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Maintenance and Troubleshooting SR-45i User’s Manual

Logic-Regulator Status LED’s

If a problem occurs with the SR-45i system, check all of the primary disconnect
fuses before proceeding. Also, check fuses F1, F2, and F3 in the power supply.
Be sure to check all fuses with an ohmmeter and replace any bad fuses.

The logic-regulator p.c. board controls all of the functions of the SR-45i 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

L2 STRT

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

•

L1

•

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

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Summary of Contents for SR-45i

Page 1: ...i User s Manual SR 45i Plasma Cutting System Revision 11 5 16 07 Manual Part Number 718061 455 Fleming Road Charleston SC 29412 USA 800 252 2850 Toll free 843 795 4286 Phone 843 795 8931 Fax www kaliburn net ...

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Page 3: ...pair 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 equ...

Page 4: ...lasma 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: ...round A 1 Installation and Use A 1 Assessment of Area A 2 Methods of Reducing Emissions A 2 Primary Power Connection A 4 EMI Filter Parts List A 5 Illustrations Figure 2 1 Power Supply Dimensions 2 2 Figure 2 2 Torch Dimensions 2 3 Figure 3 1 Primary Power Connections 3 2 Figure 3 2 Power Supply Output Connections 3 4 Figure 3 3 Torch Connections 3 5 Figure 3 4 Gas Supply Connections 3 7 Figure 4 ...

Page 7: ...Figure 6 6 Rear View Outside 6 8 Figure 6 7 Torch and Handle Assembly 6 9 Figure 6 8 Shielded Torch Leads 6 10 Figure 6 9 Logic Regulator P C Board 6 12 Figure 6 10 Chopper P C Board 6 13 Figure A 1 Primary Power Connection A 4 Figure A 2 EMI Filter A 5 ...

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Page 9: ... 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 ...

Page 10: ... SR 45i 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 45i power supply Make sure the connection is securely tightened Make sure the positive output work ground of the SR 45i 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: ...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 prevent the accumulation of hydrogen ...

Page 12: ...rch 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 informa...

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: ...gton 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: ...hese 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 Power Supply Torch and Handle Assembly Torch Lead Set Work Ground Lead Air regulator Filter System Manual Consumable Spare Parts Kit Power Supply Specifica...

Page 16: ...e 100 Maximum Ambient Temperature 104 F 40 C Dimensions Width 19 in 483 mm Height 32 5 in 826 mm Depth 20 in 508 mm Weight Single Phase 245 lb 111 kg Three Phase 265 lb 120 kg Gas Supply Requirements Quality Clean dry oil free air Flow Rate 250 scfh 7075 liters hour Inlet Pressure 65 psi 4 5 bar 25 40 35 20 45 MIN MAX 30 OFF ON A C POWER D C POWER GAS AMPS MOTION DELAY SET RUN SR 45i Figure 2 1 Po...

Page 17: ...ications Stock Number Torch main body 770073 Torch handle assembly 770075 Diameter 1 375 in 35 mm Length Torch main body 3 5 in 118 mm Torch main body handle assembly 12 8 in 325 mm Weight including handle 1 33 lb 6 kg Figure 2 2 Torch Dimensions 2 3 ...

Page 18: ...on should be used as defined by local or national codes The following chart gives the noise levels generated by the SR 45i when operating at 45 amps 115 arc volts The measurements were made with a sound level meter Distance From Torch A Weighted Sound Pressure Level C Weighted Sound Pressure Level 1 meter horizontal 1 6 meters above the workpiece 91 dB 88 dB The maximum noise level is 117 dB at a ...

Page 19: ...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 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 a...

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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: ...mum 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 Note that the center terminal of CON1 is not used in single phase systems Be sure to connect the primary ground cable to the ground stud on the sub pa...

Page 23: ...nnect 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 5 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 ...

Page 24: ...Installation SR 45i User s Manual SR 45i Tighten Securely Figure 3 2 Power Supply Output Connections 3 4 ...

