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Kaliburn FineLine 200PC User Manual

High density plasma cutting system with automatic gas console
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FineLine 200PC User's Manual
FineLine 200PC High Density Plasma Cutting System
With Automatic Gas Console
Revision H
7/12/07
Manual Part Number 718059
455 Fleming Road
Charleston, SC 29412 USA
(800) 252-2850 – Toll Free
(843) 795-4286 – Phone
(843) 795-8931 – Fax
www.kaliburn.net

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  • Page 1 FineLine 200PC User’s Manual FineLine 200PC High Density Plasma Cutting System With Automatic Gas Console Revision H 7/12/07 Manual Part Number 718059 455 Fleming Road Charleston, SC 29412 USA (800) 252-2850 – Toll Free (843) 795-4286 – Phone (843) 795-8931 – Fax...
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  • Page 3: Limited Warranty

    (1) year for the FineLine 200PC torch and leads and three (3) years for the FineLine 200PC power supply and automatic gas console.
  • Page 4 FineLine 200PC User’s Manual Electromagnetic Compatibility (EMC) The 380V 50Hz and 415V 50Hz FineLine 200PC plasma cutting systems are manufactured to comply with the European standards EN 60974 (Arc welding equipment – Part 1: Welding power sources) and EN 50199 (Electromagnetic compatibility (EMC) –...

  • Page 5: Table Of Contents

    FineLine 200PC User’s Manual TABLE OF CONTENTS Section 1 Safety ..……………………………………..……………………………. 1-1 General Precautions .…………………………………………………..……….…..……… 1-1 Ultraviolet Radiation Protection ..…………………………………………………………. 1-1 Noise Protection .……………………………………………………..……………………. 1-1 Toxic Fume Prevention ...…………………………………………………………..……… 1-1 Electric Shock Prevention ...……………………………………………………….….…… 1-2 Fire Prevention ...…………………….………………………………….…………………. 1-3 Explosion Prevention ..…….….………….…………………………………..………….. 1-3 Health Support Equipment ...…………………….……………………………….………...
  • Page 6 FineLine 200PC User’s Manual Setting up a Cut ..……………………………………………………………………… 4-5 Making a Cut ....……………………………………………………………………4-11 Cut Quality ....……………………………………………………………………… 4-11 Consumable Life ..……………………………………………………………………… 4-12 Cutting Charts ...……………………………………………………………………… 4-13 Section 5 Automatic Gas Console Advanced Functions ....5-1 Altering the Current Set Point ....................5-1 Setting the Pierce Delay Time ....................
  • Page 7 FineLine 200PC User’s Manual Chopper Test Procedure ......................7-12 Section 8 Parts List ....................8-1 Power Supply ........................8-1 Remote High Frequency Console ..................8-7 Torch and Torch Valve Assembly ..................8-9 Shielded Torch Leads ......................8-10 Gas Hose Package ......................... 8-11 Coolant and Power Leads .....................
  • Page 8 FineLine 200PC User’s Manual Figure 2-3 Torch Dimensions ..................2-6 Figure 3-1 System Interconnection Diagram ..............3-2 Figure 3-2 Primary Power Connections ................. 3-4 Figure 3-3 Power Supply Output Connections ............... 3-7 Figure 3-4 Torch Leads to RHF Console Connections ..........3-9 Figure 3-5 Torch Connections ..................
  • Page 9 FineLine 200PC User’s Manual Figure 8-5 Remote High Frequency Console ..............8-8 Figure 8-6 Torch and Torch Valve Assembly ..............8-9 Figure 8-7 Shielded Torch Leads ................... 8-10 Figure 8-8 Gas Hose Package ..................8-11 Figure 8-9 Coolant and Power Leads ................8-12 Figure 8-10 Work Ground Cable ..................
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  • Page 11: Section 1 Safety

    Installation, as well as repairs, made to the FineLine 200PC system should only be performed by qualified personnel. The FineLine system makes use of both A.C.

  • Page 12: Electric Shock Prevention

    Electric Shock Prevention The FineLine 200PC 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 FineLine system. Observe the following guidelines to protect against electric shock: •...

