds of gas preflow Throughout the cut the red D C Power light on the front panel should be illuminated to indicate that current is flowing through the torch The cutting operation is terminated when the start signal is removed At the completion of a cut gas should flow through the torch for approximately 10 seconds Operation SR 451 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 character
25. SR 451 User s Manual SR 45i Plasma Cutting System Revision 11 5 16 07 Manual Part Number 718061 J KALIBURN 455 Fleming Road Charleston SC 29412 USA 800 252 2850 Toll free 843 795 4286 Phone 843 795 8931 Fax www kaliburn net This page intentionally left blank SR 451 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 the SR 451 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 responsib
26. See the following chart for recommended fuse sizes 3 1 Installation SR 451 User s Manual Input Voltage Phase Input Current Recommended VAC at Maximum Output Time Delay Fuse Size amps 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 primary power to the SR 451 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 CONI as shown in Figure 3 1 Note that the center terminal of CON is not used in single phase systems Be sure to connect the primary ground cable to the ground stud on the sub panel Main Contactor Sub Panel Ground Stud CON2 Jee Dean ic Safety Contactor CONI erung QP rem Type SO Power Cable Disconnect Box Connections LI U C L2 V A L3 W Ground Figure 3 1 Primary Power Connections 3 2 Installation SR 451 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 T
27. 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 Check for open wires between the chopper output and the Torch Minus connection on the I O p c board skip the rest of this test 14 Remove the start signal and measure the voltage between P1 9 and P1 10 on the chopper pc board It should read 120 VAC If the voltage 1s not correct make the measurement with Pl disconnected from the chopper If the voltage 1s correct with the chopper disconnected replace the chopper If the voltage is still not correct check the primary and secondary voltages of the control transformer TR3 the auxiliary contacts of CON1 and fuse F3 15 a If the voltage between P1 9 and P1 10 were correct in step 14 move the negative lead of the voltmeter to P1 5 Connect the positive lead of the voltmeter to P1 4 Apply primary power to the unit a start signal is not required The voltage on P1 4 should measure approximately 5 8 VDC If P1 4 measures 5 8 VDC go to step d b If the voltage between P1 4 and P1 5 did not measure 5 8 VDC in step a unplug P2 from the logic regulator p c board If P1 4 still does not measure 5 8 VDC go to step c If P1 4 now measures 5 8 VDC measure the voltage between TP2 and TP6 on the logic regulator p c board If TP6 measures 10 5 VDC replace the logic regulator p c board skip the rest of this test If TP6 measures 0 VDC check t
28. adiation 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 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 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 1
29. ate problems of interference Screening of the entire welding installation may be considered for special applications Electromagnetic Compatibility EMC SR 451 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 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 Connect the primary ground wire to the ground stud on the line side of the filter Tighten the terminal screws securely but do not over tighten The terminals are subject to damage if the screws are over tightened Main Contactor ie CON2 S Sub Panel Ground Stud Safety Contactor CONI Type SO Power Cable Ground Stud Below o Type SO Power Cable Disconnect Bo
30. aterial to drain through the lower exit tube Some units are equipped with an automatic drain and others have a manual drain In either case be sure that contaminants do not accumulate in the filter bowl The filter element will require periodic replacement depending on the amount of contamination in the line Replacement filter elements are available from KALIBURN Looking at the rear of the power supply connect the gas supply to the right port of the regulator A 1 4 6 mm inside diameter minimum hose size should be used Using the hose provided connect the left port of the regulator to the inlet port on the lower left of the power supply See Figure 3 4 for more information Be sure that all gas supply connections are tight Leaks in the supply can cause poor cut quality 3 6 Installation SR 451 User s Manual e HOH 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 Figure 3 4 Gas Supply Connections 3 7 Installation SR 451 User s Manual CNC Machine Interface Connections Perform the following steps to properly interface the SR 451 system with a CNC cutting machine See the system schematic for additional information Plasma Start Signal e 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
