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Maintenance and Troubleshooting SR-100i User’s Manual

Section 5 Maintenance and Troubleshooting

Warning: Only qualified maintenance personnel should perform
maintenance on the SR-100i 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 capacitors
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-100i 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-100i to 85 psi. Return the Gas switch to the Run position.

5.

Raise the torch 2 inches above the workpiece. Apply a start signal to the SR-
100i using the CNC control. 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-100i 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-100i Torch

1.

Remove all consumables from the torch and verify that the anode-cathode
insulator (brown plastic) is in good condition and has no signs of arcing.

2.

Check all consumables and discard any damaged items.

3.

Verify that the electrode seat is clean to insure proper electrical contact.

4.

Reassemble the electrode, swirl ring, and nozzle and install them in the torch.

5.

Make sure that the retaining cap is hand tight and all parts are seated properly.

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Summary of Contents for SR-100i

Page 1: ...l SR 100i Plasma Cutting System Without Ohmic Contact Torch Revision 10 5 17 07 Manual Part Number 718048 455 Fleming Road Charleston SC 29412 USA 800 252 2850 Toll free 843 795 4286 Phone 843 795 8931 Fax www kaliburn net ...

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Page 3: ...epair 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 eq...

Page 4: ...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 ...

Page 5: ...y 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 ...

Page 6: ... 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...

Page 7: ...ormer 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 ...

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Page 9: ...lding 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 ins...

Page 10: ...R 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...

Page 11: ... presence of explosive gases or other explosive materials Never cut pressurized cylinders or any closed container 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 preve...

Page 12: ...torch leads and remote high frequency console as possible Route the torch leads as close as possible to the work ground cable 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 Never stand in the center of a coiled up set of torch leads or work ground cable Safety Standards Booklet Index For further infor...

Page 13: ...y 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 Pa...

Page 14: ...ngton VA 22202 18 CSA Standard W117 2 Safety in Welding Cutting and Allied Processes obtainable from Canadian Standards Association 178 Rexdale Boulevard Toronto Ontario M9W lR3 Canada 19 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 ...

Page 15: ...ity for cutting all types of material including expanded metal and insulation A digital current thumbwheel provides repeatable current settings which results in repeatable cuts These features alone provide durability cost effective operation and excellent cut quality In addition the use of air as the plasma and cooling gases enhances the cost effectiveness For better cut quality on stainless steel...

Page 16: ...ltage 250 VDC Output Current 25 100 amps Maximum Output Voltage 175 VDC Duty Cycle 100 Maximum Ambient Temperature 104 F 40 C Dimensions Width 22 in 559 mm Height 35 5 in 902 mm Depth 24 in 610 mm Weight 400 lb 181 kg Gas Supply Requirements Quality Clean dry oil free air or nitrogen Flow Rate 430 scfh 12 175 liters hour Inlet Pressure 85 psi 5 9 bar SR 100i Figure 2 1 Power Supply Dimensions 2 2 ...

Page 17: ...fications Stock Number Torch main body 800280 Torch handle assembly 770075 Diameter 1 375 in 35 mm Length Torch main body 3 5 in 89 mm Torch main body handle assembly 12 8 in 325 mm Weight including handle 1 5 lb 7 kg Figure 2 2 Torch Dimensions 2 3 ...

Page 18: ...n should be used as defined by local or national codes The following chart gives the noise levels generated by the SR 100i when operating at 100 amps 120 arc volts The measurements were made with a sound level meter Distance From Torch A Weighted Sound Pressure Level C Weighted Sound Pressure Level 1 meter horizontal 1 6 meters above the workpiece 98 dB 96 dB The maximum noise level is 123 dB at a...

Page 19: ... the restart and is disabled only when the plasma start signal is removed Grate Cutting Mode The starting sequence is the same as that in the mechanized cutting mode However it is not necessary to transfer the arc to the workpiece in order to get an x y machine motion signal The x y machine motion signal is enabled after the pilot arc is established but can be delayed using the motion delay potent...

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Page 21: ...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 Powe...

