Kaliburn ProLine 2200 User Manual
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Kaliburn ProLine 2200 User Manual

Precision plasma cutting system
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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.
ProLine 2200 Precision Plasma Cutting System
Manual Part Number 718063
Revision N
10/15/2012
R
EVISION
N

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  • Page 1 ProLine 2200 Precision Plasma Cutting System Revision N 10/15/2012 Manual Part Number 718063 EVISION 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...

  • Page 2: Revision History

    ProLine 2200 User’s Manual REV N Revision History ECO# Author Date Description of Change As released • Section 4 • Section 6 • Schematic update • Section 4 • Section 6 • Section 2 • Section 4 03/30/04 • Section 6 •...
  • Page 3 ProLine 2200 User’s Manual REV N • Section 4 • Section 4 • Section 4 • Section 6 • Changed coolant level switch location • Removed PAR, changed CR3 • Section 4 • Added PAR relay in series with surge injection circuit to schematic and parts list •...

  • Page 4: Limited Warranty

    (1) year for the ProLine 2200 torch and leads and three (3) years for the ProLine 2200 power supply and gas console. This product is intended for commercial use and is not intended for personal, family, or household purposes.

  • Page 5: Table Of Contents

    ProLine 2200 User’s Manual REV N TABLE OF CONTENTS Section 1 Safety ..……………………………………..……………………………. 1-1 General Precautions .…………………………………………………..……….…..……… 1-1 Ultraviolet Radiation Protection ..…………………………………………………………. 1-1 Noise Protection .……………………………………………………..……………………. 1-1 Toxic Fume Prevention ...…………………………………………………………..……… 1-1 Electric Shock Prevention ...……………………………………………………….….…… 1-2 Fire Prevention ...…………………….………………………………….…………………. 1-3 Explosion Prevention ..…….….………….…………………………………..…………..
  • Page 6 ProLine 2200 User’s Manual REV N Section 4 Operation ……………………………………………………………… 4-1 Power Supply Front Panel Controls ..……………………………………………………… 4-1 Optional Hydrogen Manifold Controls …………………………………………………… 4-3 Setting up a Cut ..……………………………………………………………………… 4-4 Gas Purge…....…………………………………………………………………… 4-5 Making a Cut ....……………………………………………………………………4-6 Consumable Life ..……………………………………………………………………… 4-6 Cut Quality ....………………………………………………………………………...
  • Page 7 ProLine 2200 User’s Manual REV N Hydrogen Manifold Assembly (Optional) ................6-33 Hydrogen Manifold Interface Cable (Optional) ..............6-34 Consumable Spare Parts Kit ....................6-35 Appendix A Electromagnetic Compatibility (EMC) Background ........................... A-1 Installation and Use .......................A-1 Assessment of Area .......................A-2 Methods of Reducing Emissions ..................
  • Page 8 ProLine 2200 User’s Manual REV N Figure 6-16 Torch Consumables - Aluminum Cutting, Copper Electrode......6-19 Figure 6-17 Torch Consumables - Aluminum Cutting, Silver Electrode......6-20 Figure 6-18 Torch Consumables – Marking, Copper Electrode ........6-21 Figure 6-19 Gas Console - Exterior .................. 6-24 Figure 6-20 Gas Console - Interior ...................

  • Page 9: Section 1 Safety

    Installation, as well as repairs, made to the ProLine 2200 system should only be performed by qualified personnel. The ProLine system makes use of both A.C. and D.C.

  • Page 10: Electric Shock Prevention

    ProLine 2200 User’s Manual REV N Electric Shock Prevention The ProLine 2200 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 ProLine system. Observe the following guidelines to protect against electric shock: •...

  • Page 11: Fire Prevention

    ProLine 2200 User’s Manual REV N Fire Prevention When using the ProLine 2200 system, it is necessary to exercise good judgment. While cutting, the arc produces sparks that could cause a fire should they fall on flammable material. Make sure that all flammable material, such as paper, cloth, etc., is a suitable distance away from the cutting area.

  • Page 12: Health Support Equipment

    ProLine 2200 User’s Manual REV N Health Support Equipment The ProLine 2200 system creates electric and magnetic fields that may interfere with certain types of health support equipment, such as pacemakers. Any person who uses a pacemaker or similar item should consult a doctor before operating, observing, maintaining, or servicing the ProLine system.
  • Page 13 Safety ProLine 2200 User’s Manual REV N 10. ANSI Standard Z88.2, Respiratory Protection, obtainable from the American National Standards Institute, 11 West 42nd Street, New York, NY 10036. 11. OSHA Standard 29CFR 1910.252, Safety and Health Standards, obtainable from the U.S. Government Printing Office, Washington, D.C. 20402.
  • Page 14 Safety ProLine 2200 User’s Manual REV N BLANK PAGE 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.

