SR-100i Plasma Cutting System
Without Ohmic Contact Torch
Revision 10
5/17/07
Manual Part Number 718048
SR-100i User’s Manual
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-100i User’s Manual
Limited Warranty
KALIBURN expressly warrants that this product shall be free from defects in
materials and workmanship, under proper and normal use for the intended
function of such equipment, for a period of one (1) year for the SR-100i torch and
leads and three (3) years for the SR-100i power supply. This product is intended
for commercial use and is not intended for personal, family, or household
purposes. There are no warranties that extend beyond the description on the face
hereof. All other warranties, either expressed or implied, including any
implied warranty of merchantability or fitness for any particular purpose,
are expressly excluded.
If this product or any component thereof is determined to be defective in
manufacture, KALIBURN will repair or replace the defective component or
product. The buyer’s remedies are limited to the return of the product for repair
or replacement of any non-conforming product or part at the sole discretion of
KALIBURN. No freight charges of any kind are covered under this warranty.
All returned goods shall be at the buyer’s risk and expense. Beyond this remedy,
KALIBURN will not be responsible for any special, incidental or consequential
damages or injury to the person or property of anyone by reason of any defect in
any equipment sold hereunder.
This warranty will be considered void if torches or torch
consumables manufactured by anyone other than
KALIBURN are incorporated into this product.
Returned Goods Procedure
KALIBURN utilizes a returned goods procedure that must be followed before
returning any items for repair, replacement, or restocking. This means that a
returned goods authorization number must be obtained prior to shipment to
KALIBURN. It will be necessary for the customer to provide a description, along
with the stock number and serial number, if applicable, of the item to be returned.
In no case will KALIBURN accept a returned shipment without the proper
returned goods authorization number.
SR-100i User’s Manual
Electromagnetic Compatibility (EMC)
The 220/380V 50Hz and 415V 50Hz SR-100i plasma cutting systems are
manufactured to comply with the European standards EN 60974 (Arc welding
equipment – Part 1: Welding power sources) and EN 50199 (Electromagnetic
compatibility (EMC) – Product standard for arc welding equipment). Information
about the EMC standard EN 50199 can be found in Appendix A.
SR-100i User’s Manual
TABLE OF CONTENTS
Section 1 Safety ..……………………………………..……………………………. 1-1
General Precautions .…………………………………………………..……….…..……… 1-1
Ultraviolet Radiation Protection ..…………………………………………………………. 1-1
Noise Protection .……………………………………………………..……………………. 1-1
Toxic Fume Prevention ...…………………………………………………………..……… 1-1
Electric Shock Prevention ...……………………………………………………….….…… 1-2
Fire Prevention ...…………………….………………………………….…………………. 1-3
Explosion Prevention .....…….….………….…………………………………..………….. 1-3
Health Support Equipment ...…………………….……………………………….………... 1-4
Safety Standards Booklet Index ...…………………….……………………………….…... 1-4
Section 2 Specifications ...….……...……………………………………………… 2-1
System Description ...……………………………………………………………………… 2-1
System Components ………………………………………………………………………. 2-1
Power Supply Specifications ……………………………………………………………… 2-1
Torch Specifications ...…………………………………………………………………….. 2-3
Airborne Noise Emissions ..……………………………………………………………….. 2-4
Operating Modes .........…………………………………………………………………….. 2-5
Section 3 Installation .....………………………………………………………… 3-1
Initial Inspection .......……………………………………………………………………… 3-1
Power Supply Installation .………………………………………………………………… 3-1
Primary Power Connection ...……………………………………………………………… 3-1
Power Supply Output Connections .......…………………………………………………… 3-3
Torch Connections ....……………………………………………………………………… 3-5
Gas Supply Connections ...............................……………………………………………… 3-6
CNC Machine Interface Connections ...…………………………………………………… 3-8
Section 4 Operation ……………………………………………………………… 4-1
Power Supply Front Panel Controls ..……………………………………………………… 4-1
Mechanized Cutting Mode ............………………………………………………………… 4-2
Manual Cutting Mode ...........................…………………………………………………… 4-2
Grate Cutting Mode ..............................…………………………………………………… 4-3
Insulation Cutting Mode ...………………………………………………………………… 4-3
Torch Consumables ......…………………………………………………………………… 4-4
Advanceable Electrode .…………………………………………………………………… 4-5
Setting up a Cut .........……………………………………………………………………… 4-6
Cut Quality ................……………………………………………………………………… 4-7
Cutting Charts ...........……………………………………………………………………… 4-8
SR-100i User’s Manual
Section 5 Maintenance and Troubleshooting ............................ 5-1
Daily Procedures ...................……........................................................................................ 5-1
Monthly Procedures .............................................................................................................. 5-2
230/460V 60 Hz Transformer Configurations ...................................................................... 5-4
220/380V 50 Hz Transformer Configurations ...................................................................... 5-6
Logic-Regulator Status LED’s .............................................................................................. 5-8
Logic-Regulator Sequence of Operation .............................................................................. 5-8
General Troubleshooting ...................................................................................................... 5-9
Chopper Test Procedure ........................................................................................................ 5-12
Section 6 Parts List ........................................................................................... 6-1
