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1. Retaining Swirl Ring Mechanized Torch Main Body Cap 980551 980531 980100 Mild Steel Material Arc Arc Optimum Travel Maximum Travel Cutting Pierce Pierce Kerf Width Thickness Current Voltage Speed Speed Height Height Time in mm amp volts ipm mm min ipm mm min in mm in mm ms in mm 1 4 6 4 130 140 3556 208 5283 090 2 3 200 5 1 400 085 2 2 3 8 9 5 82 2082 112 2845 250 6 5 600 140 136 3 5 100 2 5 1 2 12 7 60 1524 81 2057 300 7 6 800 5 8 15 9 100 150 40 1016 52 1321 150 3 8 325 8 3 1200 joe as 3 4 19 1 155 30 762 38 965 155 3 9 400 9 0 2200 1 25 4 161 18 457 23 584 160 4 1 200 5 1 1000 155 3 9 1 1 4 32 175 10 254 16 406 165 4 2 Stainless Steel Material Arc Arc Optimum Travel Maximum Travel Cutting Pierce Pierce Kerf Width Thickness Current Voltage Speed Speed Height Height Time in mm amp volts ipm mm min ipm mm min in mm in mm ms in mm 1 4 6 4 140 150 3810 235 5969 115 2 9 200 5 1 400 090 2 3 3 8 9 5 145 80 2032 110 2794 120 ae 250 6 5 600 090 2 3 1 2 12 7 m 150 52 1321 72 1829 120 300 7 6 1500 100 2 5 5 8 15 9 151 32 864 48 1219 125 3 2 400 9 0 2200 455 57 3 4 19 0 153 25 635 36 914 130 3 3 l l 200 5 1 1000 1 25 4 162 15 381 21 533 150 3 8 120 3 1 Aluminum Material Arc Arc Optimum Travel Maximum Travel Cutting Pierce Pierce Kerf Width Thickness Current Voltage Speed Speed Height Height Time
2. Q SYSTEM STATUS i MODE CURRENT 2 o fu mO S ol e C se ourer 7 i Dagger OO O ras i KALIBURN SET RUN Figure 2 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 2 Operation Dagger100 User s Manual Rev E Operating Modes The operating mode of the Dagger100 is switch selectable and can either be Normal Expanded Metal or Marking The mode switch is located on the control panel of the power supply The operating modes are described below Marking can also be selected through the Machine Interface on the rear of the power supply see Section 3 Normal Cutting Mode To place the Dagger100 in the normal cutting mode set the Mode Switch to the normal position The start signal initiates the following sequence of events 1 1 5 second gas preflow 2 Pilot arc initiation pilot arc will be maintained for 3 seconds after which if a transferred arc has not been detected the pilot arc will terminate to minimize nozzle and electrode wear 3 Transferred arc establishes cutting arc 4 X Y mot
3. 3 4 19 1 162 12 305 20 508 140 3 6 Stainless Steel Material Arc Arc Optimum Travel Maximum Pierce Pierce Thickness Current Voltage Speed Travel Speed Cutting Height Height Time kert yvidth ga in mm amp volts ipm mm min ipm mm min in mm in mm ms in mm 16 060 1 5 138 406 10312 625 15875 100 2 5 300 070 1 8 10 135 3 4 140 159 4039 235 5969 100 2 5 400 ors T 1 4 6 4 150 72 1829 100 2540 800 i 60 115 2 9 200 5 1 3 8 9 5 153 35 889 46 1168 080 2 0 1 2 12 7 156 23 584 29 737 125 3 2 1000 090 2 3 3 4 19 1 163 12 305 15 381 140 3 6 105 2 7 Aluminum Material Arc Arc Optimum Travel Maximum Pierce Pierce Thickness Current Voltage Speed Travel Speed Cutting Height Height Time aria ga in mm amp volts ipm mm min ipm mm min in mm in mm ms in mm 1 16 1 6 138 433 10998 566 14376 100 2 5 300 070 1 8 1 8 3 2 140 260 6604 340 8636 1 4 6 4 146 95 2413 135 3429 100 2 5 400 075 1 9 60 200 5 1 3 8 9 5 153 50 1270 75 1905 448 Pn 080 2 0 1 2 12 7 161 30 762 50 1270 i i 1000 085 2 2 5 8 19 1 165 21 533 31 787 125 3 2 095 2 4 Edge Start Marking Arc Current Tara Optimum Travel Speed Marking Height Initial Height Pierce Time amps volts ipm mm min in mm in mm ms 12 170 250 6350 100 2 5 100 2 5 0 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any m
4. 20 100 amps Standard Output Voltage 160VDC Ambient Temperature 104 F 40 C Duty Cycle percentage of time during a 10 minute period that the power supply can cut 80 amps 100 200 208 VAC 30 60Hz 100 amps 60 85 amps 100 230 240 VAC 60H 30 pO Ore 100 amps 70 89 amps 100 380 415 VAC 39 50 60Hz 100 amps 79 90 amps 100 480 VAC 30 60Hz 100 amps 80 90 amps 100 600 VAC 30 60Hz 100 amps 80 Dimensions Width 12 5 in 317 5 mm Height 18 88 in 479 43 mm Length 23 12 in 587 24 mm Weight 105 Ib 47 6 kg This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 2 Specifications Dagger100 User s Manual Rev E Gas Supply Requirements Compressed air must be clean dry and oil free and may be supplied from compressed cylinders or from an air compressor Be aware that shop air systems are prone to oil and moisture contamination If shop air is used it must be cleaned to ISO 8573 1 Class 1 4 1 Specify dry air when using compressed cylinders Breathing quality air contains moisture and must not be used 3 8 inside diameter hoses are required for all inlet gas connections Quick connect fittings must not be used Quali
5. 4 3 Place the nozzle 3 into the retaining cap shield cap assembly 4 Place the electrode 4 into the swirl ring 2 5 Insert the electrode swirl ring assembly into the nozzle retaining cap assembly until it is seated properly 6 Thread the brass retaining cap assembly 6 onto the body This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 5 Operation Dagger100 User s Manual Rev E so Oo OY goog Note The Mechanized torch is equipped with a safety switch that detects when the consumables are installed The consumables must be installed properly in order to operate the mechanized torch Removing the Torch Consumables To remove the torch consumables perform the following steps 1 Remove the retaining cap from the torch 2 Remove the nozzle from the retaining cap 3 Separate the shield cap from retaining cap 4 Remove the electrode from the torch body Pull straight down on the electrode to aid in removal 5 Remove the swirl ring from the electrode Note the swirl ring may come out with the retaining cap This information is subject to the controls of the Export Administration Regulations EAR This in
6. All maintenance should be performed with safety in mind Be aware that the large 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 Power Supply 1 Verify that the green status light is illuminated when primary power is applied to the system 2 Place the Gas switch in the Set position and verify that air is flowing through the torch 3 With the Set Run switch in the Set position adjust the regulator on the rear panel of the Dagger100 to 90 psi Return the Set Run switch to the Run position 4 Raise the mechanized torch 2 inches above the workpiece Apply a start signal to the Dagger100 using the CNC control The pilot arc should be established in approximately 2 seconds The arc should extend approximately 1 inch from the nozzle WARNING Remove primary power from the system before performing the following procedures Mechanized Torch Assembly 1 Check the outer cover of the torch lead for nicks or cuts If the outer cover is damaged make sure the underlying wires are in good working condition If there is any damage to the insulation of the underlying wires the torch lead must be replaced 2 Remove all consumables from the torch and verify that the anode cathode insulator brown plastic is in good condition and has no signs of arcin
7. 5 T 142 54 1397 80 2032 150 3 8 225 5 7 800 070 1 8 1 2 12 7 150 33 812 45 1143 155 3 9 300 A 1200 3 4 19 1 164 16 406 22 559 160 4 1 200 5 1 1000 115 2 9 1 25 4 170 9 229 12 305 Aluminum Material Arc Arc Optimum Maximum Cutting P Pierce Thickness Current Voltage Travel Speed Travel Speed Height Fierce Height Time Kerf Width in mm amp volts ipm mm min ipm mm min in mm in mm ms in mm 1 8 3 2 138 300 7620 455 11 557 iad 400 080 2 0 1 4 6 4 147 115 2921 180 4572 400 25 20 i 600 085 2 2 3 8 9 5 80 153 65 1651 115 2921 l 225 5 7 800 095 24 1 2 12 7 157 40 1016 72 1829 300 7 6 1200 115 2 9 3 4 19 1 164 20 508 35 889 115 2 9 200 5 1 1000 120 3 1 Edge Start Marking Arc Current Ton Optimum Travel Speed Marking Height Initial Height Pierce Time amps volts ipm mm min in mm in mm ms 15 165 250 6350 100 2 5 100 2 5 0 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 14 Operation Dagger100 User s Manual Rev E 100 Amps mechanized shielded consumables Shield Cap Nozzle Electrode 980572 980510 980520