Page 25: ...ndle 2 Attach the cathode torch lead 1 4 hose to the 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...

Page 26: ...egulator 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 Rep...

Page 27: ...allation SR 45i User s Manual Adjust regulator to 65 psi with gas switch in the set position Connect gas supply to this port using 1 4 6 mm I D minimum hose size SR 45i Figure 3 4 Gas Supply Connections 3 7 ...

Page 28: ...4VAC 10mA Motion Output Signal 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 b...

Page 29: ... Illuminates to show that the system is energized 2 AC Power Indicator Illuminates when primary power is applied to the SR 45i 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 Cu...

Page 30: ...ote that the machine motion signal can be delayed for up to three seconds using the motion delay potentiometer on the front panel 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 45i system disables the x y machine motion signal and initiat...

Page 31: ...d 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 lost 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...

Page 32: ...ORCH BODY 770073 SWIRL RING 770012 RETAINING CAP 770098 TAPERED NOZZLE 770104 ELECTRODE 770015 or 770017 TORCH BODY 770073 SWIRL RING 770012 RETAINING CAP 770098 INSULATION NOZZLE 770030 ELECTRODE 770015 or 770017 TORCH BODY 770073 TORCH CONSUMABLES WHEN CUTTING MATERIALS GREATER THAN 1 8 3 mm THICK TORCH CONSUMABLES WHEN CUTTING MATERIALS UP TO 1 8 3 mm THICK TORCH CONSUMABLES WHEN CUTTING INSULA...

Page 33: ...te 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 commo...

Page 34: ...ropriate 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 f...

Page 35: ...for material thicknesses up to 1 8 Thicker materials will require longer motion delays to allow the arc to fully penetrate the material 11 Set the Current potentiometer according to the cutting chart in this section 12 Set the Mode Switch to the proper mode as previously described 13 The cutting operation is initiated after a start signal is received The arc should establish after approximately 2 ...

Page 36: ...zzle 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 n...

Page 37: ... 1 16 1 6 45 1 16 1 5 275 6 985 135 3 430 Mild Steel 1 8 3 2 45 1 16 1 5 130 3 300 65 1 650 Mild Steel 1 4 6 4 45 075 2 0 45 1 145 Mild Steel 3 8 9 5 45 075 2 0 25 635 Mild Steel 1 2 12 7 45 075 2 0 15 380 Stainless 015 28 4 35 1 16 1 5 425 10 795 220 5 590 Stainless 018 26 5 35 1 16 1 5 400 10 160 210 5 335 Stainless 024 24 6 35 1 16 1 5 375 9 525 195 4 955 Stainless 030 22 8 35 1 16 1 5 350 8 89...

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Page 39: ...the rear panel of the SR 45i to 65 psi Return the Gas switch to the Run position 5 Raise the torch 2 inches above the workpiece Apply a start signal to the SR 45i using the CNC control 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...

Page 40: ...ecurely 6 Verify that the rear panel Amp connectors are installed securely 7 Check the pilot arc relay contacts for signs of pitting and replace if necessary 8 Verify that all hardware connections are tight 9 Clean and reset the spark gap spacing to 015 38 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 4...

Page 41: ...e o ring 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 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 o...

Page 42: ... 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 CON2 to the 240V connection on each primary winding Whe...

Page 43: ...ch 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 from the side terminal of the rear panel fuse F1 to TB2 14 380V 50Hz Operation For 380V operation T...

Page 44: ...5i User s Manual 0 220 0 220 0 220 220V 3 Phase 220 220 220 0 0 0 220 V 3 PHASE Figure 5 2 220V 50 Hz Three Phase Transformer 0 220 0 220 0 220 380V 3 Phase 220 220 220 0 0 0 380 V 3 PHASE Figure 5 3 380V 50 Hz Three Phase Transformer 5 6 ...

Page 45: ...ure switch PRS2 closed L2 STRT 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 Sequenc...