31. bad fuses The logic regulator p c board controls all of the functions of the SR 451 system It has 10 LED s which aid in troubleshooting the system The LED s illuminate when a particular event occurs Illuminated LED s indicate the following LED Indication L1 Torch interlock pressure switch PRS2 closed L2STRT Plasma start signal applied L3 CON Main contactor CON2 energized L4 REG Chopper energized L5 H F High frequency transformer energized L6 PAR Pilot arc relay energized L7 GAS Gas solenoid valve energized L8 MOT X Y machine motion relay energized L9 PCB Indicates p c board power L10 TAC Transferred arc current established from torch to workpiece Logic Regulator Sequence of Operation The following LED s should illuminate after primary power is applied L9 PCB The following LED s should illuminate in sequence after a start signal is received L2 STRT L7 GAS Ll L3 CON L6 PAR L4 REG L5 H F L10 TAC L8 MOT After a transferred cutting arc is established the following LED s will go out L5 H F L6 PAR L6 will remain illuminated in modes 5 and 9 5 7 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 cover
32. cathode fitting on the torch body The cathode lead has a right handed nut 3 Attach the pilot arc torch lead 3 16 hose to the pilot arc fitting on the torch body The pilot arc fitting has a left handed nut and is identified by a machined line on the nut itself 4 Slide the torch handle down over the connections and thread the handle onto the torch body being careful to avoid cross threading the handle When tightening the handle be sure to turn the handle and not the torch body This will avoid twisting the torch leads Torch Cathode Lead aa Gy ee Pilot Arc Lead GE Torch Handle ANNO OOOO OC O RIRE Figure 3 3 Torch Connections 3 5 Installation SR 451 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 431 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 The regulator filter supplied with the SR 45i should be used with industrial compressed air systems only It must not be used where the inlet pressure can exceed 150 psi or when the temperature can exceed 125 F The SR 45i is shipped without the regulator filter installed to avoid shipping damage The regulator should be mounted in the vertical position on the rear panel to allow filtered m
33. ch 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 damaged items Verify that the electrode seat is clean to insure proper electrical contact 4 Check the o ring on the torch for signs of damage Apply a thin film of o ring lubricant to the o ring 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 gt SN Work Ground 1 Using an ohmmeter measure zero ohms between the power supply Work Ground connection on the I O p c board and the star ground point on the cutting table The star ground connection should be kept clean and free from oxidation or corrosion Use a wire brush to clean the connection point if necessary Gas Supply 1 Check for signs of contamination in the gas supply lines and replace any filters as necessary The SR 45i requires clean dry oil free compressed air for good cut quality as well as long consumable life 2 Listen for gas leaks in the supply lines and in the internal plumbing system of the SR 451 Tighten any connections that are leaking Leaks in the supply can cause poor cut quality as well as torch overheating 5 3 Maintenance and Troubleshooting SR 451 User s Manual 220 230 240V 60 Hz TRANSFORMER CONFIGUR
34. cked or has other signs of physical damage e All gas cylinders should be secured to a wall or rack to prevent accidental knock over e If a compressed gas cylinder is not being used replace the protective valve cover e Never attempt to repair compressed gas cylinders e Keep compressed gas cylinders away from intense heat sparks or flames e Clear the compressed gas cylinder connection point by opening the valve momentarily prior to installing a regulator e Never lubricate compressed gas cylinder valves or pressure regulators with 1 3 Safety SR 451 User s Manual any type of oil or grease e Never use a compressed gas cylinder or pressure regulator for any purpose other than which it is intended e Never use a pressure regulator for any gas other than which it is intended e Never use a pressure regulator that is leaking or has other signs of physical damage e Never use oxygen hoses and pressure regulators for any gas other than oxygen e Never use any gas hose that is leaking or has other signs of physical damage Health Support Equipment The SR 451 system creates electric and magnetic fields that may interfere with certain types of health support equipment such as pacemakers Any person who uses a pacemaker or similar item should consult a doctor before operating observing maintaining or servicing the SR 431 system Observe the following guidelines to minimize exposure to these electric and magnetic fields e Stay