8. Dagger100 plasma cutting systems are manufactured to comply with the European standard EN 60974 10 Electromagnetic compatibility EMC Product standard for arc welding equipment The system has been tested in accordance with CISPR 11 EMC classification Group 2 ISM Class A The limits used in this standard are based on practical experience However the ability of plasma cutting equipment to work in a compatible manner with other radio and electronic systems is greatly influenced by the manner in which it is installed and used For this reason it is important that the plasma cutting equipment be installed and used in accordance with the information below if electromagnetic compatibility is to be achieved Plasma cutting equipment is primarily intended for use in an industrial environment There may be potential difficulties in ensuring electromagnetic compatibility in other environments Installation and Use The user is responsible for installing and using the plasma cutting equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the plasma cutting equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the plasma cutting circuit see Note In other cases it could involve constructing an electromagnetic screen enclosing the plasma power source and
9. J KALIBURN 3DAGGER 100 Plasma Cutting and Marking System User s Manual Part Number 718100 Rev E 04 23 2012 This information is subject to the controls of the Export REVISION Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Dagger100 User s Manual Rev E Revision History Rev ECO Author Date Description of Change A TDS 04 27 2010 As released e Updated sections to reflect CE unit B TDS 05 28 2010 requirements e Cut Chart updates e Changed voltage divider board part number and description e Added duty cycle limits for expanded metal cutting C JLW 05 16 2011 e Updated consumable part numbers e Updated error codes e Added caution concerning keeping torch consumables mating surfaces clean e Added instructions for installing voltage divider card in Section 3 e Updated Section 5 with D 01 27 2012 troubleshooting for Exceeded Max Cut Voltage 11 blinks e Changed torch handle part number and air regulator filter in Section 6 e Updated consumable part numbers e Updated Cut Charts E PKN 04 23 2012 This documentation may not be copied photocopied reproduced translated or reduced to any electronic medium or machine readable format without explicit written permission from Kaliburn 4130 Carolina Commerc
10. Pierce Pierce Kerf Width Thickness Current Voltage Speed Speed Height Height Time ga in mm amp volts ipm mm min ipm mm min in mm in mm ms in mm 18 048 1 3 350 8890 550 13970 16 060 1 5 140 258 6553 425 10795 100 2 5 100 2 5 150 060 1 5 14 075 1 9 n 225 5715 370 9398 10 135 3 4 150 105 2667 155 3937 125 3 2 125 3 2 250 3 16 4 8 65 1651 86 2184 600 070 1 8 155 150 3 8 150 3 8 1 4 6 4 50 1270 60 1524 1200 Stainless Steel Material Arc Arc Optimum Travel Maximum Travel Cutting Pierce Pierce Kerf Width Thickness Current Voltage Speed Speed Height Height Time ga in mm amp volts ipm mm min ipm mm min in mm in mm ms in mm 18 048 1 3 140 335 8509 500 13970 86 m 16 060 1 5 142 245 6223 365 9271 l 100 2 5 125 32 300 14 075 1 9 144 145 3683 216 5486 40 060 1 5 10 135 3 4 148 70 1778 110 2794 500 3 16 4 8 152 44 1118 64 1626 115 2 9 150 3 8 1200 065 1 7 1 4 6 4 158 31 787 45 1143 Aluminum Material Arc Arc Optimum Maximum Travel f Pierce Pierce Thickness Current Voltage Travel Speed Speed Cutting Height Height Time pone ga in mm amp volts ipm mm min ipm mm min in mm in mm ms in mm 16 1 16 1 6 325 8255 433 10998 200 090 23 115 29 050 1 3 14 3 32 2 3 m 145 215 5461 286 7264 300 1 8 3 2 135 3429 180 4572 100 2 5 125 3 2 060 1 5 1 4 6 4 153 45 1143 70 1778 115 2 9 150 3 8 1200 065 1 7 Marking Arc Current oie Optimum Travel Speed Marking Height Initial Height Pierce Tim
11. U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 9 Installation Dagger100 User s Manual Rev E Interface Connections Inputs are available through the machine interface oO The machine interface connection is located on the rear of the power supply CNC 9 Perform the following steps to properly interface the system with a CNC cutting machine See the system schematic for additional information The mating plug and associated pins are included for customer connection Plasma Start Input The Dagger100 requires a contact closure between P8 pins 3 and 4 to commence the cutting or marking sequence The sequence is terminated when the contacts are opened The contacts should be rated for 24VDC 10mA Plasma Cut Mark Input The Dagger100 requires a contact closure between P8 pins 1 and 2 to put the system in plasma marking mode Opening the contacts puts the system in cutting mode The operating mode should be selected prior to applying a start signal The contacts should be rated for 24VDC 10mA Motion Output The Dagger100 provides a maintained contact closure between P8 pins 12 and 14 as long as a cutting arc is maintained between the torch and the work piece This infor
12. United States contrary to the requirements of the EAR Safety Dagger100 User s Manual Rev E 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 The following safety information must be provided to each person who will operate observe perform maintenance or work in close proximity to this piece of equipment Installation operation and repairs made to the Dagger system should only be performed by qualified personnel The Dagger 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 Safety decals On the Dagger100 power supply should not to be removed A 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 12 shade or ISO 4850 No 13 shade which provides protection up to 400 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 curtai
13. in mm amp volts ipm mm min ipm mm min in mm in mm ms in mm 1 4 6 4 140 165 4191 250 6349 100 2 5 200 5 1 400 085 2 2 3 8 9 5 150 92 2337 140 3556 115 2 9 250 6 5 600 Ae 1 2 12 7 400 155 70 1778 105 2667 145 3 7 300 7 6 1500 me j 5 8 15 9 160 48 1219 76 1930 155 3 9 400 9 0 2200 40 25 3 4 19 0 162 33 838 55 1397 160 4 1 200 5 1 1000 1 25 4 172 20 508 30 761 160 140 3 6 Edge Start Marking Arc Current UR Optimum Travel Speed Marking Height Initial Height Pierce Time amps volts ipm mm min in mm in mm ms 15 165 250 6350 100 2 5 100 2 5 0 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 15 Operation Dagger100 User s Manual Rev E BLANK This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 16 Maintenance and Troubleshooting Dagger 100 User s Manual Rev E Section 5 Maintenance and Troubleshooting Warning Only qualified maintenance personnel should perform maintenance on the Dagger100 system The system utilizes potentially fatal A C and D C voltages
14. not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 11 Installation Dagger100 User s Manual Rev E BLANK This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 12 Operation Dagger100 User s Manual Rev E Section 4 Operation Power Supply Controls and Status Indicators The Dagger100 power on off switch is located in the rear of the power supply All of the other Dagger100 controls and status indicator lights are located on the front panel of the power supply as shown below This section describes the function of each control and indicator See Figure 1 for power switch location and see Figure 2 for front panel control and indicator locations Power Switch o When in the OFF position the Dagger100 system will be de energized and all power removed at the load side of the switch Note The line side of the switch will be electrically hot When in the ON position the Dagger100 system will be energized and ready for operation Mode Switch Used to set the operating mode of the Dagger100 Set Run Switch 3 In the Set mode the gas solenoid will energize so the gas pressure may be adjusted and will reset specific faults