  • Page 13: Fire Prevention

    Fire Prevention When using the FineLine 200PC 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 14: Health Support Equipment

    • Never use any gas hose that is leaking or has other signs of physical damage. Health Support Equipment The FineLine 200PC system creates electric and magnetic fields that may interfere with certain types of health support equipment, such as pacemakers.
  • Page 15 Safety FineLine 200PC User’s Manual 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.
  • Page 16 Safety FineLine 200PC User’s Manual 16. CGA booklet P-14, Accident Prevention in Oxygen-Rich and Oxygen- Deficient Atmospheres, obtainable from the Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202. 17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from the Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202.

  • Page 17: Section 2 Specifications

    For cutting mild steel, the FineLine 200PC uses oxygen for the plasma gas and either oxygen or air for the shielding gas. When cutting stainless steel or other non-ferrous materials, air or H17 (17.5% hydrogen, 32.5% argon, 50% nitrogen) is used for...

  • Page 18: System Components

    Specifications FineLine 200PC User’s Manual System Components The FineLine 200PC consists of the following components: Standard Components • Power Supply • Automatic Gas Console • Remote High Frequency (RHF) Console • RHF Console Control Cable • Torch and Handle Assembly •...

  • Page 19: Figure 2-1 Power Supply Dimensions

    Specifications FineLine 200PC User’s Manual Dimensions: Width ..............30 in (762 mm) Height (including AGC) ........48 in (1219 mm) Depth ..............43 in (1092 mm) Weight (including AGC) ........... 700 lb (317 kg) Torch Cooling System: Discharge pressure ..........150 psi (10.2 bar) Flow rate ..............

  • Page 20: Automatic Gas Console Specifications

    Specifications FineLine 200PC User’s Manual Automatic Gas Console Specifications Stock Number ............200865 Height ................ 9 in (229 mm) Width ................ 25 in (635 mm) Depth ................. 23.8 in (605 mm) Weight ............... 80 lb (36.2 kg) Gas Supply Requirements Plasma gas types: Mild Steel ............

  • Page 21: Remote High Frequency Console Specifications

    Specifications FineLine 200PC User’s Manual 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 ............ .025 in (.635 mm) Innerlogic, Inc.

  • Page 22: Torch Specifications

    Specifications FineLine 200PC User’s Manual Torch Specifications Stock Number: Torch main body ..........277000 Torch handle assembly ........820134 Diameter ..............2 in (50.8 mm) Length: Torch main body ..........4.65 in (118 mm) Torch main body / handle assembly ....13.85 in (352 mm) Weight (including handle and valves) ......

  • Page 23: Airborne Noise Emissions

    The following chart gives the noise levels generated by the FineLine 200PC when operating at 200 amps, 135 arc volts. The measurements were made with a sound level meter.
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  • Page 25: Section 3 Installation

    KALIBURN so a replacement item can be sent to you. Also, KALIBURN has taken special care in packaging your FineLine 200PC 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 FineLine 200PC User’s Manual Figure 3-1 System Interconnection Diagram...

  • Page 27: Power Supply Installation

    Torch Installation The FineLine 200PC 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. The positioner must be rigid to ensure cut quality and a torch collision sensor is highly recommended.

  • Page 28: Figure 3-2 Primary Power Connections

    Installation FineLine 200PC User’s Manual 3 Phase Input Current Recommended Input Voltage at Maximum Output Time-Delay Fuse Size (VAC) (amps) (amps) 208V 60Hz 230V 60Hz 380V 50Hz 415V 50Hz 460V 60Hz 575V 60Hz Use a Type SO power cable to connect the primary power to the FineLine power supply.

  • Page 29: Power Supply Output Connections

    Installation FineLine 200PC User’s Manual 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 1. Route one end of the #1/0AWG Power Supply Electrode Lead through the upper strain relief on the rear of the power supply and connect it to the Electrode terminal.

  • Page 30: Rhf Console Ground Connection

    Installation FineLine 200PC User’s Manual Power Supply Coolant Return Hose 1. Connect one end of the Power Supply Coolant Return Hose to the coolant return fitting on the rear of the power supply. Note that the coolant return fitting has left hand threads.