Page 22: ...a 600 volt minimum rating and should be sized according to local and national codes Route the power cable through the strain relief on the rear of the power supply and connect the hot lines to the input terminals on the safety contactor CON1 as shown in Figure 3 1 Be sure to connect the primary ground cable to the ground stud on the sub panel Type SO Power Cable Safety Contactor CON1 Main Contacto...

Page 23: ...b panel inside the power supply 4 Connect the torch electrode lead 3 8 hose to the Torch Electrode fitting on the I O board 5 Connect the torch nozzle lead 3 16 hose to the Torch Nozzle fitting on the I O board Work Ground Lead 1 Route one end of the 4 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 2 2 Co...

Page 24: ...Installation SR 100i User s Manual SR 100i Figure 3 2 Power Supply Output Connections 3 4 ...

Page 25: ... torch handle assembly from the torch main body and slide the torch leads through the handle 2 Attach the torch electrode lead 3 8 hose to the torch electrode fitting on the torch body 3 Attach the torch nozzle lead 3 16 hose to the torch nozzle fitting on the torch body 4 Slide the torch handle down over the connections and thread the handle onto the torch body being careful to avoid cross thread...

Page 26: ...regulator should be mounted in the vertical position on the rear panel to allow filtered material 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 Re...

Page 27: ...Installation SR 100i User s Manual SR 100i Figure 3 4 Gas Supply Connections 3 7 ...

Page 28: ...sitions 7 and 8 and another jumper wire between terminal block TB1 positions 10 and 11 To configure the motion signal for 24VAC connect one jumper wire between terminal block TB1 positions 5 and 8 Connect a second jumper wire between terminal block TB1 positions 7 and 11 and connect a third jumper wire between terminal block TB1 positions 10 and 12 TB1 is located on the sub panel of the system beh...

Page 29: ...s to show that the system is energized 2 AC Power Indicator Illuminates when primary power is applied to the SR 100i system 3 DC Power Indicator Illuminates when then main contactor has been energized and D C current is flowing through the torch 4 Gas Switch In the Set mode energizes the gas solenoid so the gas pressure may be adjusted In the Run mode the gas solenoid is deenergized 5 Motion Delay...

Page 30: ...he x y machine motion signal and initiates postflow 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 Manual Cutting Mode To place the SR 100i 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 automatic...

Page 31: ...uency 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 100i 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 nonmetal...

Page 32: ...Operation SR 100i User s Manual Torch Consumables Figure 4 2 shows the different torch consumable configurations for cutting various materials with the SR 100i Figure 4 2 Torch Consumables 4 4 ...

Page 33: ...asing 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 shou...

Page 34: ...seated in the retaining cap recess 5 Thread the retaining cap onto the torch and hand tighten It is very important that all parts are seated tightly to prevent the torch from arcing internally 6 Apply primary power to the SR 100i The white A C Power light on the front panel should illuminate indicating that primary power has been applied however never assume the power is disconnected when the whit...

Page 35: ...etermining 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 85 psi with the Gas switch in...

Page 36: ...e 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 Cutting Chart Index Material Current Page Mild Steel 30 50 Amps 4 9 Mild Steel 75 100 Amps 4 10 Stainless Steel 30 50 Amps 4 11 Stainless Steel 75 100 Amps 4 12 Aluminum 30 50 Amps 4 13 Aluminum 75 100 Amps 4 14 4 8 ...

Page 37: ...Operation SR 100i User s Manual Figure 4 4 Mild Steel Cutting Chart 30 50 amps 4 9 ...

Page 38: ...Operation SR 100i User s Manual Figure 4 5 Mild Steel Cutting Chart 75 100 amps 4 10 ...

Page 39: ...Operation SR 100i User s Manual Figure 4 6 Stainless Steel Cutting Chart 30 50 amps 4 11 ...

Page 40: ...Operation SR 100i User s Manual Figure 4 7 Stainless Steel Cutting Chart 75 100 amps 4 12 ...

Page 41: ...Operation SR 100i User s Manual Figure 4 8 Aluminum Cutting Chart 30 50 amps 4 13 ...

Page 42: ...Operation SR 100i User s Manual Figure 4 9 Aluminum Cutting Chart 75 100 amps 4 14 ...