15. provided the fault has been cleared In the Run mode the gas solenoid will de energize and await a start command Current Thumbwheel 4 Used to set the output current of the Dagger100 The output current can be set in 1 amp increments System Status Indicator 8 After the main power switch has been placed in the ON position the system status indicator illuminates green provided no system faults have been detected The system status indicator will flash on and off when a fault exists and prevent system operation Gas Pressure Indicator 6 llluminates when there is acceptable gas pressure for torch operation Remains extinguished when there is low gas pressure DC Power Indicator 7 Illuminates when a start command has been initiated and voltage is present at output terminals of the power supply Fault Indicator Illuminates when an error exists A blinking pattern will identify the type of error This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 1 Operation Dagger100 User s Manual Rev E Figure 1
16. see installing consumable section 4 Check all connections on the work ground lead Verify that the connections are tight and free from corrosion If necessary use a wire brush to clean the connections See section 3 for work ground lead installation Check the torch work standoff initial height Check gas flow adjust if needed see section 2 Gas Supply Requirements Torch will not ignite e Consumables worn e Torch connection not tight e Torch leads are damaged Check torch consumables replace install correctly if needed see installing torch consumable section 4 Verify that torch connection to the power supply is tight Tighten if needed See section 3 quick disconnect torch lead Verify that all torch lead fittings are secure Replace the torch leads if there are any visible signs of damage See section 3 for torch to torch lead connections This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 4 Maintenance and Troubleshooting Dagger 100 User s Manual Rev E Problem Possible Causes Possible Solutions e Consumables worn or e Check torch consumables replace install Poor cut incorrect consumables in correctly if needed see installing torch quality torch consumabl
17. that is leaking cracked or has other signs of physical damage e All gas cylinders should be secured to a wall or rack to prevent accidental knock over This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 3 Safety Dagger100 User s Manual Rev E Health Support Equipment 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 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 any gas hose that is leaking or has other signs of physical damage 9 M The Dagger 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 simila
18. the Dagger100 with a torch height control system If the unit didn t come from the factory with this option installed contact Kaliburn to obtain the Voltage Divider Board Kit 980610 and then 1 Remove the right side of the Install a supplied standoff onto each Locate the 8 female receptacles Remove and discard the cable ties Install all 8 female connector Position the 4 holes in the Voltage Secure the Voltage Divider Board to Replace the right side of the Disconnect the Dagger100 from wall power Wait 5 minutes Dagger100 cover Standoffs installed onto threaded studs of the 4 pre installed threaded studs indicated 4 pairs on the wire harness shown 3 typically holding each pair of receptacles to the wire harness receptacles 4 pairs onto the corresponding male tabs indicated on the Voltage Divider Board IMPORTANT Stressing flexing the male tab while installing the receptacle may damage the Voltage Divider Board IMPORTANT Connecting the wrong receptacle to the wrong male tab may damage the Voltage Divider Board Voltage Divider Board Flat Washer Lock Washer Divider Board over each of the 4 ud standoffs Orient as shown dae Vog each of the 4 standoffs using the supplied flat washers lock washers and nuts Over tightening the nut may crack the board Dagger100 cover End of procedure This information is subject to the controls of the
19. the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer troublesome Note The plasma cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel plasma cutting current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC 974 13 Arc welding equipment Installation and use This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 1 Electromagnetic Compatibility EMC Dagger100 User s Manual Rev E Assessment of Area Before installing plasma cutting equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the plasma cutting equipment b radio and television transmitters and receivers C computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the peop
20. Assemblies Part Number Length 980195 25 25 ft 3 0 m 980195 35 35 ft 4 6 m 980195 50 50 ft 6 1 m This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 4 Parts List Dagger100 User s Manual Rev E Consumable Spare Parts Kit 980135 Part Number Quantity Description 980520 980510 98051 1 980512 980531 980551 980572 12 2 1 Electrode 100a Nozzle 80a Nozzle 60a 40a Nozzle Swirl Ring Retaining Cap 100A 80a 60a 40a Shield Cap This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 5 Parts List Dagger100 User s Manual Rev E BLANK This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 6 Electromagnetic Compatibility EMC Dagger100 User s Manual Rev E Appendix A Electromagnetic Compatibility EMC Background The CE marked
21. Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 2 Installation Dagger100 User s Manual Rev E Primary Power Connection A primary disconnect switch switching all ungrounded supply conductors should be provided for each Dagger 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 CSA Model 3 Phase Input Current Recommended Input Voltage at Rated Output Time Delay Fuse Size VAC amps amps 200 208V 52 80 230 240V 45 80 400V 27 50 480V 22 40 600V 23 40 CE Model 3 Phase Input Current Recommended Input Voltage at Rated Output Time Delay Fuse Size VAC amps amps 230V 45 80 400V 27 50 Use a type SO 90 C rated power cable to connect the primary power to the Dagger power supply The supply cables should have a 600 volt minimum rating and should be sized accordin
22. Marklngs iicet co eO oo PRO IR eR OR EH MIERRRR HIR eee 2 5 Airborne Noise Emissions sessssssssssssseseeeeeeeenee eren enne ern innen nennen rnnt n entere enne 2 5 I ITEMDICIEUDTIESE 3 1 Initial InSpectlon 23i tt d tated cote edd eei ene bed qt eel ect teste abbia dades Doce oos ei 3 1 Power Supply Installation 1 idet rte de e e te bte eb e HEC adea abita dadas 3 1 Mechanized Torch Installation aa 2 11th e teet eiit Mom iita m babitu 3 1 Voltage Divider Card Installation Optional ssene eem 3 2 Primary Power Connection serorei aas eai aaa i eene nennen nennen ennt ne a nennen 3 3 Power Supply Output Connections sssssssssssssesseeneneen eene nennen Ennn nennen 3 5 Mechanized Torch Connections ssssssssssssssssseseeeeneeneneerener enne nennen nnn n nnne 3 8 Gas Input Connectlons 5 ioi decent ese tae de daa e ate amba 3 9 Interface ConnectlOns itc eer et ed nsu tree tu ore IP ead ET Erde foa eee ae 3 10 IIWIDEBecrume 4 1 Power Supply Controls and status Indicators ssssssssssssssseeeeme 4 1 Operating Modes nachts diced de ded ced de oe Pe edd i d on ro dud da dod v da cite ean 4 3 Mechanized Torch Consumable Selection ssssssssssssseseeeeeeeeene nennen 4 4 Installing the Mechanized Torch Consumables ssssessse emen enn 4 5 Removing the Torch Consumab
23. R This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 7 Operation Dagger100 User s Manual Rev E Making a Cut or Mark Setting up a Cut Use the following procedure to make a cut with the Dagger 100 1 Using the charts in this section determine the proper torch parts and cutting conditions for the material being cut Install the proper consumables into the torch Turn the power switch to the ON position to apply power to the Dagger 100 The System Status light on the front panel should illuminate Place the Set run switch in the set position and adjust the regulator pressure to 90 psi while gas is flowing through the torch Return the Gas switch to the Run position Set the Current thumbwheel according to the cutting chart in this section Set the Mode Switch to the proper mode as previously described The cutting operation is initiated after a start signal is received The arc should establish approximately 2 seconds after application of the start command Throughout the cut the red D C Power light on the front panel should be illuminated to indicate that current is flowing through the torch The cutting operation is terminated when the start signal is removed At the completion of a cut gas flow through the torch will continue for approximately 20 seconds When cutting expanded metal the dur