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

    Installation FineLine 200PC User’s Manual Figure 3-3 Power Supply Output Connections...

  • Page 32: Torch Leads To Rhf Console Connections

    Installation FineLine 200PC User’s Manual 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. The fittings are subject to damage if over tightened.

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

    Installation FineLine 200PC User’s Manual Figure 3-4 Torch Leads to RHF Console Connections...

  • Page 34: Torch Connections

    Installation FineLine 200PC User’s Manual Torch Connections Perform the following steps to connect the torch leads and gas hoses to the torch 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 FineLine 200PC User’s Manual Torch to Torch Handle Installation 1. Thread the torch handle onto the torch body. 2. Attach the solenoid valve assembly to the torch handle. The top of the aluminum solenoid bracket should be flush with the top of the torch handle.

  • Page 36: Figure 3-5 Torch Connections

    Installation FineLine 200PC User’s Manual Figure 3-5 Torch Connections 3-12...

  • Page 37: Automatic Gas Console Input Connections

    Installation FineLine 200PC User’s Manual Automatic 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.

  • Page 38: Automatic Gas Console Output Connections

    Installation FineLine 200PC User’s Manual Automatic 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 39: Cnc Machine Interface Connections

    CNC cutting machine. See the system schematic for additional information. Plasma Start Signal • The FineLine 200PC 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 40: Figure 3-8 Freezing Points Of Aqueous Propylene Glycol Solutions

    Installation FineLine 200PC User’s Manual This solution provides freezing protection down to -13º C (9º F). For operating temperatures below -13º C, the concentration of propylene glycol in the coolant solution must be increased. See Figure 3-8 to determine the percentage of propylene glycol required for the application.

  • Page 41: Filling The Torch Coolant Reservoir

    Installation FineLine 200PC User’s Manual Filling the Torch Coolant Reservoir Note: Never turn on the power supply before filling the torch coolant reservoir with the proper coolant solution. 1. Remove the coolant reservoir cap and fill the reservoir with 2 gallons of coolant solution.
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  • Page 43: Section 4 Operation

    Operation FineLine 200PC User’s Manual Section 4 Operation Power Supply Front Panel Controls All of the FineLine 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 44: Figure 4-1 Front Panel Controls

    Operation FineLine 200PC User’s Manual • Coolant Temperature Indicator Illuminates when the torch coolant temperature is satisfactory. Remains extinguished when the coolant temperature is too hot. If the torch coolant indicator goes out, leave the unit energized until it illuminates.

  • Page 45: Automatic Gas Console Keypad

    Operation FineLine 200PC User’s Manual Automatic Gas Console Keypad All cutting information is entered on the keypad of the automatic gas console as shown in Figure 4-2. This section provides a description of each key and its function. Figure 4-2 Automatic Gas Console Keypad Menu Key The Menu key is used to select the bottom portion of a split-level key.

  • Page 46: Automatic Gas Console Help Prompt

    Operation FineLine 200PC User’s Manual Arrow Keys The Arrow keys are used to scroll up and down in order to edit or select a particular item. Function Keys The Function keys are used for various purposes in the editing and maintenance modes.

  • Page 47: Automatic Gas Console Status Screen

    Operation FineLine 200PC User’s Manual Automatic Gas Console Status Screen When the automatic gas console is in the status mode, the status screen is displayed as shown in Figure 4-4. The status screen displays all of the primary cutting parameters. To edit a parameter on the status screen, the arrow keys can be used to scroll through the different parameters or the Menu key can be used as described previously.

  • Page 48: Figure 4-5 Selecting Material Substance

    Operation FineLine 200PC User’s Manual Selecting Material Type From the status mode, press the down arrow once to scroll down to substance, or press Menu, then Material. The substance area should be highlighted as shown in Figure 4-5 and the substance type should be blinking. To change the substance type, press F3 as indicated by the help prompt.