  • Page 15: Section 2 Specifications System Description

    For excellent cut quality on mild steel, the ProLine 2200 uses oxygen for the plasma gas and either oxygen or air for the shielding gas. When cutting stainless steel or other non-ferrous materials, either air or H17 (17.5% hydrogen, 32.5% argon, 50% nitrogen) is used for the plasma...

  • Page 16: System Components

    ProLine 2200 User’s Manual REV N System Components The degree of protection provided by the ProLine 2200 system is IP21S and as such is intended only for indoor use. It is not suitable for use in rain or snow. The Proline 2200 system is tested in accordance with CISPR 11, EMC classification – Group 2 ISM (Class A).

  • Page 17: Figure 2-1 Power Supply Dimensions

    Specifications ProLine 2200 User’s Manual REV N Open Circuit Voltage ..........300 VDC Output Current (drooping characteristic)....8-200 amps Maximum Output Voltage ........190 VDC Duty Cycle ..............100% @ 32 kW Maximum Ambient Temperature ......104° F (40° C) Dimensions: Width ..............

  • Page 18: Gas Console Specifications

    Specifications ProLine 2200 User’s Manual REV N Gas Console Specifications Stock Number (without Inova height control) ...... 277080 Stock Number (with imperial Inova height control) ..... 277085 Stock Number (with metric Inova height control) ....277090 Height ..................9 in (229 mm) Width ..................25 in (635 mm)

  • Page 19: Remote High Frequency Console Specifications

    Specifications ProLine 2200 User’s Manual REV N Remote High Frequency Console Specifications Stock Number ............205500 Height ................ 5.35 in (136 mm) Width ................ 13.5 in (343 mm) Depth ................. 10 in (25 mm) Weight ............... 22 lb (10 kg) Spark gap distance ............

  • Page 20: Torch Specifications

    Specifications ProLine 2200 User’s Manual REV N Torch Specifications Stock Number: Torch Handle............820134 Torch Base ............279050 Torch Head (Copper Electrode)......279150 Torch Head (Silver Electrode)......279160 Weight: Valves, Handle, Base and Head......6.2 lb (2.8 kg) Valves 3.40 [86] Torch Handle 9.20 [234]...

  • Page 21: Remote On/Off Control Specifications (Optional)

    Specifications ProLine 2200 User’s Manual REV N Remote On/Off Control Specifications (Optional) Stock Number ............277079 Height ................ 2.0 in (51 mm) Width ................ 5.455 in (139 mm) Depth ................. 4.4 in (112 mm) Weight ............... 1.5 lb (.7 kg) ...

  • Page 22: Hydrogen Manifold Specifications (Optional)

    Specifications ProLine 2200 User’s Manual REV N Hydrogen Manifold Specifications (Optional) Stock Number ............277098 Height ................ 6.15 in (156 mm) Width ................ 7.11 (181 mm) Depth ................. 6.25 in (159 mm) Weight ............... 6.0 lb (2.7 kg) Figure 2-5 Hydrogen Manifold Dimensions (Optional) This information is subject to the controls of the Export Administration Regulations [EAR].

  • Page 23: Airborne Noise Emissions

    Proper ear protection should be used as defined by local or national codes. The following chart gives the noise levels generated by the ProLine 2200 when operating at 200 amps, 135 arc volts. The measurements were made with a sound level meter.
  • Page 24 Specifications ProLine 2200 User’s Manual REV N BLANK PAGE 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.

  • Page 25: Section 3 Installation Initial Inspection

    KALIBURN so a replacement item can be sent to you. Also, KALIBURN has taken special care in packaging your ProLine 2200 system. If your system was damaged during shipment, you will have to file a claim with the shipping company.

  • Page 26: Figure 3-1 System Interconnection Diagram

    Installation ProLine 2200 User’s Manual REV N         Figure 3-1 System Interconnection Diagram This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to...

  • Page 27: Power Supply Installation

    See Figure 2-2 for RHF console mounting dimensions. Torch Installation The ProLine 2200 torch must be installed on the positioner of an arc voltage control capable of maintaining the cutting arc voltage within 1 arc volt. The arc voltage must be adjustable in 1 arc volt increments.

  • Page 28: Figure 3-2 Primary Power Connections

    Installation ProLine 2200 User’s Manual REV N 3 Phase Input Current Recommended Input Voltage at Maximum Output Time-Delay Fuse Size (VAC) (amps) (amps) 208V 60Hz 230V 60Hz 380V 50/60Hz 415V 50/60Hz 460V 60Hz 575V 60Hz Use a Type SO power cable to connect the primary power to the ProLine power supply.