24. SEOs ms es 00 OO eS ie This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 2 Parts List Dagger100 User s Manual Rev E 9S EALIBUEN WORE RET MP j Dagger OO O nas Ne ci Z As LS far cr qusc c x03 L y A E f NS VE n C X ne C CN CN aed pus eM qu This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 3 Parts List Dagger100 User s Manual Rev E Mechanized Torch Assembly Item Number PartNumber Quantity Description 1 980100 1 Mechanized torch main body 2 980099 1 Mechanized torch handle Leads Assemblies Part Number Length 980190 25 25 ft 3 980190 35 35 ft 4 6 m 980190 50 50 ft 6 CTP Leads
25. ation and or duty cycle for cutting may be limited depending upon the mesh opening width of the web and travel speeds The table below gives approximate duty cycles based on duration of cut The maximum current for expanded metal cutting is 80 amps Duration of Cut Duty Cycle 30 sec 70 60 sec 60 90 sec 40 120 sec 15 An adaptive post flow is used for expanded metal cutting which will extend the gas flow though the torch longer than 20 seconds after cutting based on the time of the cut and pilot arc duty This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 8 Operation Dagger100 User s Manual Rev E Cut Quality Before the optimum cutting condition can be achieved on a particular material type and thickness the machine operator must have a thorough understanding of the cutting characteristics of the Dagger100 system When the cut quality is not satisfactory the cutting speed torch height or gas pressures may need to be adjusted in small increments until the proper cutting condition is obtained The following guidelines should be useful in determining which cutting parameter to adjust Before making any parameter changes verify that the torch is square to the work piece Also it is essent
26. bjected to the fumes wear proper air breathing equipment Electric Shock Prevention pac 5N 7 The Dagger 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 Dagger system Observe the following guidelines to protect against electric shock e A wall mounted disconnect switch should be installed and fused according to local and national electrical codes The disconnect switch should be located as close as possible to the power supply so it can be turned off in case of an emergency e The primary power cord should have a 600 volt minimum rating in order to protect the operator In addition it should be sized according to local and national electrical codes Inspect the primary power cord frequently Never operate the Dagger system if the power cord is damaged in any way e Make sure the primary power ground wire is connected at the input power ground location on the Dagger power supply Make sure the connection is securely tightened e Make sure the positive output work ground of the Dagger 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 e Inspect the torch leads frequently Never use the syste
27. bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applications This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 3 Electromagnetic Compatibility EMC Dagger100 User s Manual Rev E BLANK This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 4
28. connectors are installed securely Mechanized Torch Assembly 1 2 3 Verify that the torch lead connection at the power supply is tight and that there are no leaks Only tighten the enough to provide a gas tight seal The connections are subject to damage if over tightened Inspect the torch leads for nicks or cuts and replace if necessary Remove the torch handle and verify that the connections at the rear of the torch are tightened securely Only tighten the fitting enough to make the gas seal The fittings are subject to damage if over tightened Work Ground 1 Verify that the work ground lead is securely fastened to the star ground on the cutting table and that the connection point is free from corrosion Use a wire brush to clean the connection point if necessary Gas Supply 1 2 Check for signs of contamination in the gas supply lines Drain Filter Bowl as needed 3 Listen for gas leaks in the supply lines and in the internal plumbing system Tighten any connections that are leaking Leaks in the supply can cause poor cut quality as well as torch overheating Replace the Regulator Filter Element as necessary A good rule to follow is to replace the filter element whenever the pressure drop across a filter at rated flow is approximately 10 psi To replace the element e Remove the bowl from the filter body e Remove the element from the filter body The plastic ring and or o ring may come off with the e
29. ctor on the base of the power supply 3 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 inch 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 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 7 Installation Dagger100 User s Manual Rev E Mechanized Torch Connections Perform the following steps to connect the torch lead assembly to the mechanized torch Note When making hose connections only tighten the brass fittings enough to make a gas seal The fittings are subject to damage if over tightened Also use two wrenches when tightening the torch fittings to av
30. e amps volts ipm mm min in mm in mm ms 12 170 250 6350 100 2 5 100 2 5 0 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 12 Operation Dagger100 User s Manual Rev E 60 Amp mechanized shielded consumables Shield Cap 980572 Nozzle 980512 Electrode 980520 Retaining Swirl Ring Mechanized Torch Main Body Cap 980551 980531 980100 Mild Steel Material Arc Arc Optimum Travel Maximum f Pierce Pierce Thickness Current Voltage Speed Travel Speed Cutting Height Height Time Kere viam ga in mm amp volts ipm mm min ipm mm min in mm in mm ms in mm 1 8 3 2 220 5588 271 6883 130 063 1 6 150 3 8 200 068 1 7 10 135 3 4 215 5588 265 6731 3 16 4 7 135 130 3300 170 4318 080 2 0 200 5 1 300 075 1 9 1 4 6 4 60 90 2286 118 2997 225 5 7 400 145 128 3 3 095 24 3 8 9 5 48 1219 60 1524 250 6 4 1000 1 2 12 7 157 30 762 38 965 125 3 2 200 5 1 1000 115 2 9
31. e Parkway Ladson SC 29456 USA 843 695 4000 Phone 843 659 4001 Fax www kaliburn net This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Dagger100 User s Manual Rev E 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 Dagger100 torch and leads and three 3 years for the Dagger100 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 bu
32. e section 4 e Gas pressure not adjusted correctly e Incorrect cutting conditions current speed torch height mode of operation etc e Workpiece not grounded to the cutting table e Gas supply contaminated e Check gas pressure adjust pressure if needed see section 2 Gas Supply Requirements e Check Cutting conditions See Section 4 for cutting conditions e Check cutting table Replace the table slats if needed e Check the filter regulator Install replace filters or drain filter bowl if needed This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 5 Maintenance and Troubleshooting Dagger 100 User s Manual Rev E BLANK This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 6 Parts List Dagger100 User s Manual Rev E Section 6 Parts List Power Supply See Figures Below Item Number Part Number Quantity Description 1 705011 1 Pilot Arc transistor IGBT 2 980610 1 Optional Height Control Voltage Divider P C Board 3 980009 2 Solenoid Valve 3 way 4 708205 1 Pr