35. d Allied Processes obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 7 ANSI Standard Z41 1 Standard For Men s Safety Toe Footwear obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 8 ANSI Standard Z49 2 Fire Prevention in the Use of Cutting and Welding Processes obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 9 ANSI Standard Z87 1 Safe Practices For Occupation and Educational Eye and Face Protection obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 10 ANSI Standard Z88 2 Respiratory Protection obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 11 OSHA Standard 29CFR 1910 252 Safety and Health Standards obtainable from the U S Government Printing Office Washington D C 20402 12 NFPA Standard 51 Oxygen Fuel Gas Systems for Welding Cutting and Allied Processes obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 13 NFPA Standard 51B Cutting and Welding Processes obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 14 NFPA Standard 70 National Electrical Code obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 15 CGA booklet P 1 Safe Handling o
36. e 200 220V 50 Hz 1 phase 220 230 240V 60 Hz 1 phase 220 380V 50 Hz 3 phase 208 480V 60 Hz 3 phase 415V 50 Hz 3 phase 575V 60 Hz 3 phase PAR pilot arc relay RS surge injection resistor R5 mounting hardware C7 filter capacitor C7 mounting bracket R1 bleed resistor R1 mounting hardware TRS high frequency coupling transformer C9 high frequency capacitor Spark gap assembly Spark gap electrode TR4 high frequency transformer L1 inductor Air regulator with filter Air regulator mounting bracket Air regulator filter Mode switch Mode switch mounting hardware 6 2 SR 451 User s Manual Parts List AN DO NOU OW SdAv yaMOod 20 YSMOd 9V 1 Control Panel Figure 6 Parts List SR 451 User s Manual TORCH MINUS PILOT ARC WORK GROUND Figure 6 2 Rear View Inside 6 4 Parts List SR 45i User s Manual Figure 6 3 Base Top View 6 5 Parts List SR 451 User s Manual SS E Figure 6 4 Left Side View 6 6 SR 451 User s Manual Parts List WC A 9 GE UN Figure 6 5 Right Side View 6 7 Parts List SR 451 User s Manual Figure 6 6 Rear View Outside 6 8 Parts List SR 451 User s Manual Torch and Handle Assembly Item Number Part Number Ouantity Description 1 3 Nn 8 9 Not Shown Not Shown Not Shown Not Shown 770073 770059 770060 770065 770061 770098 770015 770017 770000 770104
37. ed in this section Before any tests are performed make sure that all system fuses are good The primary system fuse Fl is located on the rear panel of the unit The control fuses F2 and F3 are located behind the rear panel of the unit on the sub panel Problem Possible Cause Front panel white A C power light will Primary disconnect fuse blown not illuminate Fuse Fl blown White light or associated wiring bad Transformer TR2 or associated wiring bad ONS Unit will not energize or fan motor will 1 Inlet gas pressure below 65 psi not energize when the ON button is 2 Fuse F2 or F3 blown pressed 3 Inlet gas pressure switch PRS1 or associated wiring bad PRS1 is normally open 4 Faulty ON switch or associated wiring The ON switch is normally open 5 Faulty OFF switch or associated wiring The OFF switch is normally closed 6 Diode bridge temperature switch open 7 Safety contactor CON1 defective or needs cleaning Open contactor and blow out with compressed air 8 CONI auxiliary switch or associated wiring bad 9 Fan motor or associated wiring bad Front panel red D C power light will 1 Regulator pressure below 65 psi while gas is not illuminate flowing 2 Torch retaining cap or consumables not installed correctly 3 If the SR 451 is given a start signal and the PCB STRT GAS and L1 LED s illuminate but the CON LED does not replace the logic regulator p c board 4 If the STRT LED does not illuminate