  • Page 29: Power Supply Output Connections

    Installation ProLine 2200 User’s Manual REV N Power Supply Output Connections Perform the following steps to connect the output of the power supply to the RHF console and the work table. See Figure 3-3 for additional information. Power Supply Electrode Lead...

  • Page 30: Rhf Console Ground Connection

    Installation ProLine 2200 User’s Manual REV N Work Ground Lead Route one end of the #1/0AWG Work Ground Lead through the middle strain relief on the rear of the power supply and connect it to the Work terminal. Connect the other end of the Work Ground Lead to the star ground point on the cutting table.

  • Page 31: Figure 3-3 Power Supply Output Connections

    Installation ProLine 2200 User’s Manual REV N            Figure 3-3 Power Supply Output Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to...

  • Page 32: Torch Leads To Rhf Console Connections

    Installation ProLine 2200 User’s Manual REV N Torch Leads to RHF Console Connections Perform the following steps to connect the torch leads to the RHF console. See Figure 3- 4 for additional information. Note: When making hose connections, only tighten the brass fittings enough to make water or gas seals.

  • Page 33: Figure 3-4 Torch Leads To Rhf Console Connections

    Installation ProLine 2200 User’s Manual REV N Figure 3-4 Torch Leads to RHF Console 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.

  • Page 34: Torch Connections

    Installation ProLine 2200 User’s Manual REV N Torch Connections Perform the following steps to connect the torch leads and gas hoses to the torch base and torch solenoid assembly. See Figure 3-5 for additional information. Note: When making hose connections, only tighten the brass fittings enough to make water or gas seals.
  • Page 35 Installation ProLine 2200 User’s Manual REV N Torch to Torch Handle Installation • Thread the torch handle onto the torch base. • Tighten the base to the handle using a pin style adjustable spanner wrench (fits 2" diameter with ¼" diameter pin).

  • Page 36: Figure 3-5 Torch Connections

    Installation ProLine 2200 User’s Manual REV N Figure 3-5 Torch 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.

  • Page 37: Torch Head Connection

    Installation ProLine 2200 User’s Manual REV N Torch Head Connection Perform the following steps to connect the torch head to the torch base. 1. Each time the torch head is connected to the torch base, use a cotton swab to apply a small amount of o-ring lubricant on each of the seven o-rings on the top of the torch head.

  • Page 38: Gas Console Input Connections

    Installation ProLine 2200 User’s Manual REV N Gas Console Input Connections Perform the following steps to connect the gas supply lines to the automatic gas console. See Section 2 for gas supply requirements. Mating hose barbs and connectors are supplied with the system and are sized for 1/4 inch inside diameter hose. Do not change the inlet gas supply fittings to quick-connect fittings.

  • Page 39: Gas Console Output Connections

    Installation ProLine 2200 User’s Manual REV N Gas Console Output Connections Perform the following steps to connect the automatic gas console outputs to the torch gas hoses. Note: When making hose connections, only tighten the brass fittings enough to make gas seals. The fittings are subject to damage if over tightened.

  • Page 40: Cnc Machine Interface Connections

    See the system schematic for additional information. Plasma Start Signal • The ProLine 2200 requires a contact closure between P8 pins 3 and 4 to commence the cutting sequence. The cutting sequence is terminated when the contacts are opened.

  • Page 41: Torch Coolant Requirements

    The ProLine 2200 system is shipped without torch coolant in the reservoir. Coolant must be added before applying power to the system. Only use Kaliburn approved torch coolant solution for optimal system performance as commercially available antifreeze contains corrosion inhibitors that will damage the cooling system.

  • Page 42: Initial Filling Of The Torch Coolant Reservoir

    Installation ProLine 2200 User’s Manual REV N Initial Filling of the Torch Coolant Reservoir Note: Never turn on the power supply before filling the torch coolant reservoir with the proper coolant solution. When handling coolant, it is recommended that you wear nitrile gloves and safety glasses.

  • Page 43: Optional Remote On/Off Control Installation

    Hydrogen Manifold Interface Cable between the plug on the rear of the hydrogen manifold and the plug labeled Hydrogen Manifold on the rear of the ProLine 2200 gas console. Note that the cable has a key installed on the end that plugs into the gas console.
  • Page 44 Installation ProLine 2200 User’s Manual REV N BLANK PAGE 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.

  • Page 45: Section 4 Operation

    Operation ProLine 2200 User’s Manual REV N Section 4 Operation Power Supply Front Panel Controls All of the ProLine controls and status indicator lights are located on the front panel of the system. This section describes the function of each control and indicator.
  • Page 46 Operation ProLine 2200 User’s Manual REV N Current Thumbwheel Used to set the output current of the ProLine 2200. The output current can be set to 10, 30, 50, 70, 100, 150, and 200 amps. Status Indicators • RHF Door Indicator Illuminates when the RHF console door is closed securely.