33. eans to any location outside the United States contrary to the requirements of the EAR 4 13 Operation Dagger100 User s Manual Rev E 80 Amps mechanized shielded consumables Shield Cap Nozzle Electrode 980572 980511 980520 Retaining Swirl Ring Mechanized Torch Main Body Cap 980551 980531 980100 Mild Steel Material Arc Arc Optimum Maximum Cutting Pierce Thickness Current Voltage Travel Speed Travel Speed Height Pierce Height Time Kerf MI in mm amp volts ipm mm min ipm mm min in mm in mm ms in mm 3 16 4 8 135 150 3809 230 5842 100 2 5 200 5 1 200 080 2 0 1 4 6 4 140 110 2793 165 4191 125 3 2 225 5 7 300 085 22 3 8 9 5 m 140 65 1651 98 2489 145 3 6 250 6 4 400 098 2 5 1 2 12 7 145 40 1016 65 1651 185 4 7 300 7 6 1200 15 35 3 4 19 1 155 23 584 35 889 i 170 4 3 200 5 1 1000 1 25 4 174 10 254 17 432 135 3 4 Stainless Steel Material Arc Arc Optimum Maximum Cutting Pierce Thickness Current Voltage Travel Speed Travel Speed Height Fierce Height Time Ren in mm amp volts ipm mm min Ipm mm min in mm in mm ms in mm 3 16 4 8 138 145 3683 220 5588 400 1 4 6 4 138 105 2667 156 3962 dis em EM ad 600 3 8 9
34. ents Section T Safety a viedo ecm sense N 1 1 Genetal Precautlons px eio 1 1 Ultraviolet Radiation Protection ssssssssssssssseenee eene eren ener etnies 1 1 Noise DrotectlOr stet DR E I RIP E CIEN 1 1 Toxic F me PreventiOn iieri c niei e aca Rode ete deu YE n dea eae dees n d aL HD ede aud 1 2 Electric Shock Prevention iiri coi e edte eee Ded aedes enden doa de VE Fun e te eade nag ane den 1 2 Fire Prevention Lech ed eee e eite ed coed abge ed ee ried eet te de Po ERU aa te iva edu ees ace aes 1 3 Explosion Prevention 2 ice cen eee Io ede vee Flay atten e us RI evade eade ieee aes 1 4 Health Support Equipment i iniii iiaa eaan aneda ae aaia aa E aada Eaa aaaeaii 1 5 Safety Standards Booklet Index sse eene nennen nnne 1 5 Section 2 Specifications e P eod e ERE a eo ae nennen ennenen 2 1 System DescriptloFi 1 2 iei ede ce ae dte Cea eto LER le ze Ce LOR E deu ed A 2 1 System Components rrara titre ee o Ec UR aab cit v REP PUO ee tnu n go ds 2 1 Power Supply Specifications ccceccccecceceeeeeeecenceeceeeeececenaeeeeeeeeeseceaeeeeeeeseseccaeaeeeeeeesssnneeeees 2 2 Gas Supply Specifications sssssssssssssssssssseseenee eene nennen enirn nnne 2 3 Mechanized Torch Specifications cccccceeeeeeececeeeeeeeeeeeaeeeeeeeeecesecaeeeeeeeseseccaeeeeeeeeeeesnneeeeess 2 4 Synibols arid
35. eral troubleshooting guidelines for the Dagger100 system Please contact KALIBURN technical support for any issues not covered in this section Before any tests are performed make sure that all system fuses are good Problem Possible Causes Possible Solutions Front panel e Regulator pressure too low e Check gas pressure adjust pressure if needed red D C power see section 2 Gas Supply Requirements light will not illuminate e Torch consumables not e Check torch consumables replace install installed correctly or correctly if needed see installing torch damaged consumable section 4 e Red D C Power light or e Check the D C power light and associated associated wiring may be wiring replace if needed see system Schematic bad Front panel e Supply gas pressure low e Check the gas supply pressure and adjust green Gas replace if pressure low Pressure Indicator will e Faulty Green Gas Pressure e Check electrical connections to Gas Pressure not illuminate light or associated wiring e Faulty pressure switch or associated wiring light replace if needed see system schematic Check pressure switch and or wiring Contact KALIBURN technical support The arc will not transfer to the work piece e Incorrect damaged or worn consumables e Loose work ground connection e Pierce height too high e There is not adequate gas flow install torch Check torch consumables replace correctly if needed
36. essure Switch 5 740120 1 Air Regulator with Filter 6 740146 1 Air Regulator Filter 7 980500 2 Fan 8 980200 1 Impulse Starting P C Board 9 708203 1 Disconnect Switch 10 709298 1 Fuse 11 850100 1 Sequencer P C Board 12 277070 1 Current Thumbwheel Assembly 13 702086 1 Line Filter CE Model Only This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 6 1 Parts List Dagger100 User s Manual Rev E 516 A Hl r J
37. essure can exceed 150 psi or when the temperature can exceed 125 F The 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 Replacement filter elements are available from KALIBURN Perform the following steps to connect the power supply to the gas supply 1 Mount the regulator filter in a vertical position on the rear left side of the power supply 2 Connect a 3 8 9 5 mm minimum inside diameter hose to the inlet port of the regulator filter A 74 NPT to 3 8 flair fitting and a 3 8 hose barb are included for making connection 3 Be sure that all gas supply connections are tight Leaks in the supply can cause poor cut quality 1 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non
38. formation is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 4 Specifications Dagger100 User s Manual Rev E Symbols and Markings IEC Symbols Used on the Dagger100 f Direct Power is Curent ON DC Power is Protective OFF Earth Inverter Plasma 3 Based b Torch ZOH Pasea u Cutting die Power Caution DEDS Sree device Read LU Instruction Manual Airborne Noise Emissions The Dagger100 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 Dagger100 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 work piece 98dB 96dB 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 This information is subject to the controls of the Export Adminis
39. formation shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 6 Operation Dagger100 User s Manual Rev E N WARNING Contaminants such as dirt metallic dust oil and moisture present on the surface of the electrode and or torch body can cause electrical arcing between these components and ultimately result in failure of the torch and consumables In order to avoid damaging the torch and or consumables adhere to the following guidelines 1 Ensure that the air supplied to the torch does not contain contaminants such as debris moisture and oil Ensure that the torch cathode body and electrode body are clean prior to assembling the consumables into the torch Wipe away any contaminants with a dry lint free cloth Be sure that the consumables are properly tightened when installing them into the torch to ensure that there is no gap between the electrode body and cathode body Check the installation of the consumables before the start of each work shift and frequently during each work shift to ensure that the parts have not become loose as a result of normal operation Inspect the surfaces of the cathode body and electrode body to ensure no contaminants have collected during operation Reference Figure Below Electrode Body This information is subject to the controls of the Export Administration Regulations EA
40. g 3 Check all consumables and discard any damaged items 4 Verify that the electrode seat is clean to ensure proper electrical contact 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 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 1 Maintenance and Troubleshooting Dagger 100 User s Manual Rev E Monthly Procedures Note At minimum these checks should be performed on a monthly basis In excessively dirty environments or in heavy usage situations the checks should be performed more frequently Power Supply 1 2 3 4 5 6 Remove the left and right panels of the power supply Using clean dry compressed air blow out all accumulated dust inside the power supply including dust on p c boards and fans Be sure to blow out the fan at the rear of the unit In an excessively dirty environment blow out the unit on a weekly basis Verify that all torch lead and work ground connections are secure and free from corrosion Verify that the primary three phase A C voltage connections are tight Verify that all p c board connectors are installed securely Verify that the rear panel cable
41. g Society 550 NW LeJeune Road Miami FL 33126 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 AWS Standard ULR Ultraviolet Reflectance of Paint obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 AWS ANSI Standard 249 1 Safety in Welding Cutting and Allied Processes obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 ANSI Standard 241 1 Standard For Men s Safety Toe Footwear obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 ANSI Standard 249 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 ANSI Standard 287 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 ANSI Standard Z88 2 Respiratory Protection obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 OSHA Standard 29CFR 1910 252 Safety and Health Standards obtainable from the U S Government Printing Office Washington D C 20402 NFPA Standard 51 Oxygen Fuel Gas Systems for Welding Cutting and Allied Processes obtainable fr