Power Supply ........................................................................................................................ 6-1
Torch and Handle Assembly ................................................................................................. 6-9
Shielded Torch Leads ........................................................................................................... 6-10
Consumable Spare Parts Kit ................................................................................................. 6-11
Logic-Regulator P.C. Board ................................................................................................. 6-12
Chopper P.C. Board .............................................................................................................. 6-13
Appendix A Electromagnetic Compatibility (EMC) .......... A-1
Background ........................................................................................................................... A-1
Installation and Use ...............................................................................................................A-1
Assessment of Area ............................................................................................................... A-2
Methods of Reducing Emissions .......................................................................................... A-2
Primary Power Connection ................................................................................................... A-4
EMI Filter Parts List ............................................................................................................. A-5
Illustrations
Figure 2-1 Power Supply Dimensions ............................................................................ 2-2
Figure 2-2 Torch Dimensions ......................................................................................... 2-3
Figure 3-1 Primary Power Connections ......................................................................... 3-2
Figure 3-2 Power Supply Output Connections ............................................................... 3-4
Figure 3-3 Torch Connections ........................................................................................ 3-5
Figure 3-4 Gas Supply Connections ............................................................................... 3-7
Figure 4-1 Front Panel Controls ..................................................................................... 4-2
Figure 4-2 Torch Consumables ...................................................................................... 4-4
Figure 4-3 Electrode Advancing Tool ............................................................................ 4-5
Figure 4-4 Mild Steel Cutting Chart (30-50 amps) ........................................................ 4-9
Figure 4-5 Mild Steel Cutting Chart (75-100 amps) ...................................................... 4-10
Figure 4-6 Stainless Steel Cutting Chart (30-50 amps) .................................................. 4-11
Figure 4-7 Stainless Steel Cutting Chart (75-100 amps) ................................................ 4-12
Figure 4-8 Aluminum Cutting Chart (30-50 amps) ........................................................ 4-13
Figure 4-9 Aluminum Cutting Chart (75-100 amps) ...................................................... 4-14
SR-100i User’s Manual
Figure 5-1 230V 60 Hz Three Phase Transformer ......................................................... 5-5
Figure 5-2 460V 60 Hz Three Phase Transformer ......................................................... 5-5
Figure 5-3 220V 50 Hz Three Phase Transformer ......................................................... 5-7
Figure 5-4 380V 50 Hz Three Phase Transformer ......................................................... 5-7
Figure 6-1 Control Panel ................................................................................................ 6-3
Figure 6-2 Rear View - Inside ........................................................................................ 6-4
Figure 6-3 Base – Top View ........................................................................................... 6-5
Figure 6-4 Left Side View .............................................................................................. 6-6
Figure 6-5 Right Side View ............................................................................................ 6-7
Figure 6-6 Rear View – Outside ..................................................................................... 6-8
Figure 6-7 Torch and Handle Assembly ......................................................................... 6-9
Figure 6-8 Shielded Torch Leads ................................................................................... 6-10
Figure 6-9 Logic-Regulator P.C. Board ......................................................................... 6-12
Figure 6-10 Chopper P.C. Board ...................................................................................... 6-13
Figure A-1 Primary Power Connection ........................................................................... A-4
Figure A-2 EMI Filter ......................................................................................................A-5
This page intentionally left blank
Safety SR-100i User’s Manual
Section 1 Safety
General Precautions
Whereas plasma cutting has been used safely for years, it does require certain
precautions to ensure the safety of the operator and other people around the
equipment. It is management’s responsibility to see that the following safety
information is provided to each person who will operate, observe, perform
maintenance, or work in close proximity to this piece of equipment.
Installation and repairs made to the SR-100i system should only be performed by
qualified personnel. The SR-100i system makes use of both A.C. and D.C.
circuitry for operation. Fatal shock hazard does exist. Exercise extreme
caution while working on the system.