  • Page 47: Optional Hydrogen Manifold Controls

    (17.5% hydrogen / 32.5% argon / 50% nitrogen) must be connected to the Hydrogen In port and the Plasma Out hose must be connected to the Hydrogen Out port. H17 must not be routed through the ProLine 2200 gas console. Figure 4-2 Hydrogen Manifold Controls (Optional) Inlet Pressure Gauge Displays the H17 incoming supply pressure.

  • Page 48: Setting Up A Cut

    2200 gas console to the Hydrogen Out port on the H17 manifold. Do not route H17 through the ProLine 2200 gas console. NOTE: Always turn the system off prior to changing gases. 15. Depress and hold the Power On button until the Coolant Flow status LED illuminates.

  • Page 49: Gas Purge

    Operation ProLine 2200 User’s Manual REV N 16. Set the Gas Test/Run switch to the Test Preflow position. Adjust both the preflow and shield outlet pressures to their correct values as indicated in the cutting chart. Note that final shield outlet pressure adjustment will be performed in the next step.

  • Page 50: Making A Cut

    Operation ProLine 2200 User’s Manual REV N Making a Cut Once the unit has been properly set up and the x/y machine and height control systems have been properly configured, perform the following steps to cut with the system: 1. Use the x/y machine control to apply a start signal to the system. Upon the reception of a cycle start signal, the following sequence will take place: •...

  • Page 51: Cut Quality

    Operation ProLine 2200 User’s Manual REV N 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 ProLine 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.
  • Page 52 Operation ProLine 2200 User’s Manual REV N 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.
  • Page 53 Operation ProLine 2200 User’s Manual REV N Mild Steel - 30 Amps – Oxygen Plasma / Oxygen Shield Copper Electrode Shield Cap Nozzle Electrode 277145 277120 277130 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277140 279150 Imperial...
  • Page 54 Operation ProLine 2200 User’s Manual REV N Mild Steel - 50 Amps – Oxygen Plasma / Oxygen or Air Shield Copper Electrode Shield Cap Nozzle Electrode 277115 277122 277131 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277140 / 277142...
  • Page 55 Operation ProLine 2200 User’s Manual REV N Mild Steel - 70 Amps – Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode 277150 277125 277131 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277142 279150 Imperial...
  • Page 56 Operation ProLine 2200 User’s Manual REV N Mild Steel - 100 Amps – Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode 277286 277284 277282 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277151 277283 279150 Imperial...
  • Page 57 Operation ProLine 2200 User’s Manual REV N Mild Steel - 150 Amps – Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode 277117 277293 277292 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277151 / 277152 277139...
  • Page 58 Operation ProLine 2200 User’s Manual REV N Mild Steel - 200 Amps – Oxygen Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode 277274 277289 277291 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 277143 279150 Imperial...
  • Page 59 Operation ProLine 2200 User’s Manual REV N Stainless Steel - 30 Amps – Air Plasma / Air Shield Copper Electrode Shield Cap Nozzle Electrode 277144 277121 277137 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277110 277138 279150 Imperial...
  • Page 60 Operation ProLine 2200 User’s Manual REV N Stainless Steel - 50 Amps – Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277149 277123 277137 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277110 277142 279150 Imperial...
  • Page 61 Operation ProLine 2200 User’s Manual REV N Stainless Steel - 70 Amps – H17 Plasma / Nitrogen Shield Copper Electrode This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277150 277124 277132 Outer Cap...
  • Page 62 Operation ProLine 2200 User’s Manual REV N Stainless Steel - 70 Amps – Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277150 277125 277131 Outer Cap...
  • Page 63 Operation ProLine 2200 User’s Manual REV N Stainless Steel - 100 Amps – H17 Plasma / Nitrogen Shield Copper Electrode This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277146 277126 277133 Outer Cap...
  • Page 64 Operation ProLine 2200 User’s Manual REV N Stainless Steel - 100 Amps – Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277286 277284 277282 Outer Cap...
  • Page 65 Operation ProLine 2200 User’s Manual REV N Stainless Steel - 150 Amps – H17 Plasma / Nitrogen Shield Copper Electrode This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277298 277297 277135 Outer Cap...
  • Page 66 Operation ProLine 2200 User’s Manual REV N Stainless Steel - 150 Amps – Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277117 277293 277292 Outer Cap...
  • Page 67 Operation ProLine 2200 User’s Manual REV N Stainless Steel - 200 Amps – H17 Plasma / Nitrogen Shield Copper Electrode This gas combination gives the good cut quality and minimum dross levels Shield Cap Nozzle Electrode 277274 277287 277135 Outer Cap...
  • Page 68 Operation ProLine 2200 User’s Manual REV N Stainless Steel - 200 Amps – Air Plasma / Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277274 277289 277291 Outer Cap...
  • Page 69 Operation ProLine 2200 User’s Manual REV N Aluminum - 30 Amps – Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277145 277120 277130 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277140 279150 Imperial Material...
  • Page 70 Operation ProLine 2200 User’s Manual REV N Aluminum - 50 Amps – Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277150 277122 277131 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277142 279150 Imperial Material...
  • Page 71 Operation ProLine 2200 User’s Manual REV N Aluminum - 70 Amps – Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277150 277125 277131 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277142 279150 Imperial Material...
  • Page 72 Operation ProLine 2200 User’s Manual REV N Aluminum - 100 Amps – Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277286 277284 277282 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277151 277283 279150 Imperial Material...
  • Page 73 Operation ProLine 2200 User’s Manual REV N Aluminum - 150 Amps – Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277117 277293 277292 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277152 277139 279150 Imperial Material...
  • Page 74 Operation ProLine 2200 User’s Manual REV N Aluminum - 200 Amps – Air Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277274 277289 277291 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 277143 279150 Imperial Material...
  • Page 75 Operation ProLine 2200 User’s Manual REV N Mild Steel Marking - 10 Amps – Nitrogen Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277145 277120 277190 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277152 277140 279150...
  • Page 76 Operation ProLine 2200 User’s Manual REV N Stainless Steel Marking - 10 Amps – Nitrogen Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277145 277120 277190 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277152 277140 279150...
  • Page 77 Operation ProLine 2200 User’s Manual REV N Aluminum Marking - 10 Amps – Nitrogen Plasma / Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277145 277120 277190 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277152 277140 279150 Imperial...
  • Page 78 Operation ProLine 2200 User’s Manual REV N Mild Steel - 200 Amps – Oxygen Plasma / Air Shield Silver Electrode Shield Cap Nozzle Electrode 277274 279489 279440 (yellow o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 279443...
  • Page 79 Operation ProLine 2200 User’s Manual REV N Stainless Steel - 200 Amps – Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode 277274 279489 279440 (yellow o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 279443...
  • Page 80 Operation ProLine 2200 User’s Manual REV N Aluminum - 200 Amps – Air Plasma / Nitrogen Shield Silver Electrode Shield Cap Nozzle Electrode 277274 279489 279440 (yellow o-ring) Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277266 279443 279160...