42. g to local and national codes Route the supply cables through the strain relief in the lower rear portion of the power supply and connect the hot lines to the L1 U L2 V L3 W terminals of the line disconnect switch as shown in figure below Be sure to connect the protective ground PE cable to the PE terminal adjacent to the disconnect switch This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 3 Installation Dagger100 User s Manual Rev E Oe we n Input Power Connections This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 4 Installation Dagger100 User s Manual Rev E Power Supply Output Connections Perform the following steps to connect the output of the power supply to the quick disconnect torch lead assembly and the work table Quick Disconnect Torch Lead Note Use only the torch specified in this manual Do not attempt to install any other torch 1 Make sure the power switch is in the OFF position 2 Align the torch lead quick disconnect C with the connec
43. he material thickness range The Dagger100 also has 3 modes of operation which provide the capability for cutting and marking all types of material 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 The degree of protection provided by the Dagger100 system is IP21S and as such is intended only for indoor use It is not suitable for use in rain or snow System Components The Dagger100 consists of the following components Standard Components e Power Supply e Mechanized Torch and Lead Assembly e System Manual e Consumable Spare Parts Kit see Section 6 for details This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 1 Specifications Dagger100 User s Manual Rev E Power Supply Specifications Stock Number 980000 Input Current at Rated Output 200 208 VAC 52 amps 230 240 VAC 45 amps 380 415 VAC 27 amps 480 VAC 3PH 22 amps 600 VAC 3PH 23 amps Open Circuit Voltage 300VDC Arc Striking Voltage 5 75kV Output Current drooping characteristic
44. ial 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 and shield cap orifices for roundness Also check the parts for any dents or distortions Irregularities in the torch parts can cause cut quality problems 1 A positive cut angle top dimension of piece smaller than the bottom dimension usually occurs when the torch standoff distance is too high when cutting too fast or when excessive power is used to cut a given plate thickness 2 A negative cut angle top dimension of piece larger than the bottom dimension usually occurs when the torch standoff distance is too low or when the cutting speed is too slow 3 Top dross usually occurs when the torch standoff distance is too high 4 Bottom dross usually occurs when the cutting speed is either too slow slow speed dross or too fast high speed dross Low speed dross is easily removed while high speed dross usually requires grinding or chipping off Bottom dross also occurs more frequently as the metal heats up As more pieces are cut out of a particular plate the more likely they are to form dross 5 Note that different material compositions have an effect on dross formation 6 If the material is not being completely severed the likely causes are that the cutting current is too low the travel speed is too high the gas pressures are incorrect the incorrect gas types are selected the inco
45. idden and the power supply regulates the output current to a lower current appropriate for marking This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 3 Operation Dagger100 User s Manual Rev E Mechanized Torch Consumables Figure 4 3 shows the different torch consumables Shield Cap Retaining Cap Nozzle 980572 980551 980512 Torch Body 980572 980551 980512 a L L Swirl Ring Electrode L 980531 980520 980100 980551 980511 980572 980551 980510 CTP Retaining Cap Use CTP Retaining Cap with appropriate torch height control system This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 4 Operation Dagger100 User s Manual Rev E Installing the Mechanized Torch Consumables To install the torch parts perform the following steps Note Do not over tighten the consumables Only tighten until the parts are seated properly 1 Inspect the threads on the torch body and copper retaining cap and clean as necessary 2 Thread the shield cap 5 onto the retaining cap assembly
46. ion signal enabled There is no motion delay provided by the Dagger100 If motion delay is required it will have to be programmed into the X Y Controller Removal of the plasma start signal terminates the cutting or marking process disables the x y motion signal and initiates gas postflow Note Loss of the cutting arc even if a plasma start signal is applied deenergizes the Dagger100 system disables the x y machine motion signal and initiates postflow of gas Expanded Metal Cutting Mode To place the Dagger100 in the expanded metal cutting mode set the Mode Switch to the expanded metal position The starting sequence is the same as that for Normal cutting with the following exceptions The system reverts to a pilot arc condition for a period of 3 seconds when the transferred arc is lost The x y motion signal is enabled as soon as the pilot arc is established and remains enabled until the plasma start signal is removed or the pilot arc times out The cutting sequence is terminated when the plasma start signal is disabled The pilot arc circuit is limited in duty cycle and may limit the cut duty depending upon the size of the mesh being cut and duration of the cut Marking Mode To place the Dagger100 in the marking mode set the mode switch to the marking position or select marking through the CNC Machine Interface The starting sequence is the same as that for Normal cutting However the current selected via the thumbwheel switch is over r
47. le around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may require additional protection measures h the time of day that plasma cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Plasma cutting equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed plasma cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the plasma power source so that good electrical contact is maintained between the conduit and the plasma power source enclosure Maintenance of the Plasma Cutting Equipment The plasma cutting equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fas
48. lement e Pull down on the element to separate the plastic ring and the o ring from the element Discard the used element Place the new element inside the plastic ring and the o ring Thread the element onto the filter body Thread the bowl onto the filter body This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 2 Maintenance and Troubleshooting Dagger 100 User s Manual Rev E Troubleshooting The front panel red Fault Status indicator will display fault information useful in troubleshooting The power supply microprocessor displays an error code by blinking the Fault Status indicator on and off to indicate which error has occurred The number of blinks will indicate the type of error as outlined in the chart below The chart lists the errors and possible solutions Number of Blinks Error Possible Solution 0 T ri arp etait e Remove power and check the torch consumables incorrectly Make sure ambient temperature does not exceed rated temperature Verify cooling fans are operating properly and are not clogged or air flow blocked Make sure ambient temperature does not exceed rated temperature Verify cooling fans are operating properly and are not clogged or air flow blocked e Check gas supply