  • Page 49: Figure 4-6 Setting Material Thickness

    Operation FineLine 200PC User’s Manual Setting Material Thickness To set the material thickness, use the down arrow to scroll down to Thickness. The material thickness should be highlighted as shown in Figure 4-6 and the editing cursor should be blinking. Use the numerical keypad to enter the material thickness.

  • Page 50: Figure 4-7 Selecting Process

    Operation FineLine 200PC User’s Manual Selecting Process To set the operating process, use the down arrow to scroll down to Process. The process area should be highlighted as shown in Figure 4-7 and the process should be blinking. To change the process, press F3 as indicated by the help prompt.

  • Page 51: Figure 4-8 Torch Parts

    Operation FineLine 200PC User’s Manual Viewing the Torch Parts Required to Make the Cut Once the material substance, thickness, and process have been chosen, the default cutting parameters are selected and adjusted accordingly. To display a pictorial view of the torch parts required to make the cut, scroll down to Torch Parts and press enter.

  • Page 52: Figure 4-9 Voltage Screen

    Figure 4-9. The x/y machine speed should be set to the value shown. Also, the height control should be set to the proper pierce height, cutting height and arc voltage. If a KALIBURN Inova height control is being used, simply press the F3 key to automatically transmit the parameters to the Inova.

  • Page 53: Making A Cut

    Operation FineLine 200PC User’s Manual Making a Cut Once the material type, thickness, and process have been entered, the correct torch parts are installed, and the x/y machine and height control systems have been properly configured, perform the following steps to cut with the system: 1.

  • Page 54: Consumable Life

    Operation FineLine 200PC User’s Manual 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).