  • Page 81: Section 5 Maintenance And Troubleshooting

    Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N Section 5 Maintenance and Troubleshooting WARNING: Only qualified maintenance personnel should perform maintenance on the ProLine system. The system utilizes potentially fatal A.C. and D.C. voltages. All maintenance should be performed with safety in mind.
  • Page 82 Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N Torch, Torch Leads, and Gas Hoses 1. Verify that all torch lead and gas hose connections are tight and that there are no gas or water leaks. Only tighten the fittings enough to make a water or gas seal. The fittings are subject to damage if over tightened.

  • Page 83: Replacing The Torch Coolant

    9. Reconnect the coolant hoses and replace the coolant and coolant filter/deionization cartridge. Only use Kaliburn approved torch coolant solution. Commercially available antifreeze contains corrosion inhibitors that will damage the cooling system. See Section 3 for more information on torch coolant requirements.

  • Page 84: 230/460V 60 Hz Transformer Configurations

    Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N 230/460V 60 Hz TRANSFORMER CONFIGURATIONS 230V 60 Hz and 460V 60 Hz power supplies are shipped with a dual voltage main transformer TR1. The primary taps on TR1 are labeled with their corresponding voltages.

  • Page 85: Figure 5-2 460V 60 Hz Transformer Configuration

    Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N 460V 60Hz Operation For 460V operation, install a #4 AWG jumper wire from 0V to 230V on each primary winding (total of 3 wires). Now install a #4 AWG jumper wires from 0V on the first primary winding to 0V on the second primary winding and another #4 AWG jumper wire from 0V on the second primary winding to 0V on the third primary winding.

  • Page 86: Microprocessor Status Led's

    Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N Microprocessor Status LED’s The microprocessor p.c. board controls all of the functions of the ProLine system. It has 31 LED’s which aid in troubleshooting the system. The LED’s illuminate when a particular event occurs. Illuminated LED’s indicate the following:...

  • Page 87: Microprocessor Sequence Of Operation

    Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N Microprocessor Sequence of Operation The following LED’s should illuminate after primary power is applied: • LED 16 5V uP PWR • LED 17 12V uP PWR • LED 18 ILK PWR •...

  • Page 88: Troubleshooting Using The Control Panel Status Led's

    Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N Troubleshooting Using the Control Panel Status LED’s If the ProLine system develops a problem, first check the control panel status LED’s. If one or more of the LED’s does not illuminate after the ON button is depressed, use the status LED’s to pinpoint the problem.

