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Kaliburn SR-45i User Manual

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SR-45i 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

Table of Contents

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Kaliburn SR-45i Specifications

General IconGeneral
BrandKaliburn
ModelSR-45i
CategoryWelding System
LanguageEnglish

Summary

Limited Warranty

Returned Goods Procedure

Outlines the process for returning items for repair, replacement, or restocking.

Section 1 Safety

General Safety Precautions

Covers essential safety information, including UV protection, noise, and toxic fumes.

Electric Shock Prevention

Details measures to protect against electric shock hazards when operating or maintaining the system.

Fire and Explosion Prevention

Provides guidelines to prevent fire hazards and risks associated with compressed gases.

Health and Environmental Safety

Addresses interference with health support equipment and lists relevant safety standards.

Section 2 Specifications

System Description

Overview of the SR-45i system's capabilities and features.

System Components

Lists the main components included in the SR-45i system.

Power Supply Specifications

Details electrical specifications, dimensions, weight, and gas requirements for the power supply.

Torch Specifications

Provides dimensional and weight information for the SR-45i torch.

Airborne Noise Emissions

Presents data on noise levels generated by the SR-45i system during operation.

Operating Modes

Describes the different cutting modes available on the SR-45i system.

Section 3 Installation

Initial Inspection

Instructions for inspecting the SR-45i system upon receipt and handling potential issues.

Power Supply Installation

Guidance on the proper placement and installation of the SR-45i power supply unit.

Primary Power Connection

Details on connecting the primary power supply to the SR-45i system, including fuse recommendations.

Power Supply Output Connections

Procedures for connecting torch leads and the work ground lead to the power supply output.

Torch Connections

Step-by-step instructions for connecting the torch leads to the torch assembly.

Gas Supply Connections

Guidance on connecting the compressed air supply to the SR-45i system.

CNC Machine Interface Connections

Instructions for interfacing the SR-45i system with a CNC cutting machine.

Section 4 Operation

Power Supply Front Panel Controls

Explanation of the controls and indicators located on the SR-45i power supply front panel.

Mechanized Cutting Mode

Details the sequence of events for operating the SR-45i in mechanized cutting mode.

Manual Cutting Mode

Explains the operation of the SR-45i in manual cutting mode for arc reestablishment.

Grate Cutting Mode

Describes the SR-45i's grate cutting mode, suitable for expanded or grate material.

Insulation Cutting Mode

Outlines the SR-45i's insulation cutting mode for nonmetallic materials.

Torch Consumables

Illustrates and describes the various torch consumable parts for different cutting applications.

Advanceable Electrode

Information on using and maintaining the SR-45i's patented advanceable electrode.

Setting up a Cut

Procedure for setting up the SR-45i system to perform a cutting operation.

Cut Quality

Guidelines for achieving optimal cut quality and troubleshooting common issues.

Cutting Chart

A chart providing recommended cutting conditions for various materials and thicknesses.

Section 5 Maintenance and Troubleshooting

Daily Procedures

Routine checks and maintenance tasks to be performed daily on the SR-45i system.

Monthly Procedures

Recommended maintenance checks and cleaning tasks for monthly performance.

Logic-Regulator Status LED's

Explains the function of status LEDs on the logic-regulator board for troubleshooting.

Logic-Regulator Sequence of Operation

Details the expected illumination sequence of LEDs during system operation.

General Troubleshooting

A guide to diagnosing and resolving common problems not covered by LED indicators.

Chopper Test Procedure

A step-by-step procedure for testing the chopper circuit's functionality.

Section 6 Parts List

Power Supply Parts

A comprehensive list of part numbers and descriptions for power supply components.

Torch and Handle Assembly Parts

Lists parts for the torch main body, handle, and associated components.

Shielded Torch Leads

Details the part numbers and descriptions for various lengths of shielded torch leads.

Consumable Spare Parts Kit

Lists the components included in the SR-45i consumable spare parts kit.

Logic-Regulator P.C. Board

Identification of components on the logic-regulator printed circuit board.

Chopper P.C. Board

Identification of components on the chopper printed circuit board.

Appendix A Electromagnetic Compatibility (EMC)

Background

Explains the compliance of the SR-45i with EMC standards and its intended environment.

Installation and Use

User responsibility for proper installation and resolving detected electromagnetic disturbances.

Assessment of Area

Factors to consider when assessing potential electromagnetic issues in the surrounding area.

Methods of Reducing Emissions

Techniques for minimizing electromagnetic emissions from the SR-45i system and its installation.

Primary Power Connection

Guidance on connecting the primary power to the system via an EMI filter.

EMI Filter Parts List

Lists parts required for EMI filter assemblies for different voltage configurations.

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