49. les sssssssseseeneeeee nennen mmn nre nnns 4 6 Making a Cut or Malik nectit ente amid enhn Mn eS 4 8 Cut Quality ocn ditm d E De e toten elite dm o ett 4 9 Inspection of Consumable Pars irran e ae a ea a A P E E eren a e enne 4 10 CUNE Chans miana ett ein E a e d OE ceed 4 11 Section 5 Maintenance and Troubleshooting eee 5 1 Daily Procedures en ett eR ERE EO Ui tad DO te 5 1 Monthly Procedures cie lee heh ee HE eade e BE cada eet seed ev eu eae a Ive aa e EE 5 2 Trouble Shooting ci eee ei a eee ena ee ei a 5 3 Section 6 Parts Lists M 6 1 POWER SSL PLY eee 6 1 Mechanized Torch ASsSembl yssir iritas aieiaa ea a ne enne nnne nennen enne rennen nnn nennen 6 4 Leads Assemblies I E 6 4 Consumable Spare Parts Kit eene eren en nennen nennen nnns 6 5 Appendix A Electromagnetic Compatibility EMC eeeeeeeeeeseee A 1 Background a xd eniti dme pen e nadie mede aco atu ete seis A 1 Installation and WSC ion tede nta uten eu ena nene idest A 1 Assessment of Area as ioter eet tert case A 2 Methods of Reducing EMISSIONS erioa r aE EE EEE EEE ener enne nn nene A 2 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the
50. m if the leads are damaged in any way e Do not stand in wet damp areas when operating or performing maintenance on the system e Wear insulated gloves and shoes while operating or performing maintenance on the system e Make sure the system is switched off at the wall disconnect before servicing the power supply or torch This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 2 Safety Dagger100 User s Manual Rev E e Never change torch consumable parts unless main power to the Dagger system is switched off at the power supply or wall disconnect e Do not attempt to remove any parts from beneath the torch when cutting Remember that the workpiece forms the current path back to the power supply e Never bypass the safety interlock devices e Before removing any of the Dagger covers switch the system off at the wall disconnect Wait at least five 5 minutes before removing any cover This will give the capacitors inside the unit time to discharge e Never operate the Dagger system without all of the covers in place e Preventive maintenance should be performed daily to avoid possible safety hazards Fire Prevention It When using the Dagger system it is necessary to exercise good judgment While cutting the arc
51. mation is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 10 Installation Dagger100 User s Manual Rev E Mechanized Torch Height Control Arc Voltage Output The Dagger100 with the optional Voltage Divider board Part Number 980610 installed supplies a voltage output signal between pins 1 and 4 of P7 Pin 1 is the PS signal and Pin 4 is the PS signal The mating plug and associated sockets are included for customer connection A 40 1 voltage ratio for use with Inova Height Controls or a 28 1 ratio for use with Smart HC Height Controls can be selected by a jumper on the voltage divider board Clear the Plate Function In order to utilize the clear the plate CTP function route the end of the CTP lead through the strain relief on the rear of the unit and connect it to the CTP tab on the voltage divider Tighten the strain relief after the connection is made Route the other end of the CTP as required to the mechanized torch with consumables installed and connect it to the tab on the retaining cap The CTP logic output is provided through pins 2 and 3 of P7 Pin 2 is the Logic signal and Pin 3 is the Logic signal This information is subject to the controls of the Export Administration Regulations EAR This information shall
52. ns should be installed to protect additional workers in the area from ultraviolet radiation Noise Protection O The Dagger 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 Ultraviolet Radiation Protection This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 1 Safety Dagger100 User s Manual Rev E Toxic Fume Prevention E 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 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 su
53. oid damaging the torch 1 Unscrew the torch handle assembly from the torch main body and slide the torch leads through the handle 2 Attach the pilot arc lead to the torch pilot arc lead 5 3 Attach the electrode lead to 6 the electrode fitting on the torch body 4 Attach the torch switch to the torch switch leads 7 5 Slide the handle down over the connections and thread the handle onto the torch body being careful to avoid cross threading the handle When tightening the handle be sure to turn the handle and not the torch body This will avoid twisting the torch leads 6 Tighten the strain relief at the rear of the torch handle A This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 8 Installation Dagger100 User s Manual Rev E Gas Input Connections The Dagger requires clean dry oil free compressed gas for good cut quality as well as long consumable life The plasma system is supplied with a regulator filter 8 to filter the incoming gas supply Additional filtration may be required if there is moisture oil or other contaminants in the gas supply The regulator filter supplied with the Dagger100 should be used with industrial compressed air systems only It must not be used where the inlet pr
54. om the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 5 Safety Dagger100 User s Manual Rev E 13 14 NFPA Standard 51B Cutting and Welding Processes obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 NFPA Standard 70 National Electrical Code obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 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 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 CGA booklet TB 3 Hose Line Flashback Arrestors obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 CSA Standard W117 2 Safety in Welding Cutting and Allied Processes obtainable from Canadian Standards Association 178 Rexdale Boulevard Toronto Ontario M9W IR3 Canada Canadian Electrical Code Part 1 Safety Standard f
55. or Electrical Installations obtainable from the Canadian Standards Association 178 Rexdale Boulevard Toronto Ontario M9W 1R3 Canada This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 6 Specifications Dagger100 User s Manual Rev E Section 2 Specifications System Description The Dagger100 is a versatile 100 amp variable duty cycle plasma cutting and marking system It utilizes a single gas torch that is capable of cutting gauge to 1 inch 38 mm thick material Recommended pierce capacity of the Dagger100 is 72 inch 13 mm with a maximum piercing capacity of inch 19mm The Dagger100 can severe material up to 1 inch with an edge start at slow speeds The Dagger100 is equipped with a quick disconnect torch lead This feature allows the torch lead connections to be completed with one connection on the front of the power supply The Dagger100 power supply utilizes a universal input and will operate on AC voltages from 200V 600V 3PH The temperature controlled fan feature allows the Dagger system to maintain proper operating temperature The fans automatically turn on when the system reaches a specified temperature The Dagger100 uses four nozzle sizes 40 60 80 and 100 that are available to cut throughout t
56. pressure Verify there are no restrictions in the supply gas hose Contact KALIBURN technical support Check torch connections and consumables Check work ground for proper Transformer over temperature e Heatsink over temperature N e wo e Low gas pressure 4 e Over Current output oa e Pilot arc not established 6 e Transferred arc not installation established e Check for adequate gas flow e Check consumables e Check operating conditions current 7 e Output voltage below 30V Pucca e Contact KALIBURN technical support e Verify Input voltage g A Voltage Hover pt e Contact KALIBURN technical support e Torch retract before downslope completed 9 e Loss of transferred arc heck work grounddead e Check operating conditions e Check consumables 10 e Exceeded Pilot Arc duty e du le section on expanded e Exceeded Max Cut Voltage 11 During the cut the arc voltage Inclease react delay exceeded 220V e Verify not running off the plate during cut The fault LED is illuminated with no blinks This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 5 3 Maintenance and Troubleshooting Dagger 100 User s Manual Rev E The following chart lists gen