  • Page 89: Troubleshooting Using The Microprocessor Error Led

    Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N Troubleshooting Using the Microprocessor Error LED If all of the status LED’s are illuminated but the ProLine system still has a problem, remove the front panel of the power supply to gain access to the microprocessor control board.

  • Page 90: General Troubleshooting

    LED’s or the error LED do not give any insight to the particular problem being experienced. 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.
  • Page 91 Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N Problem Possible Cause 6. Damaged or loose torch lead connections. 7. Shorted torch or torch leads. Check the continuity between the Electrode lead and the Nozzle lead to make sure they are not shorted.

  • Page 92: Chopper Test Procedure

    Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N Chopper Test Procedure WARNING: Only qualified maintenance personnel should perform the chopper test procedure. The system utilizes potentially fatal A.C. and D.C. voltages. All maintenance should be performed with safety in mind Use extreme caution when working near the power conversion module (i.e., chopper).
  • Page 93 Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N If 300 VDC is not present at the output terminal block, leave the jumper wire installed between P28-7 & P28-8 (ILK1). Check the chopper status LED’s when a start signal is applied: a) LED’s 4 &...

  • Page 94: Figure 5-3 Chopper Diagnostics - Part 1

    Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N Figure 5-3 Chopper Diagnostics - Part 1 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.

  • Page 95: Figure 5-4 Chopper Diagnostics - Part 2

    Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N Figure 5-4 Chopper Diagnostics - Part 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.
  • Page 96 Maintenance and Troubleshooting ProLine 2200 User’s Manual REV N BLANK PAGE 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.

  • Page 97: Section 6 Parts List

    Parts List ProLine 2200 User’s Manual REV N Section 6 Parts List Power Supply Note: See Figures 6-1 to 6-4. Item Number Part Number Quantity Description 708088 Off switch, red 708111 Off actuator, red 708090 On switch, green 708089 On actuator, green / illuminated...
  • Page 98 Parts List ProLine 2200 User’s Manual REV N Item Number Part Number Quantity Description 708061 Solenoid valve, 220/240VAC 715084 Check valve, coolant return 708068 CON3 coolant pump relay 708059 FS1 coolant flow switch 500516 Fan, heat exchanger / front panel...

  • Page 99: Figure 6-1 Power Supply Front View

    Parts List ProLine 2200 User’s Manual REV N             Front panel fans not shown (item numbers 42 and 85) Figure 6-1 Power Supply Front View This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to...

  • Page 100: Figure 6-2 Power Supply Rear View

    Parts List ProLine 2200 User’s Manual REV N Figure 6-2 Power Supply Rear View 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.

  • Page 101: Figure 6-3 Power Supply Left Side View

    Parts List ProLine 2200 User’s Manual REV N     Figure 6-3 Power Supply Left Side View 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.

  • Page 102: Figure 6-4 Power Supply Right Side View

    Parts List ProLine 2200 User’s Manual REV N Figure 6-4 Power Supply Right Side View 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.

  • Page 103: Remote High Frequency Console

    Parts List ProLine 2200 User’s Manual REV N Remote High Frequency Console Note: See Figure 6-5. Item Number Part Number Quantity Description 715051 Coolant return fitting (left hand) 715050 Coolant supply fitting (right hand) 709227 Strain relief 709001 4 pin receptacle...

  • Page 104: Figure 6-5 Remote High Frequency Console

    Parts List ProLine 2200 User’s Manual REV N Figure 6-5 Remote High Frequency Console 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.

  • Page 105: Torch And Torch Valve Assembly

    Parts List ProLine 2200 User’s Manual REV N Torch and Torch Valve Assembly Item Number Part Number Quantity Description 277475 Torch valve assembly (includes bracket) 500549 Torch valve bracket 820134 Torch Handle 279050 Torch Base 279150 Torch Head (Copper Electrode)

  • Page 106: Shielded Torch Leads

    Parts List ProLine 2200 User’s Manual REV N Shielded Torch Leads Part Number Length 277304-10 10 ft. (3.0 m) 277304-15 15 ft. (4.6 m) 277304-20 20 ft. (6.1 m) 277304-25 25 ft. (7.6 m) 277304-30 30 ft. (9.1 m) 277304-35 35 ft.

  • Page 107: Gas Hose Package

    Parts List ProLine 2200 User’s Manual REV N Gas Hose Package Part Number Length 277317-20 20 ft. (6.1 m) 277317-25 25 ft. (7.6 m) 277317-30 30 ft. (9.1 m) 277317-35 35 ft. (10.7 m) 277317-40 40 ft. (12.2 m) 277317-45 45 ft.