38. elay contacts for signs of pitting and replace if necessary Verify that all hardware connections are tight Clean and reset the spark gap spacing to 015 38 mm Check the connection of the high frequency coupling transformer leads to the VO p c board Verify that the fan blades spin freely SR 45i Torch Leads 1 Verify that all torch lead connections are secure Only tighten the gas fittings enough to make a gas seal The fittings are subject to damaged if over tightened Remove the retaining cap and consumables from the torch Using an ohmmeter measure zero ohms between the power supply Torch Minus connector on the I O p c board and the cathode body inside the torch The cathode body is the brass piece that the electrode seats against Using an ohmmeter measure zero ohms between the power supply Pilot Arc connector on the I O p c board and the torch anode body The anode body is the brass piece that the retaining cap threads onto Verify that the braided shield of the torch leads is secured to the brass adaptor that connects to the power supply Also make sure the adaptor is secured 5 2 SR 451 User s Manual Maintenance and Troubleshooting SR 451 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 the tor
39. f Compressed Gases in Containers obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 16 CGA booklet P 14 Accident Prevention in Oxygen Rich and Oxygen Deficient Atmospheres obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 1 5 Safety 17 18 19 SR 451 User s Manual CGA booklet TB 3 Hose Line Flashback Arrestors obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 CSA Standard W117 2 Safety in Welding Cutting and Allied Processes obtainable from Canadian Standards Association 178 Rexdale Boulevard Toronto Ontario M9W 1R3 Canada Canadian Electrical Code Part 1 Safety Standard for Electrical Installations obtainable from the Canadian Standards Association 178 Rexdale Boulevard Toronto Ontario M9W 1R3 Canada 1 6 Specifications SR 451 User s Manual Section 2 Specifications System Description The SR 451 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 utilizes a single gas torch that is capable of cutting gauge to 1 2 thick material The SR 431 also has 4 modes of operation which provide the capability for cutting all types of material including expanded metal
40. flow of gas Reapplying the plasma start signal while in the gas postflow stage will initiate the cutting arc immediately without going through the gas preflow sequence 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 pre cut kerf during a cutting sequence the arc may be lost In mode 0 the pilot arc relay will automatically close and the arc will be reignited The sequence for initiating the arc is the same as in the mechanized cutting mode However when the cutting arc is lost the pilot arc is reestablished with continuous high frequency and will remain in the pilot arc high frequency state until a cutting arc is reestablished The x y machine motion signal will remain 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 451 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 However the pilot arc relay remains closed during the cut As a result the torch reverts to a pilot arc condition when the transferred arc is l
41. he continuity from the current feedback shunt SH1 through RP2 and back to P4 on the logic regulator p c board If both of the lines are good replace the logic regulator p c board skip the rest of this test c If Pl 4 did not measure 5 8 VDC in step b unplug the chopper connector P1 and measure the continuity between the two wires connected to pins 4 and 5 leave P2 unplugged from the logic regulator p c board If the two wires are not shorted together replace the chopper skip the rest of this test d Unplug P4 from the logic regulator pc board The voltage on P1 4 should drop to approximately 8 VDC If it does not measure the voltage between TP2 and TP6 on the logic regulator p c board If TP6 measures 0 VDC check the continuity in the lines between the logic regulator p c board and the chopper If the lines are good replace the logic regulator p c board 16 a Move the positive lead of the voltmeter to P1 2 Leave the negative lead connected to P1 5 Apply primary power to the unit a start signal is not required P1 2 should measure 4 25 VDC If P1 2 measures 4 25 VDC go to step c b If P1 2 did not measure 4 25 VDC in step a above unplug P2 from the logic regulator p c board If P1 2 now reads 4 25 VDC replace the logic regulator p c board If P1 2 still does not read 4 25 VDC check the continuity in the lines between the logic regulator p c board and the 5 12 Maintenance and Troubleshooting SR 451 User s Ma