Page 43: ...to 85 psi Return the Gas switch to the Run position 5 Raise the torch 2 inches above the workpiece Apply a start signal to the SR 100i using the CNC control 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 correcti...

Page 44: ...s are tight 9 Clean and reset the spark gap spacing to 018 46 mm 10 Check the connection of the high frequency coupling transformer leads to the I O p c board 11 Verify that the fan blades spin freely SR 100i 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 2 Remove the reta...

Page 45: ...rly 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...

Page 46: ...ach primary winding See Figure 5 1 When the primary voltage of TR1 is changed the control transformer TR2 must also be rewired for the correct service voltage For 230V operation connect the white wire of control transformer TR2 to TB2 13 connect the brown wire to TB2 14 and connect the red white wire to the side terminal of fuse F1 460V 60Hz Operation For 460V operation install a 8 AWG jumper wire...

Page 47: ...Maintenance and Troubleshooting SR 100i User s Manual Figure 5 1 230V 60 Hz Three Phase Transformer Figure 5 2 460V 60 Hz Three Phase Transformer 5 5 ...

Page 48: ...winding See Figure 7 3 When the primary voltage of TR1 is changed the control transformer TR2 must also be rewired for the correct service voltage For 220V operation connect the white wire of control transformer TR2 to TB2 13 connect the brown wire to TB2 14 and connect a wire 20 AWG minimum from the side terminal of fuse F1 to TB2 14 380V 50Hz Operation For 380V operation install a 8 AWG jumper w...

Page 49: ...Maintenance and Troubleshooting SR 100i User s Manual Figure 5 3 220V 50 Hz Three Phase Transformer Figure 5 4 380V 50 Hz Three Phase Transformer 5 7 ...

Page 50: ...sma start signal applied G1 Gas solenoid valve 1 energized ILK Torch interlock pressure switch PRS1 closed CON Main contactor CON2 energized PAR Pilot arc relay energized REG Chopper energized H F High frequency transformer energized TAC Transferred arc current established from torch to workpiece G2 Gas solenoid valve 2 energized MOT2 X Y machine motion relay 2 energized immediately after TAC MOT1...

Page 51: ...l not energize or fan motor will not energize when the ON button is pressed 1 Inlet gas pressure below 85 psi 2 Fuse F2 or F3 blown 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 S...

Page 52: ... Set the spark gap to 018 46 mm 2 Worn spark gap electrodes Clean electrodes with fine sandpaper and set the gap to 018 46 mm Replace electrodes that have a rounded face 3 Verify that all LED s illuminate in the proper order 4 In mode 0 or 2 if all LED s illuminate but the HF LED does not replace the logic regulator p c board 5 Visually check all terminal connections around the high frequency tran...

Page 53: ... 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 and C4 on the I O p c board and the surge injection resistor R2 which is mounted just above the I O p c board Replace if necessary 11 Proceed to chopper test Poor cut quality 1 Consumables worn Replace as necessary 2 Gas ...

Page 54: ...R5 5 Turn the mode switch to position number 9 6 Install a jumper wire across the terminals of pressure switch PRS1 and another jumper wire across the terminals of pressure switch PRS2 7 Connect the 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 Electrode connection Configure the voltmeter to read D C voltage 8 Use a jumpe...

Page 55: ...the unit a start signal is not needed Pin 5 of U1 should measure approximately 5 8 VDC If pin 5 measures 5 8 VDC go to step d b If pin 5 did not measure 5 8 VDC in step a unplug P26 from the logic board If pin 5 still does not measure 5 8 VDC go to step c If pin 5 now measures 5 8 VDC measure the voltage between TP5 and TP11 on the logic board If TP11 measures 0 VDC replace the logic board skip th...

Page 56: ...to approximately 5 8 VDC If pin 10 does not read 5 8 VDC check the continuity in the lines between the chopper and the logic board Next measure the voltage between P26 9 and P26 10 on the logic board It should read 0 VDC If the voltage between P26 9 and P26 10 is correct replace the chopper If the voltage between P26 9 and P26 10 is incorrect replace the logic board 5 14 ...