  • Page 55: Cutting Charts

    Operation FineLine 200PC User’s Manual 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 56 Operation FineLine 200PC User’s Manual Mild Steel - Cutting 30 Amps – Oxygen Plasma / Oxygen Shield Shield Cap Nozzle Electrode 277145 277120 277130 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277153 277140 277000 Imperial Material Preflow...
  • Page 57 Operation FineLine 200PC User’s Manual Mild Steel - Cutting 50 Amps – Oxygen Plasma / Oxygen or Air Shield Shield Cap Nozzle Electrode 277115 277122 277131 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277153 277140 / 277000...
  • Page 58 Operation FineLine 200PC User’s Manual Mild Steel - Cutting 70 Amps – Oxygen Plasma / Air Shield Shield Cap Nozzle Electrode 277150 277125 277131 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277153 277142 277000 Imperial Material Preflow...
  • Page 59 Operation FineLine 200PC User’s Manual Mild Steel - Cutting 100 Amps – Oxygen Plasma / Air Shield Shield Cap Nozzle Electrode 277286 277284 277282 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277151 277283 277000 Imperial Material Preflow...
  • Page 60 Operation FineLine 200PC User’s Manual Mild Steel - Cutting 150 Amps – Oxygen Plasma / Air Shield Shield Cap Nozzle Electrode 277117 277293 277292 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277151 / 277152 277139 277000 Imperial...
  • Page 61 Operation FineLine 200PC User’s Manual Mild Steel - Cutting 200 Amps – Oxygen Plasma / Air Shield Shield Cap Nozzle Electrode 277274 277289 277291 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277266 277143 277000 Imperial Material Preflow...
  • Page 62 Operation FineLine 200PC User’s Manual Stainless Steel - Cutting 30 Amps – Air Plasma / Air Shield Shield Cap Nozzle Electrode 277144 277121 277137 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277110 277138 277000 Imperial Material Preflow...
  • Page 63 Operation FineLine 200PC User’s Manual Stainless Steel - Cutting 50 Amps – Air Plasma / Nitrogen Shield Shield Cap Nozzle Electrode 277149 277123 277137 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277110 277142 277000 Imperial Material Preflow...
  • Page 64 Operation FineLine 200PC User’s Manual Stainless Steel - Cutting 70 Amps – H17 Plasma / Nitrogen Shield This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277150 277124 277132 Outer Cap Retaining Cap...
  • Page 65 Operation FineLine 200PC User’s Manual Stainless Steel - Cutting 70 Amps – Air Plasma / Nitrogen Shield This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277150 277125 277131 Outer Cap Retaining Cap Swirl Ring...
  • Page 66 Operation FineLine 200PC User’s Manual Stainless Steel - Cutting 100 Amps – H17 Plasma / Nitrogen Shield This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277146 277126 277133 Outer Cap Retaining Cap...
  • Page 67 Operation FineLine 200PC User’s Manual Stainless Steel - Cutting 100 Amps – Air Plasma / Nitrogen Shield This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277286 277284 277282 Outer Cap Retaining Cap Swirl Ring...
  • Page 68 Operation FineLine 200PC User’s Manual Stainless Steel - Cutting 150 Amps – H17 Plasma / Nitrogen Shield This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277298 277297 277135 Outer Cap Retaining Cap...
  • Page 69 Operation FineLine 200PC User’s Manual Stainless Steel - Cutting 150 Amps – Air Plasma / Nitrogen Shield This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277117 277293 277292 Outer Cap Retaining Cap Swirl Ring...
  • Page 70 Operation FineLine 200PC User’s Manual Stainless Steel - Cutting 200 Amps – H17 Plasma / Nitrogen Shield This gas combination gives the good cut quality and minimum dross levels Shield Cap Nozzle Electrode 277274 277287 277135 Outer Cap Retaining Cap...
  • Page 71 Operation FineLine 200PC User’s Manual Stainless Steel - Cutting 200 Amps – Air Plasma / Nitrogen Shield This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277274 277289 277291 Outer Cap Retaining Cap Swirl Ring...
  • Page 72 Operation FineLine 200PC User’s Manual Aluminum - Cutting 30 Amps – Air Plasma / Nitrogen Shield Shield Cap Nozzle Electrode 277145 277120 277130 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277153 277140 277000 Imperial Material Preflow Plasma...
  • Page 73 Operation FineLine 200PC User’s Manual Aluminum - Cutting 50 Amps – Air Plasma / Nitrogen Shield Shield Cap Nozzle Electrode 277150 277122 277131 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277153 277142 277000 Imperial Material Preflow Plasma...
  • Page 74 Operation FineLine 200PC User’s Manual Aluminum - Cutting 70 Amps – Air Plasma / Nitrogen Shield Shield Cap Nozzle Electrode 277150 277125 277131 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277153 277142 277000 Imperial Material Preflow Plasma...
  • Page 75 Operation FineLine 200PC User’s Manual Aluminum - Cutting 100 Amps – Air Plasma / Nitrogen Shield Shield Cap Nozzle Electrode 277286 277284 277282 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277151 277283 277000 Imperial Material Preflow Plasma...
  • Page 76 Operation FineLine 200PC User’s Manual Aluminum - Cutting 150 Amps – Air Plasma / Nitrogen Shield Shield Cap Nozzle Electrode 277117 277293 277292 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277152 277139 277000 Imperial Material Preflow Plasma...
  • Page 77 Operation FineLine 200PC User’s Manual Aluminum - Cutting 200 Amps – Air Plasma / Nitrogen Shield Shield Cap Nozzle Electrode 277274 277289 277291 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277266 277143 277000 Imperial Material Preflow Plasma...
  • Page 78 Operation FineLine 200PC User’s Manual Mild Steel - Marking 10 Amps – Nitrogen Plasma / Nitrogen Shield Shield Cap Nozzle Electrode 277145 277120 277190 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277152 277140 277000 Imperial Material Preflow...
  • Page 79 Operation FineLine 200PC User’s Manual Stainless Steel - Marking 8 Amps – Nitrogen Plasma / Nitrogen Shield Shield Cap Nozzle Electrode 277145 277120 277190 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277152 277140 277000 Imperial Material Preflow...
  • Page 80 Operation FineLine 200PC User’s Manual Aluminum - Marking 10 Amps – Nitrogen Plasma / Nitrogen Shield Shield Cap Nozzle Electrode 277145 277120 277190 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277152 277140 277000 Imperial Material Preflow Plasma...

  • Page 81: Section 5 Automatic Gas Console Advanced Functions

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Section 5 Automatic Gas Console Advanced Functions This section describes how to operate the FineLine unit when non-standard cutting conditions are desired. Instructions are also given on how to access the various maintenance modes of the system.