42. he fittings are subject to damage if over tightened Torch Leads W 1 Remove the threaded ring from the brass shield connector on the end of the braided shield Route the torch leads through the opening in the rear of the power supply and push the shield connector through the hole until it is seated against the sheet metal Slide the threaded ring over the torch leads and thread onto the shield connector Tighten the threaded ring firmly The shield connector grounds the braided shield to the power supply enclosure to help eliminate high frequency noise emission Using an ohmmeter measure zero ohms between the braided shield and the ground stud on the sub panel inside the power supply Connect the cathode torch lead 1 4 hose to the Torch Minus fitting on the I O board The cathode lead has a right handed nut Connect the pilot arc lead 3 16 hose to the Pilot Arc fitting on the I O board The pilot arc lead has a right handed nut Work Ground Lead 1 Route one end of the 6 AWG work ground lead through the bushing on the lower rear of the power supply and connect it to the Work Ground connection on the I O board Connect the other end of the work ground lead to the star ground point on the cutting table The star ground point is generally referred to as the common ground point on the cutting table where all subsystems of the machine are grounded This point is then connected to a driven earth ground r
43. istics 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 The following guidelines should be useful in determining which cutting parameter to adjust Note Before making any parameter changes verify that the torch is square to the workpiece Also it is essential to have the correct torch parts in place and to ensure that they are in good condition Check the electrode for excessive wear and the nozzle orifice for roundness Also make sure that the air pressure is adjusted to 65 psi with the Gas switch in the Set position and that the air supply is not contaminated 1 A positive cut angle top dimension of piece smaller than the bottom dimension usually occurs when the torch standoff distance is too high when cutting too fast or when excessive power is used to cut a given plate thickness 2 A negative cut angle top dimension of piece larger than the bottom dimension usually occurs when the torch standoff distance is too low or when the cutting speed is too slow 3 Top dross usually occurs when the torch standoff distance is too high 4 Bottom dross usually occurs when the cutting speed is either too slow slow speed dross or too fast high speed dross Low speed dross is easily removed while high speed dross usually requires grinding or chipping off 5 Note that different material compositions have an
44. l on flammable material Make sure that all flammable material such as paper cloth etc is a suitable distance away from the cutting area All flammable liquids should be at least 40 feet away from the cutting area preferably stored in a metal cabinet Plasma cutting should never be attempted on containers that contain flammable materials Make sure that fire extinguishers are readily accessible in the cutting area Explosion Prevention The SR 45i system uses compressed gases Use proper techniques when handling compressed gas cylinders and other compressed gas equipment Observe the following guidelines to protect against explosion e Never operate the SR 451 system in the presence of explosive gases or other explosive materials e Never cut pressurized cylinders or any closed container e When using a water table and cutting aluminum under water or with water touching the underside of the aluminum plate hydrogen gas is produced This hydrogen gas may collect under the plate and explode during the cutting process Make sure the water table is properly aerated to help prevent the accumulation of hydrogen gas e Handle all gas cylinders in accordance with safety standards published by the U S Compressed Gas Association CGA American Welding Society AWS Canadian Standards Association CSA or other local or national codes e Compressed gas cylinders should be maintained properly Never attempt to use a cylinder that is leaking cra
45. le 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 451 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 about the EMC standard EN 50199 can be found in Appendix A SR 451 User s Manual TABLE OF CONTENTS Section 1 Safety u WAG OO ee ee LOE es 1 1 General Pr CS e pe Ie kat rd ne S iA 1 1 Ultraviolet Radiation Protec 1 1 No1s Protection eerren eebe ee 1 1 Toxi De EE EE 1 1
46. mendations Electromagnetic Compatibility EMC SR 451 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 Eguipotential Bonding Bonding of all metallic components in the plasma cutting installation and adjacent to it should be considered However metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may allevi