Ultraviolet Radiation Protection
Plasma cutting produces ultraviolet radiation similar to a welding arc. This
ultraviolet radiation can cause skin and eye burns. For this reason, it is essential
that proper protection be worn. The eyes are best protected by using safety
glasses or a welding helmet with an AWS No. 8 shade or ISO 4850 No. 11 shade,
which provides protection up to 100 amperes. All exposed skin areas should be
covered with flame-retardant clothing. The cutting area should also be prepared
in such a way that ultraviolet light does not reflect. Walls and other surfaces
should be painted with dark colors to reduce reflected light. Protective screens or
curtains should be installed to protect additional workers in the area from
ultraviolet radiation.
Noise Protection
The SR-100i system generates high noise levels while cutting. Depending on the
size of the cutting area, distance from the cutting torch, and arc current cutting
level, acceptable noise levels may be exceeded. Proper ear protection should be
used as defined by local or national codes. See Section 2 for noise emission
levels.
Toxic Fume Prevention
Care should be taken to ensure adequate ventilation in the cutting area. Some
materials give off toxic fumes that can be harmful or fatal to people in the vicinity
of the cutting area. Also, some solvents decompose and form harmful gases when
exposed to ultraviolet radiation. These solvents should be removed from the area
prior to cutting.
1-1
Safety SR-100i User’s Manual
Galvanized metal can produce harmful gases during the cutting process. Ensure
proper ventilation and use breathing equipment when cutting these materials.
Certain metals coated with or containing lead, cadmium, zinc, beryllium, and
mercury produce harmful toxins. Do not cut these metals unless all people
subjected to the fumes wear proper air breathing equipment.
Electric Shock Prevention
The SR-100i system uses high open circuit voltages that can be fatal. Extreme
care should be used when operating or performing maintenance on the system.
Only qualified personnel should service the SR-100i system. Observe the
following guidelines to protect against electric shock:
• A wall-mounted disconnect should be installed and fused according to local
and national electrical codes. The disconnect should be located as close as
possible to the power supply so it can be turned off in case of an emergency.
• The primary power cord should have a 600 volt minimum rating in order to
protect the operator. In addition, it should be sized according to local and
national electrical codes. Inspect the primary power cord frequently. Never
operate the SR-100i system if the power cord is damaged in any way.
• Make sure the primary power ground wire is connected to the input power
ground stud on the SR-100i power supply. Make sure the connection is
securely tightened.
• Make sure the positive output (work ground) of the SR-100i power supply is
connected to a bare metal area on the cutting table. A driven ground rod
should be placed no further than five feet from this connection. Make sure
this ground point on the cutting table is used as the star ground point for all
other ground connections.
• Inspect the torch leads frequently. Never use the system if the leads are
damaged in any way.
• Do not stand in wet, damp areas when operating or performing maintenance
on the system.
• Wear insulated gloves and shoes while operating or performing maintenance
on the system.
• Make sure the SR-100i system is switched off at the wall disconnect before
servicing the power supply or torch.
• Never change torch consumable parts unless the SR-100i system is switched
off at the wall disconnect.
• Do not attempt to remove any parts from beneath the torch when cutting.
Remember that the workpiece forms the current path back to the power
supply.
• Never bypass the safety interlock devices.
• Before removing any of the SR-100i covers, switch the system off at the wall
disconnect. Wait at least five (5) minutes before removing any cover. This
1-2
Safety SR-100i User’s Manual
will give the capacitors inside the unit time to discharge.
• Never operate the SR-100i system without all of the covers in place.
• Preventive maintenance should be performed daily to avoid possible safety
hazards.
Fire Prevention
When using the SR-100i system, it is necessary to exercise good judgment.
While cutting, the arc produces sparks that could cause a fire should they fall 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-100i 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:
• Never operate the SR-100i system in the 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 prevent the
accumulation of hydrogen gas.
• 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.
• Compressed gas cylinders should be maintained properly. Never attempt to
use a cylinder that is leaking, cracked, or has other signs of physical damage.
• All gas cylinders should be secured to a wall or rack to prevent accidental
knock over.
• If a compressed gas cylinder is not being used, replace the protective valve
cover.
• Never attempt to repair compressed gas cylinders.
• Keep compressed gas cylinders away from intense heat, sparks, or flames.
• Clear the compressed gas cylinder connection point by opening the valve
momentarily prior to installing a regulator.
• Never lubricate compressed gas cylinder valves or pressure regulators with
1-3
Safety SR-100i User’s Manual
any type of oil or grease.
• Never use a compressed gas cylinder or pressure regulator for any purpose
other than which it is intended.
• Never use a pressure regulator for any gas other than which it is intended.
• Never use a pressure regulator that is leaking or has other signs of physical
damage.
• Never use oxygen hoses and pressure regulators for any gas other than
oxygen.
• Never use any gas hose that is leaking or has other signs of physical damage.