  • Page 108: Coolant And Power Leads

    Parts List ProLine 2200 User’s Manual REV N Coolant and Power Leads Part Number Length 277306-5 5 ft. (1.5 m) 277306-10 10 ft. (3.0 m) 277306-15 15 ft. (4.6 m) 277306-20 20 ft. (6.1 m) 277306-25 25 ft. (7.6 m) 277306-30 30 ft.

  • Page 109: Work Ground Cable

    Parts List ProLine 2200 User’s Manual REV N Work Ground Cable Part Number Length 277318-10 10 ft. (3.0 m) 277318-15 15 ft. (4.6 m) 277318-20 20 ft. (6.1 m) 277318-25 25 ft. (7.6 m) 277318-30 30 ft. (9.1 m) 277318-35 35 ft.

  • Page 110: Torch Consumables - Mild Steel Cutting Copper Electrode

    Parts List ProLine 2200 User’s Manual REV N Torch Consumables - Mild Steel Cutting Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 277154 277145 277153 277120 277140 277130 279150 277140/ 277154 277115...

  • Page 111: Torch Consumables - Mild Steel Cutting Silver Electrode

    Parts List ProLine 2200 User’s Manual REV N Torch Consumables - Mild Steel Cutting Silver Electrode Outer Shield Inner Swirl Silver Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 279440 277154 277274 277266 279489 279443 279160 (yellow o-ring) 200A Figure 6-12 Torch Consumables - Mild Steel Cutting, Silver Electrode This information is subject to the controls of the Export Administration Regulations [EAR].

  • Page 112: Torch Consumables - Stainless Steel Cutting (Air), Copper Electrode

    Parts List ProLine 2200 User’s Manual REV N Torch Consumables - Stainless Steel Cutting (Air Plasma) Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 277154 277144 277110 277121 277138 277137 279150 277154...

  • Page 113: Torch Consumables - Stainless Steel Cutting (Air), Silver Electrode

    Parts List ProLine 2200 User’s Manual REV N Torch Consumables - Stainless Steel Cutting (Air Plasma) Silver Electrode Outer Shield Inner Swirl Silver Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 279440 277154 277274 277266 279489 279443 279160 (yellow o-ring)

  • Page 114: Torch Consumables - Stainless Steel Cutting (H17), Copper Electrode

    Parts List ProLine 2200 User’s Manual REV N Torch Consumables - Stainless Steel Cutting (H17 Plasma) Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 277154 277150 277113 277124 277140 277132 279150 277154...

  • Page 115: Torch Consumables - Aluminum Cutting Copper Electrode

    Parts List ProLine 2200 User’s Manual REV N Torch Consumables - Aluminum Cutting Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 277154 277145 277153 277120 277140 277130 279150 277154 277150 277153 277122...

  • Page 116: Torch Consumables - Aluminum Cutting Silver Electrode

    Parts List ProLine 2200 User’s Manual REV N Torch Consumables - Aluminum Cutting Silver Electrode Outer Shield Inner Swirl Silver Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 279440 277154 277274 277266 279489 279443 279160 (yellow o-ring) 200A Figure 6-17 Torch Consumables - Aluminum Cutting, Silver Electrode This information is subject to the controls of the Export Administration Regulations [EAR].

  • Page 117: Torch Consumables - Marking Copper Electrode

    Parts List ProLine 2200 User’s Manual REV N Torch Consumables – Marking Copper Electrode Outer Shield Inner Swirl Copper Torch Nozzle Retaining Cap Retaining Cap Ring Electrode Head 277154 277145 277152 277120 277140 277190 279150 Figure 6-18 Torch Consumables - Marking, Copper Electrode This information is subject to the controls of the Export Administration Regulations [EAR].

  • Page 118: Gas Console Without Integrated Inova

    Parts List ProLine 2200 User’s Manual REV N Gas Console Without Integrated Inova (Assembly 277080) Note: See Figures 6-16 and 6-17. Item Number Part Number Quantity Description 708076 Pressure gauge – 200 psi 708075 Pressure gauge – 100 psi 708113 Pressure gauge –...

  • Page 119: Gas Console With Integrated Inova

    Parts List ProLine 2200 User’s Manual REV N Gas Console With Integrated Inova (Imperial Assembly 277085 / Metric Assembly 277090) Note: See Figures 6-16 and 6-17. Item Number Part Number Quantity Description 708076 Pressure gauge – 200 psi 708075 Pressure gauge – 100 psi 708113 Pressure gauge –...

  • Page 120: Figure 6-19 Gas Console - Exterior

    Parts List ProLine 2200 User’s Manual REV N                  Figure 6-19 Gas Console - Exterior This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 121: Figure 6-20 Gas Console - Interior

    Parts List ProLine 2200 User’s Manual REV N Figure 6-20 Gas Console – Interior 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.