47. nd D C current is flowing through the torch Gas Switch O In the Set mode energizes the gas solenoid so the gas pressure may be adjusted In the Run mode the gas solenoid is deenergized Current Adjust Potentiometer 6 Used to set the output current of the SR 451 Motion Delay Potentiometer 1 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 451 and is used to set the operating mode of the system Operation SR 45i User s Manual e AC POWER DC POWER MODE SWITCH ej VIEW AT A A Figure 4 1 Front Panel Controls Mechanized Cutting Mode To place the SR 451 in the mechanized cutting mode set the Mode Switch thumbwheel to position number 2 The start signal initiates the following sequence of events Two second gas preflow Pilot arc initiation Transferred arc establishes cutting arc X Y machine motion signal enabled Note that the machine motion signal can be delayed for up to three seconds using the motion delay potentiometer on the front panel Pe Se Removal of the plasma start signal terminates cutting disables the x y machine motion signal and initiates gas postflow Note Loss of the cutting arc even if a plasma start signal is applied deenergizes the SR 451 system disables the x y machine motion signal and initiates post
48. nde 5 2 220 230 240V 60 Hz Transformer Configurations ss 5 4 220 380V 50 Hz Transformer Configurations 0 ccscceescecesncecesececeeceeceeeeeceeeeeceeeeeeeeeeeees 5 5 Legic Reaulator Status LEDS Rest ent it ee eens tesa 5 7 Logic Resulator Sequence Of Operation ses ai ycd w 5 7 General Troubleshooting versa idad ainia sacada aE E aa ini 5 8 Chopper Test TEE 5 11 section 6 Parts List 6 1 e EE 6 1 Torch and Handle Assembly saw AR AA sede 6 9 Shielded Torch eas EE 6 10 Consumable pare E 6 11 L gi Regulator WEE E 6 12 Chopper P C EE 6 13 Appendix A Electromagnetic Compatibility EMC A 1 DaACKOROUNA EE A 1 SAA and a A 1 Assessment of AU nd EE enee A 2 Methods of Reducing Emissions iii GAL GE l R AAA Aa A 2 Primary Power Re ss cda OE ad zi ad d Ozi ati A 4 EMI Filter Pati A 5 Illustrations Figure 2 1 Power Supply Ee 2 2 Figure 2 2 Toreh Be 2 3 Figure 3 1 Primary Power Connections s csicsecissscvescsdeesssossatcategscedasesvasncnsdacea o AAA 3 2 Figure 3 2 Power Supply Output Connections ss 3 4 Figure 3 3 A O O CKE 3 5 Figure 3 4 GAS Supply CONNECTION A ALA 3 7 Figure 4 1 FrontPan l Controls ss asie nn nt Re es tr de 4 2 Figure 4 2 Torch Consumables ss ita AA ia idas 4 4 Figure 4 3 Electrode Advancing Tool LA 4 5 Figure 5 1 220 230 240V 60 Hz Three Phase Transformer 5 4 Figure 5 2
49. nual 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 If P1 2 does not read 0 VDC check the continuity in the lines between the chopper and the logic board Next verify that the REG LED is illuminated on the logic regulator p c board If the REG LED is illuminated the lines between the chopper and the logic regulator are good but the voltage on P1 2 does not drop to 0 VDC replace the logic regulator p c board d If P1 2 measured 0 VDC in step c above but there is still no voltage between Torch Minus and Work Ground on the I O p c board replace the chopper 5 13 This page intentionally left blank Parts List SR 451 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 740106 2 Bulb 7 740105 1 White lens 8 740104 1 Red lens 9 708021 1 Gas switch 10 701051 1 Motion potentiometer 11 710012 2 Potentiometer knob 12 701086 1 Current potentiometer 13 708015 1 PRS1 pressure switch 14 708016 1 PRS2 pressure switch 15 708014 1 GAS solenoid valve 16 706004 1 TR6 motion transformer 241 3 24
50. od that should be as close as possible to the star ground The ground rod should have no other wires connected to it The ground rod should be at least 3 4 inches in diameter and should be driven into the earth s permanent moisture layer The length of the ground rod varies from installation to installation and should be installed according to local and national codes Refer to the National Electrical Code Article 250 Section H Ground Electrode System for additional information 3 3 Installation SR 451 User s Manual O TORCH MINUS PILOT ARC WORK GROUND 12345 67 8 91011121314 Del iid ea bbb be Ta o o slslslslslslalolslalslslsls 4 1234567 8 91011121314 Tighten Securely RRARARARARKARARE o O e o s s s o s s o o o s s s 2 Y a Kd Y ox 3 gt VES d e Z SOO RS RS X RSS LO XS O RRS Figure 3 2 Power Supply Output Connections 3 4 Installation SR 451 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 tightening the torch fittings to avoid damaging the torch 1 Unscrew the torch handle assembly from the torch main body and slide the torch leads through the handle 2 Attach the cathode torch lead 1 4 hose to the