Page 46: ...ulty 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 CON1 auxiliary switch or associated wiring bad 9 Fan motor or associated wiring bad Front panel red D C power light w...

Page 47: ...ulator p c board 5 Visually check all terminal connections around the high frequency transformer and spark gap assembly 6 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 f...

Page 48: ...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 11 Proceed to chopper test 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 ...

Page 49: ...4 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 Minus connection Configure the voltmeter to read D C voltage 8 Use a jumper wir...

Page 50: ...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 the 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 ...

Page 51: ... 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...

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Page 53: ... 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 F1 fuse holder 24 709063 709062 1 F1 2A fuse 208 220 230 240 VAC systems F1 1A fuse 380 415 460 575 VAC systems 25 709060 1 Strain relief 26 709001 1 P7 receptacle 4 pin 27 709002 1 P8 rec...

Page 54: ...e 39 708011 1 PAR pilot arc relay 40 701091 1 R5 surge injection resistor 41 701092 1 R5 mounting hardware 42 702043 2 C7 filter capacitor 43 702034 2 C7 mounting bracket 44 701084 1 R1 bleed resistor 45 701085 1 R1 mounting hardware 46 706018 1 TR5 high frequency coupling transformer 47 702041 1 C9 high frequency capacitor 48 740042 1 Spark gap assembly 49 740039 3 Spark gap electrode 50 706019 1...

Page 55: ...Parts List SR 45i User s Manual Figure 6 1 Control Panel 6 3 ...

Page 56: ...Parts List SR 45i User s Manual SR 45i Figure 6 2 Rear View Inside 6 4 ...

Page 57: ...Parts List SR 45i User s Manual Figure 6 3 Base Top View 6 5 ...

Page 58: ...Parts List SR 45i User s Manual Figure 6 4 Left Side View 6 6 ...

Page 59: ...Parts List SR 45i User s Manual Figure 6 5 Right Side View 6 7 ...

Page 60: ...Parts List SR 45i User s Manual SR 45i Figure 6 6 Rear View Outside 6 8 ...

Page 61: ...jacket retainer 5 770098 1 Retaining cap 6 770015 770017 1 Electrode advanceable Electrode non advanceable 7 770000 770104 770030 1 1 1 Flat metal cutting nozzle Tapered metal cutting nozzle Insulation cutting nozzle 8 770012 1 Swirl ring 9 770072 1 Torch o ring Not Shown 716008 1 O ring lubricant Not Shown 770023 1 Electrode advancing tool assembly Not Shown 770025 1 Advancing tool body Not Shown...

Page 62: ...ads Assembly 35 Item Number Part Number Quantity Description 1 711021 35 Braided shield 2 770068 1 Shield connector 3 770061 1 Shield connector nut 4 770010 1 Pilot arc lead assembly 5 770008 1 Torch power lead assembly 6 710103 1 Hose clamp 770080 Shielded Torch Leads Assembly 50 Item Number Part Number Quantity Description 1 711021 50 Braided shield 2 770068 1 Shield connector 3 770061 1 Shield ...

Page 63: ...770000 5 Flat metal cutting nozzle 770104 5 Tapered metal cutting nozzle 770030 5 Insulation cutting nozzle 770015 5 Electrode advanceable 770017 5 Electrode non advanceable 770012 1 Swirl ring 770098 1 Retaining cap 770023 1 Electrode advancing tool assembly 770072 2 Torch o ring 716008 1 O ring lubricant 6 11 ...

Page 64: ...Parts List SR 45i User s Manual Logic Regulator P C Board Assembly 740015 Figure 6 9 Logic Regulator P C Board 6 12 ...

Page 65: ...Parts List SR 45i User s Manual Chopper P C Board Figure 6 10 Chopper P C Board 6 13 ...

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Page 67: ...allation 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 earth...

Page 68: ...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 69: ...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 70: ...er 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 th...

Page 71: ...719002 1 EMI filter enclosure 2 702047 1 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 1 EMI filter enclosure 2 702046 1 EMI filter 10A 3 711183 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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