  • Page 82: Setting The Pierce Delay Time

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Setting the Pierce Delay Time After the FineLine cutting arc transfers to the workpiece, a motion signal (ok to move signal) is sent to the x/y controller or torch height control. The time delay between arc transfer and the motion signal output can be adjusted with the Pierce Delay Time parameter.

  • Page 83: Altering Gas Types

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Altering Gas Types Although the gas types should not normally be changed, the procedure is given here anyway. Note that the preflow gas cannot be changed. To alter the gas types used for a particular cut, use the arrows to scroll to the appropriate gas or press the Menu key then the Plasma Gas or Shielding Gas key.

  • Page 84: Altering Gas Pressures

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Altering Gas Pressures Normally, the preflow gas and plasma gas pressures should not be changed. The shield gas is normally adjusted in small increments to fine-tune a cut. To alter the gas pressures, use the arrow keys to scroll to the appropriate pressure setting.

  • Page 85: Altering Arc Voltage Control And X/Y Machine Parameters

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Altering Arc Voltage Control and X/Y Machine Parameters If the pierce height, cutting height, arc voltage, or x/y machine speed must be altered to achieve the desired cut quality, switch to the voltage screen, use the arrow keys to scroll to the desired parameter, and edit the parameter using the keypad.

  • Page 86: Saving A User Created Cutting Condition

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Saving a User Created Cutting Condition If one of the default cutting parameters must be altered to achieve good cut quality, the new cutting condition can be saved for later use. To save a user created cutting condition, use the arrow keys to scroll off all selections on the status screen.

  • Page 87: Maintenance Screen

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Maintenance Screen To display the maintenance screen, press the Menu key then the Maint key. The maintenance screen will be displayed as shown in Figure 5-7. From the maintenance screen, use the arrow keys to scroll up or down to highlight a selection and press the Ent key to enter the desired maintenance mode.

  • Page 88: Viewing Messages

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Viewing Messages To view status messages from the FineLine power supply and automatic gas console, scroll down to the View Messages selection on the maintenance screen and press ENT. The message screen will be displayed as shown in Figure 5-8.

  • Page 89: Viewing Cut Errors

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Viewing Cut Errors The FineLine has an error tracking system that keeps a record of certain cutting faults that occur during operation. These faults affect the consumable parts life and measures should be taken to prevent them from occurring. To view the cut errors, scroll down to the View Cut Errors selection on the maintenance screen and press ENT.

  • Page 90: Figure 5-10 Error Selection Screen

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Selecting an Error Set to View When the cut errors screen is being displayed, press F3 to view the actual cut errors. When F3 is pressed the error selection screen is displayed as shown in Figure 5-10.

  • Page 91: Figure 5-11 Actual Cut Errors Screen

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Viewing Actual Errors Once the error set is selected and the ENT key is pressed on the error selection screen, the actual cut errors will be displayed as shown in Figure 5-11.
  • Page 92 Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual • Transferred arc lost during downslope - This error occurs when the arc is lost after a stop signal is received but before the current downslope completes. It substantially shortens the electrode life and is typically due to an incorrect lead-out or when cutting a given material thickness with excessive current.

  • Page 93: Pressure Diagnostics

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Pressure Diagnostics To enter the pressure diagnostics mode, scroll down to the Pressure Diagnostics selection on the maintenance screen and press ENT. The pressure diagnostics screen will be displayed as shown in Figure 5-12. Pressing the Preflow Gas, Plasma Gas, and Shielding Gas buttons will toggle the corresponding valves between the off and on states.

  • Page 94: Setting The Default Delay Parameter

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Setting the Default Delay Parameter As previously mentioned, the pierce delay time is usually adjusted such that the cutting arc fully penetrates the workpiece before the motion output signal is generated. If the pierce delay time is set via the x/y machine controller, the Default Delay parameter on the FineLine must be disabled.