57. produces sparks that could cause a fire if they fall on flammable materials Make sure that all flammable materials are 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 Dagger system uses compressed gases Use proper techniques when handling compressed gas cylinders and other compressed gas equipment Observe the following guidelines to protect against explosion e Never operate the Dagger system in the presence of explosive gases or other explosive materials e Never cut pressurized cylinders or any closed container e When using a water table and cutting aluminum under water or with water touching the underside of the aluminum plate hydrogen gas is produced This hydrogen gas may collect under the plate and explode during the cutting process Make sure the water table is properly aerated to help prevent the accumulation of hydrogen gas e Handle all gas cylinders in accordance with safety standards published by the U S Compressed Gas Association CGA American Welding Society AWS Canadian Standards Association CSA or other local or national codes e Compressed gas cylinders should be maintained properly Never attempt to use a cylinder
58. r item should consult a doctor before operating observing maintaining or servicing the system Observe the following guidelines to minimize exposure to these electric and magnetic fields Stay as far away from the Dagger power supply torch and torch leads 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 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 4 Safety Dagger100 User s Manual Rev E Safety Standards Booklet Index For further information concerning safety practices to be exercised with plasma arc cutting equipment please refer to the following publications T 10 11 12 AWS Standard AWN Arc Welding and Cutting Noise obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 AWS Standard C5 2 Recommended Practices for Plasma Arc Cutting obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 AWS Standard FSW Fire Safety in Welding and Cutting obtainable from the American Weldin
59. rrect consumables are installed in the torch or the consumables are worn This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 9 Operation Dagger100 User s Manual Rev E Inspection of Consumable Parts When the cut quality is not satisfactory use the following guidelines for determining which consumable parts need to be changed Inspect all parts for dirt debris and excess o ring lubricant and clean as necessary Part Inspect For Corrective Action Shield Cap Center hole out of round Replace shield cap Dents Scratches Replace shield cap Center hole out of round Replace retaining cap Dents cracks Replace retaining cap Nozzle 6 b Center hole out of round Replace nozzle J Erosion or arcing Replace nozzle Swirl Ring Damage Replace swirl ring Clogged holes Blow out with compressed air Replace swirl ring if clogs can t be removed Electrode l Pit depth Replace electrode if center pit depth is Lp greater than 040 1 mm Erosion or arcing Replace electrode This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United S
60. tates contrary to the requirements of the EAR 4 10 Operation Dagger100 User s Manual Rev E Cutting Charts The cutting charts shown on the following pages are intended to give the operator the best starting point to use when making a cut on a particular material type and thickness Small adjustments may have to be made to achieve the best cut Also remember that the arc voltage must be increased as the electrode wears in order to maintain the correct cutting height Cutting Chart Index Current Page 40Amps 4 12 60 Amps 4 13 80 Amps 4 14 100 Amps 4 15 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 4 11 Operation Dagger100 User s Manual Rev E 40 Amp mechanized shielded consumables Shield Cap 980572 Nozzle 980512 Electrode 980520 Retaining Swirl Ring Mechanized Torch Main Body Cap 980551 980531 980100 Mild Steel Material Arc Arc Optimum Travel Maximum Travel Cutting
61. tened when the plasma cutting equipment is in operation The plasma cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Plasma Cutting Cables The plasma cutting cables should be kept as short as possible and should be positioned close together running at or close to the floor level This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR A 2 Electromagnetic Compatibility EMC Dagger100 User s Manual Rev E Equipotential Bonding Bonding of all metallic components in the plasma cutting installation and adjacent to it should be considered However metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection
62. tion point 2 located on the front of the power supply The component s alignment points are designed to insure proper connection See figure below we c wv cre LL ER CES LL EACE I RR O TA NS E ES 6 EN LJ ZQ aN NES EN URN Fo us SS y This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 5 Installation Dagger100 User s Manual Rev E x ALIGNMENT POINTS 3 Slide the nut over the threaded portion of the connection and tighten Be sure to tighten the assembly firmly in order to ensure a good electrical connection and to seal the gas line This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 6 Installation Dagger100 User s Manual Rev E Work Ground Lead 1 Route one end of the 6 AWG work ground lead 3 through the strain relief 4 on the front of the power supply WM A Fa o WO Oe 2 Connect the 6 AWG work ground lead to the work ground conne
63. tration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 5 Specifications Dagger100 User s Manual Rev E BLANK This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 6 Installation Dagger100 User s Manual Rev E 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 Dagger 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 Dagger100 power supply should be lifted by two people or a hoist In order to prevent damaging the power supply the power supply should be lifted with both handles while keeping the unit as horizontal as possible Only hoisting straps approved for the weight of the power supply sho
64. ty Dry oil free air cleaned to ISO standard 8573 1 Class 1 4 1 Flow Rate 460 scfh 13025 75liters hour Inlet Pressure 90 psig 6 2 bar E5 Gz A i Dagger1 Go On i 18 88 Ses Sy ES 479 43 0x Uc AR Y 9 9 9 12 50 f 23 12 317 50 587 24 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 2 3 Specifications Dagger100 User s Manual Rev E Mechanized Torch Specifications Stock Number 25 ft 7 5m lead 980290 25 35 ft 10 7m lead 980290 35 50 ft 15 2m lead 980290 50 Weight 25 ft 7 5m lead 8 Ib 3 6 kg 35 ft 10 7m lead 11 3 Ib 5 1kg 50 ft 15 2m lead 15 Ib 6 8 kg The Dagger100 mechanized torch and lead assembly complies with the requirements of IEC60974 7 13 30 337 73 i 1 13 1 28 58 1 07 27 19 This in
65. uld be used 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 10 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 surface on which the power supply is located should have a grade of no greater than 15 to eliminate the risk of toppling over The power supply must be cleaned as often as necessary to prevent the accumulation of metallic dust inside the unit See Section 2 for power supply dimensions Mechanized Torch Installation It is recommended that the Dagger100 mechanized torch be installed on a positioner with an arc voltage control capable of maintaining the cutting arc voltage within 1 volt The positioner must be rigid to ensure cut quality and a torch collision sensor is highly recommended See Section 2 for the mechanized torch mounting dimensions This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 3 1 Installation Dagger100 User s Manual Rev E Voltage Divider Board Installation Optional An optional voltage divider board is required to use
66. yer 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 For shipments inside the U S parts must be returned to KALIBURN within 30 days of the invoice date to be considered for credit For shipments outside the U S parts must be returned within 60 days of the invoice date to be considered for credit This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided to non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR Dagger100 User s Manual Rev E Table of Cont

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