Health Support Equipment
The SR-100i 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-100i system. Observe the following
guidelines to minimize exposure to these electric and magnetic fields:
• Stay as far away from the SR-100i power supply, torch, 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 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-100i 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, and 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 of 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 SR-100i User’s Manual
17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from the
Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004,
Arlington, VA 22202.
18. CSA Standard W117.2, Safety in Welding, Cutting, and Allied Processes,
obtainable from Canadian Standards Association, 178 Rexdale Boulevard,
Toronto, Ontario M9W lR3, Canada.
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
Specifications SR-100i User’s Manual
Section 2 Specifications
System Description
The SR-100i is a versatile, 100 amp, 100% duty cycle conventional air plasma
cutting system that provides continuous operation, patented long life electrodes,
and a true constant current output from 25 to 100 amperes. Two nozzle sizes (50
amp and 100 amp) are available to produce excellent cut quality throughout its
range. It utilizes a single gas torch that is capable of cutting gauge to 1-1/4” thick
material. The recommended piercing capacity of the SR-100i is 5/8” thick
material. The SR-100i also has 4 modes of operation, which provide the
capability 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 and aluminum, nitrogen can be used as the cutting gas.
System Components
The SR-100i 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 Specifications
Stock Number:
208 VAC, 3Ø, 60Hz ............................................. 800089
220/380 VAC, 3Ø, 50/60Hz ................................ 800092
230/460 VAC, 3Ø, 60Hz ..................................... 800118
415 VAC, 3Ø, 50Hz ............................................. 800093
575 VAC, 3Ø, 60Hz ............................................. 800094
2-1
Specifications SR-100i User’s Manual
Input Current at Maximum Output:
208 VAC, 3Ø ....................................................... 54 amps
230 VAC, 3Ø ....................................................... 49 amps
380 VAC, 3Ø ....................................................... 30 amps
415 VAC, 3Ø ....................................................... 27 amps
460 VAC, 3Ø ....................................................... 25 amps
575 VAC, 3Ø ....................................................... 20 amps
Open Circuit Voltage ................................................ 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)
i
0
0
1
−
SR
Figure 2-1 Power Supply Dimensions
2-2
Specifications SR-100i User’s Manual
Torch Specifications
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
Specifications SR-100i User’s Manual
Airborne Noise Emissions
The SR-100i system generates high noise levels while cutting. Depending on the
size of the cutting area, distance from the cutting torch, and arc current cutting
level, acceptable noise levels may be exceeded. Proper ear protection should be
used as defined by local or national codes. 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
1 meter horizontal / 1.6 meters
Pressure Level
98 dB 96 dB
above the workpiece
The maximum noise level is 123 dB at a distance of 2 inches (50.8 mm) from the
torch while cutting at 100 amps, 120 arc volts.
C-Weighted Sound
Pressure Level
2-4
Specifications SR-100i User’s Manual
Operating Modes
The operating mode of the SR-100i 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-100i 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.
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 potentiometer.
As a result, the cutting sequence can begin over a hole in the grate material or
over the metal itself. 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.
2-5
This page intentionally left blank
Installation SR-100i 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-100i system. If your system was
damaged during shipment, you will have to file a claim with the shipping
company. Next, it 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-100i power supply should be lifted by a forklift or pallet jack only. In
order to prevent damaging the power supply, the forks should be of adequate
length to protrude on the far side of the power supply. The proper location of the
power supply will provide dependable service and reduce periodic maintenance
time. 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-100i 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-100i 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. See the following chart for
recommended fuse sizes:
3-1
Installation SR-100i User’s Manual
Input Voltage
(VAC)
Phase Input Current
at Maximum Output
(amps)
Recommended
Time-Delay Fuse Size
(amps)
208 3 54 70
230 3 49 70
380 3 30 40
415 3 27 35
460 3 25 30
575 3 20 25
Use a Type SO power cable to connect the primary power to the SR-100i power
supply. The power cable should have a 600 volt minimum rating and should be
sized according to local and national codes. Route the power cable through the
strain relief on the rear of the power supply and connect the hot lines to the input
terminals on the safety contactor CON1 as shown in Figure 3-1. Be sure to
connect the primary ground cable to the ground stud on the sub-panel.
Main Contactor
(CON2)
Sub-Panel Ground Stud
Safety Contactor
(CON1)
Figure 3-1 Primary Power Connections
Type SO Power Cable
3-2
Disconnect Box
Connections
L1 (U)
L2 (V)
L3 (W)
Ground
Installation SR-100i User’s Manual
Power Supply Output Connections
Work Ground Lead
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. The fittings are
subject to damage if over tightened.
Torch Leads
1
1. Remove the threaded ring from the brass shield connector on the end of the
braided shield.
2. 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.
3. 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.
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.
2
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. 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 rod 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
Loading...