  • Page 122: Power Supply Microprocessor P.c. Board

    Parts List ProLine 2200 User’s Manual REV N Power Supply Microprocessor P.C. Board (Assembly 278450) Figure 6-21 Power Supply Microprocessor P.C. Board This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 123: A.c. Detect P.c. Board

    Parts List ProLine 2200 User’s Manual REV N A.C. Detect P.C. Board (Assembly 500810) Figure 6-22 A.C. Detect P.C. Board This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 124: Power Supply Relay P.c. Board

    Parts List ProLine 2200 User’s Manual REV N Power Supply Relay P.C. Board (Assembly 500348) Figure 6-23 Power Supply Relay P.C. Board This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 125: Power Supply I/O P.c. Board

    Parts List ProLine 2200 User’s Manual REV N Power Supply I/O P.C. Board (Assembly 277452) Figure 6-24 Power Supply I/O P.C. Board This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 126: Gas Console Relay P.c. Board

    Parts List ProLine 2200 User’s Manual REV N Gas Console Relay P.C. Board (Assembly 277060) Figure 6-25 Gas Console Relay P.C. Board This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 127: Remote On/Off Control Assembly (Optional)

    Parts List ProLine 2200 User’s Manual REV N Remote On/Off Control Assembly (Optional) Item Number Part Number Quantity Description 708087 Power Off actuator, red 708089 Power On actuator, green / illuminated 708090 Power On / Off switch, green 740106 Bulb, Power On switch...

  • Page 128: Remote On/Off Control Cable (Optional)

    Parts List ProLine 2200 User’s Manual REV N Remote On/Off Control Cable (Optional) Part Number Length 711800-10 10 ft. (3.0 m) 711800-15 15 ft. (4.6 m) 711800-20 20 ft. (6.1 m) 711800-25 25 ft. (7.6 m) 711800-30 30 ft. (9.1 m) 711800-35 35 ft.

  • Page 129: Hydrogen Manifold Assembly (Optional)

    Parts List ProLine 2200 User’s Manual REV N Hydrogen Manifold Assembly (Optional) Item Number Part Number Quantity Description 708076 Pressure gauge – 200 psi 500570 Pressure regulator – 125 psi 708113 Pressure gauge – 160 psi Not Shown 708097 Pressure switch, 80-200 psi...

  • Page 130: Hydrogen Manifold Interface Cable (Optional)

    Parts List ProLine 2200 User’s Manual REV N Hydrogen Manifold Interface Cable (Optional) Part Number Length 277089 1.5 ft. (0.5 m) Figure 6-29 Hydrogen Manifold Interface Cable (Optional) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 131: Consumable Spare Parts Kit

    Parts List ProLine 2200 User’s Manual REV N Consumable Spare Parts Kit (Part Number 282267) Part Number Quantity Description 277130 Electrode 30A Mild Steel - 30A Aluminum 277137 Electrode 30/50A Stainless (Air) 277131 Electrode 50/70A Mild Steel - 70A Stainless (Air) - 50/70A Aluminum...
  • Page 132 Parts List ProLine 2200 User’s Manual REV N Part Number Quantity Description 277287 Nozzle 200A Stainless (H17) 277145 Shield Cap 30A Mild Steel - 30A Aluminum 277144 Shield Cap 30A Stainless (Air) 277149 Shield Cap 50A Stainless (Air) 277115 Shield Cap...
  • Page 133 Parts List ProLine 2200 User’s Manual REV N Part Number Quantity Description 277151 Inner Retaining Cap 100A Mild Steel - 100A Stainless (Air) - 100A Aluminum 150A Mild Steel – 1/2” and below 277152 Inner Retaining Cap 150A Mild Steel – 5/8” and above – 150A Stainless (Air)
  • Page 134 Parts List ProLine 2200 User’s Manual REV N BLANK PAGE 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.

  • Page 135: Appendix A Electromagnetic Compatibility (Emc)

    Appendix A Electromagnetic Compatibility (EMC) Background The 380V 50/60Hz and 415V 50/60Hz CE marked ProLine 2200 plasma cutting systems are manufactured to comply with the European standard EN 60974-10 (Electromagnetic compatibility (EMC) – Product standard for arc welding equipment). The limits used in this standard are based on practical experience.

  • Page 136: Assessment Of Area

    Electromagnetic Compatibility (EMC) ProLine 2200 User’s Manual REV N 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,...
  • Page 137 Electromagnetic Compatibility (EMC) ProLine 2200 User’s Manual REV N 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. Equipotential Bonding Bonding of all metallic components in the plasma cutting installation and adjacent to it should be considered.
  • Page 138 Electromagnetic Compatibility (EMC) ProLine 2200 User’s Manual REV N BLANK PAGE 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.

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