  • Page 95: Restoring Factory Default Cutting Conditions

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Restoring Factory Default Cutting Conditions To restore a factory default cutting condition, scroll down to the Restore Factory Defaults selection on the maintenance screen and press ENT. The restore screen will be displayed as shown in Figure 5-14. Note that the present material type and thickness selected on the status screen will be automatically displayed on the restore screen.

  • Page 96: Measurement System

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Measurement System The FineLine system will operate using Imperial units or Metric units. To change the units of operation, scroll down to the Measurement System selection on the maintenance screen and press ENT. The measurement system screen will be displayed as shown in Figure 5-15.

  • Page 97: Communication Node

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Communication Node When multiple FineLine systems are being used together on an RS-422 serial communication link, each system must have a unique identification number (node number) to identify itself to the network. To set the communication node number for the FineLine system, scroll down to the Set Communication Node selection on the maintenance screen and press ENT.

  • Page 98: Inova Parameter Transmit

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Inova Parameter Transmit If an Inova arc voltage control system is not being used with the FineLine system, the Inova Parameter Transmit feature must be disabled. With the Inova Parameter Transmit feature enabled, pressing F3 while the voltage screen is being displayed will automatically transmit the pierce height, cutting height, and arc voltage set points to the Inova arc voltage control.

  • Page 99: Viewing Serial Communication

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Viewing Serial Communications To view the serial communication between the FineLine and an external device, scroll down to the View Serial Communication selection on the Maintenance screen and press enter. The Serial Communication screen will be displayed as shown in Figure 5-18.

  • Page 100: Configuring The Optional Hydrogen Manifold

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Configuring the Optional Hydrogen Manifold When a hydrogen manifold is installed on the system, the hydrogen mixture will automatically be selected as the plasma gas for certain material types and thicknesses. To prevent the use of hydrogen, the hydrogen manifold must be disabled.

  • Page 101: Setting An Arc Off Delay

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Setting an Arc Off Delay In some instances, such as when cutting thicker stainless steel materials, it may be desirable to delay the extinction of the cutting arc after a stop signal is received.

  • Page 102: Software Updates

    Automatic Gas Console Advanced Functions FineLine 200PC User’s Manual Software Updates The Automatic Gas Console has a floppy disk drive that is used to update the software as new revisions are released. To access the floppy disk drive, remove the floppy disk drive cover on the rear panel of the console. The software update may either be installed on one floppy disk or two floppy disks.

  • Page 103: Section 6 Serial Communication

    Serial Communication FineLine 200PC User’s Manual Section 6 Serial Communication Initializing the FineLine System The FineLine system uses an RS-422 serial communication port located on the rear of the automatic gas console to receive and respond to commands that are transmitted from an x/y controller.

  • Page 104: Communication Error Checking

    Serial Communication FineLine 200PC User’s Manual To send a parameter, the parameter value needs to be sent as part of the command. For example, to send a desired pierce delay time of 1000 milliseconds to the system, look up the Set Pierce Delay command in the command table. You...

  • Page 105: Troubleshooting Serial Communication

    Serial Communication FineLine 200PC User’s Manual Troubleshooting Serial Communication When troubleshooting serial communication with the FineLine system, switch to the View Serial Communication Screen to view incoming and outgoing data. See Section 5 for information on the Serial Communication Screen.

  • Page 106: Rs-422 Serial Commands

    Serial Communication FineLine 200PC User’s Manual RS-422 Serial Commands Note: In the following commands, “nn” represents the net node of the power supply that is to receive the command. To send a global command to all power supplies in a network configuration, “nn” should be set to C8 hex (200 decimal).
  • Page 107 Serial Communication FineLine 200PC User’s Manual Command # Hex String Additional Information Torch Height 12 AA nn FA 0C -- -- 0D If requested in command #30, the AGC Control Pierce will transmit the recommended pierce Height height in mils (inches x 1000). Range: 0...
  • Page 108 Serial Communication FineLine 200PC User’s Manual Command # Hex String Additional Information Torch Shield Cap 26 AA nn FA 1A -- -- 0D If requested in command #30, the AGC Part Number (msw) will transmit the most significant word of the shield cap part number.
  • Page 109 Serial Communication FineLine 200PC User’s Manual Command # Hex String Additional Information Set Process 32 AA nn FA 20 00 -- 0D 00 = Cutting 01 = Marking Software Version 33 AA nn FA 21 00 -- 0D If requested in command #30, the AGC will transmit the software version x 10.
  • Page 110 Serial Communication FineLine 200PC User’s Manual Command # Hex String Additional Information Set Pierce Height 44 AA nn FA 2C -- -- 0D Pierce height in mils (inches / 1000) Valid Range: 0 to 999. Also updates the Inova height control, if used.