51. omagnetic disturbances shall be reduced to the point where they are no longer troublesome Note The plasma cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel plasma cutting current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC 974 13 Arc welding equipment Installation and use Electromagnetic Compatibility EMC SR 451 User s Manual Assessment of rea Before installing plasma cutting eguipment 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 eguipment b radio and television transmitters and receivers c computer and other control eguipment d safety critical eguipment e g guarding of industrial eguipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may require additional protection measures h the time of day that plasma cutting or other activi
52. ost in spaces between the metal The x y machine motion signal remains enabled until the plasma start signal is removed High frequency starting is only required for the initial cutting arc but will reignite the arc if it is lost for some reason The cutting sequence is terminated when the plasma start signal is disabled Insulation Cutting Mode To place the SR 45i in the insulation cutting mode set the Mode Switch thumbwheel to position number 9 The insulation cutting mode provides a continuous pilot arc for cutting nonmetallic substances The cutting current is automatically set on the logic regulator p c board and any front panel current setting is ignored When the pilot arc is established the x y machine motion signal is enabled even there is no transferred arc As in the other modes the x y machine motion signal can be delayed for up to three seconds after arc initiation by adjusting the motion delay potentiometer on the front panel The cut is terminated when the plasma start signal is removed Operation SR 451 User s Manual Torch Consumables Figure 4 2 shows the different torch consumable configurations for cutting various materials with the SR 451 TORCH CONSUMABLES WHEN CUTTING MATERIALS GREATER THAN 1 8 3 mm THICK RETAINING CAP FLAT NOZZLE SWIRL RING ELECTRODE TORCH BODY 770098 770000 770012 770015 or 770017 710073 TORCH CONSUMABLES WHEN CUTTING MATERIALS UP TO 1 8 3 mm THICK RETAINING CAP TAPERED NOZZLE SW
53. positive lead of a voltmeter to the Work Ground connection on the I O p c board and connect the negative lead to the Torch Minus connection Configure the voltmeter to read D C voltage 8 Use a jumper wire to give the system a start command Install the jumper between P8 3 and P8 4 on the rear of the power supply or between TB1 7 and TB1 8 on the sub panel 9 When the red D C Power light on the front panel illuminates the voltmeter should read 230 VDC If the voltage reading is correct the chopper is working correctly skip the rest of this test 10 Turn off the primary power to the system and connect the positive lead of the voltmeter to the positive side of the large blue filter capacitors C7 that are mounted beside the chopper Connect the negative lead of the voltmeter to the negative side of capacitors C7 11 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 incorrect there may be a problem with CON1 CON2 TRI the diode bridge or C7 skip the rest of this test 12 If the voltage across C7 is correct then the input to the chopper is correct Turn the power off and move the negative voltmeter lead to the chopper 5 11 Maintenance and Troubleshooting SR 451 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
54. s inside the power supply store large amounts of energy even after power has been removed from the system Wait at least five minutes after turning off power before touching any of the internal components Daily Procedures SR 45i Power Supply 1 Verify that the white A C Power light is illuminated whenever primary A C power is applied to the system 2 Depress the green On push button and verify that the fan motor is on 3 Place the Gas switch in the Set position and verify that air is flowing through the torch 4 With the Gas switch in the Set position adjust the regulator on the rear panel of the SR 431 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 451 using the CNC control The pilot arc should be established in approximately 2 seconds The arc should extend approximately 1 inch from the nozzle and should make a smooth swishing sound If a popping or motorboat sound occurs there may be a problem that needs correction WARNING Remove primary power from the system before performing the following procedures SR 45i Torch Leads 1 Check the braided shield for nicks or cuts If the braided shield is damaged make sure the hoses are in good working condition If there are any holes in the hoses the torch leads must be replaced SR 45i Torch 1 Remove all consumables from the torch and verify that the anode cathode insulator brown