Page 57: ...b transformer 19 709007 2 TB1 TB2 terminal block 14 position 20 709086 2 Terminal block marker strip 14 position 21 709058 2 F2 F3 fuse holder 22 709011 1 F2 fuse AGC 5A 23 709012 1 F3 fuse AGC 3A 24 709061 1 F1 fuse holder 25 709063 709062 1 F1 2A fuse 208 230 VAC systems F1 1A fuse 380 415 460 575 VAC systems 26 709060 1 Strain relief 27 709001 1 P7 receptacle 4 pin 28 709002 1 P8 receptacle 14 ...

Page 58: ...1 1 R2 surge injection resistor 42 701092 1 R2 mounting hardware 43 702043 2 C1 filter capacitor 44 702034 2 C1 mounting bracket 45 701084 1 R1 bleed resistor 46 701085 1 R1 mounting hardware 47 800065 1 TR7 high frequency coupling transformer 49 702041 1 C8 high frequency capacitor 50 500014 1 Spark gap assembly 51 740039 3 Spark gap electrode 52 706019 1 TR5 high frequency transformer 53 707004 ...

Page 59: ...Parts List SR 100i User s Manual Figure 6 1 Control Panel 6 3 ...

Page 60: ...Parts List SR 100i User s Manual SR 100i Figure 6 2 Rear View Inside 6 4 ...

Page 61: ...Parts List SR 100i User s Manual Figure 6 3 Base Top View 6 5 ...

Page 62: ...Parts List SR 100i User s Manual Figure 6 4 Left Side View 6 6 ...

Page 63: ...Parts List SR 100i User s Manual Figure 6 5 Right Side View 6 7 ...

Page 64: ...Parts List SR 100i User s Manual SR 100i Figure 6 6 Rear View Outside 6 8 ...

Page 65: ...p 6 810130 810129 800063 800083 1 50 amp shield cap 100 amp shield cap 100 amp shield cap tapered Open shield cap 7 810132 810131 800062 810133 1 50 amp nozzle 100 amp nozzle 100 amp nozzle tapered Insulation nozzle 8 800275 800276 810235 1 Air electrode Advanceable Air electrode Non advanceable Nitrogen electrode 9 800053 1 Swirl ring Not Shown 800122 1 Electrode advancing tool assembly Not Shown...

Page 66: ...nnector nut 4 800072 1 Torch nozzle lead assembly 5 800074 1 Torch electrode lead assembly 6 710103 1 Hose clamp 800078 Shielded Torch Leads Assembly 50 Item Number Part Number Quantity Description 1 711123 50 Braided shield 2 770068 1 Shield connector 3 770061 1 Shield connector nut 4 800073 1 Pilot arc lead assembly 5 800076 1 Torch power lead assembly 6 710103 1 Hose clamp Figure 6 8 Shielded T...

Page 67: ...ription 810132 5 50 amp nozzle 810130 1 50 amp shield cap 810131 5 100 amp nozzle 810129 1 100 amp shield cap 800062 5 100 amp nozzle tapered 800063 1 100 amp shield cap tapered 800083 1 Open shield cap 800053 1 Swirl ring 800275 3 Air electrode 800071 1 Retaining cap 800122 1 Advancing tool assembly 6 11 ...

Page 68: ...Parts List SR 100i User s Manual Logic Regulator P C Board Assembly 800400 Figure 6 9 Logic Regulator P C Board 6 12 ...

Page 69: ...Parts List SR 100i User s Manual Chopper P C Board Figure 6 10 Chopper P C Board 6 13 ...

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Page 71: ...tallation 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 eart...

Page 72: ...g 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 i...

Page 73: ...o 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 wo...

Page 74: ...wer 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 t...

Page 75: ... 719003 1 EMI filter enclosure 2 702048 1 EMI filter 60A 3 711185 28 4 4 Type SO power cable 4 709105 2 Strain relief EMI Filter Assembly 415 VAC 50Hz Assembly 800107 Item Number Part Number Quantity Description 1 719002 1 EMI filter enclosure 2 702047 1 EMI filter 30A 3 711184 28 10 4 Type SO power cable 4 709060 2 Strain relief C B A LOAD LINE B C A Figure A 2 EMI Filter A 5 ...

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