55. th 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 O RING 770072 3 Place the advanceable electrode PN 770015 or non advanceable electrode PN 770017 into the swirl ring PN 770012 by inserting the small end of the electrode into the large opening of the swirl ring The large diameter of the electrode should bottom out and fit snugly into the swirl ring 4 Place the appropriate nozzle onto the small end of the swirl ring Use the tapered metal cutting nozzle PN 770104 for cutting gauge material through 1 8 or use the flat metal cutting nozzle PN 770000 for cutting material over 1 8 thick Use the insulation cutting nozzle PN 770030 for cutting insulating material Note that the insulation cutting nozzle has a groove machined in the side so it can be distinguished from the flat metal cutting nozzle METAL CUTTING NOZZLE INSULATION CUTTING NOZZLE 770000 770030 NOTE GROOVE LOCATION 5 Place the electrode swirl ring nozzle assembly into the retaining cap PN 770098 and make sure the nozzle flange is seated in the retaining cap recess 6 Thread the retaining cap onto the torch and hand tighten FIRMLY It is very important that all parts are seated tightly to prevent the torch from arcing internally Operation 7 10 11 12 13
56. ties are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Plasma cutting equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed plasma cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the plasma power source so that good electrical contact is maintained between the conduit and the plasma power source enclosure Maintenance of the Plasma Cutting Equipment The plasma cutting equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the plasma cutting equipment is in operation The plasma cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recom
57. uld 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 Choose a location that will provide unrestricted air movement into and out of the power supply Maintain at least 24 inches of space on all sides of the unit The location should subject the power supply to the least amount of dust dirt moisture and corrosive vapors The power supply must be cleaned as often as necessary to prevent the accumulation of metallic dust inside the unit See Figure 2 1 for power supply dimensions Primary Power Connection Before connecting primary power check the data plate to verify the voltage required by the SR 45i power supply Note See Appendix A for additional information on 220 380V and 415V 50Hz systems A primary disconnect switch should be provided for each SR 45i power supply The disconnect switch should be located as close as possible to the power supply so it can be turned off quickly in case of an emergency The disconnect switch should be equipped with time delay fuses only The magnetic inrush current of the power supply will cause fast acting fuses to blow The disconnect switch should be sized according to local and national codes The rating must meet or exceed the continuous rating of the fuses used
58. und The 220 380V 50Hz and 415V 50Hz SR 451 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 plasma cutting equipment to work in a compatible manner with other radio and electronic systems is greatly influenced by the manner in which it is installed and used For this reason it is important that the plasma cutting equipment be installed and used in accordance with the information below if electromagnetic compatibility is to be achieved Plasma cutting equipment is primarily intended for use in an industrial environment There may be potential difficulties in ensuring electromagnetic compatibility in other environments Installation and Use The user is responsible for installing and using the plasma cutting equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the plasma cutting equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the plasma cutting circuit see Note In other cases it could involve constructing an electromagnetic screen enclosing the plasma power source and the work complete with associated input filters In all cases electr
59. x Connections Li U L2 V O L3 W Ground Figure A 1 Primary Power Connections A 4 Electromagnetic Compatibility EMC SR 451 User s Manual EMI Filter Parts List EMI Filter Assembly 220 380 VAC 50Hz Assembly 740133 Item Number Part Number Quantity Description 1 719002 EMI filter enclosure 2 702047 i EMI filter 30A 3 711183 28 10 4 Type SO power cable 4 709060 2 Strain relief EMI Filter Assembly 415 VAC 50Hz Assembly 740132 Item Number Part Number Quantity Description 1 719001 EMI filter enclosure 2 702046 i EMI filter 10A 3 711183 28 10 4 Type SO power cable 4 709060 2 Strain relief Figure A 2 EMI Filter A 5

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