  • Page 111: Section 7 Maintenance And Troubleshooting

    Maintenance and Troubleshooting FineLine 200PC User’s Manual Section 7 Maintenance and Troubleshooting Warning: Only qualified maintenance personnel should perform maintenance on the FineLine system. The system utilizes potentially fatal A.C. and D.C. voltages. All maintenance should be performed with safety in mind. Be aware that the large blue electrolytic capacitors inside the power supply store large amounts of energy even after power has been removed from the system.
  • Page 112 Maintenance and Troubleshooting FineLine 200PC User’s Manual 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.

  • Page 113: Replacing The Torch Coolant

    Maintenance and Troubleshooting FineLine 200PC User’s Manual Replacing the Torch Coolant The torch coolant should be flushed out of the system every six months and replaced with new coolant. The following procedure should be used to prevent damage to the cooling system.

  • Page 114: 230/460V 60 Hz Transformer Configurations

    Maintenance and Troubleshooting FineLine 200PC User’s Manual 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 115: Figure 7-1 230V 60 Hz Transformer Configuration

    Maintenance and Troubleshooting FineLine 200PC User’s Manual Figure 7-1 230V 60 Hz Transformer Configuration Figure 7-2 460V 60 Hz Transformer Configuration...

  • Page 116: Microprocessor Status Led's

    Maintenance and Troubleshooting FineLine 200PC User’s Manual Microprocessor Status LED’s The microprocessor p.c. board controls all of the functions of the FineLine system. It has 31 LED’s which aid in troubleshooting the system. The LED’s illuminate when a particular event occurs.

  • Page 117: Microprocessor Sequence Of Operation

    Maintenance and Troubleshooting FineLine 200PC User’s Manual 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 • LED 19 ANALOG PWR •...

  • Page 118: Troubleshooting Using The Control Panel Status Led's

    Maintenance and Troubleshooting FineLine 200PC User’s Manual Troubleshooting Using the Control Panel Status LED’s If the FineLine 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 119: Troubleshooting Using The Automatic Gas Console Messages Screen

    Maintenance and Troubleshooting FineLine 200PC User’s Manual Troubleshooting Using the Automatic Gas Console Messages Screen If all of the status LED’s are illuminated but the FineLine system still has a problem, switch to the messages screen on the automatic gas console (see Section 5 for specific instructions on switching to the messages mode).

  • Page 120: General Troubleshooting

    LED’s or the automatic gas console messages screen 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. The primary system fuse F1 is located on the rear panel of the unit.
  • Page 121 Maintenance and Troubleshooting FineLine 200PC User’s Manual PAT is not closing properly. Check the relay for proper operation. Also, check the PAR and PAT LED’s on the microprocessor p.c. board and PAT drive p.c. board. 7. Damaged or loose torch lead connections.

  • Page 122: Chopper Test Procedure

    Maintenance and Troubleshooting FineLine 200PC User’s Manual Low pressure error 1. Supply gas pressure(s) less than 150 psi. 2. Faulty pressure switch or associated wiring inside gas console. Pressure error during cut 1. Supply gas pressure(s) fluctuating during cut. Chopper Test Procedure Warning: Only qualified maintenance personnel should perform the chopper test procedure.
  • Page 123 Maintenance and Troubleshooting FineLine 200PC User’s Manual With a start signal applied, check for 300 VDC at the FineLine output terminal block between Electrode and Work. If 300 V is present, the chopper is working properly. If 300 VDC is not present at the output terminal block, check the chopper status LED’s when a start signal is applied:...

  • Page 124: Figure 7-3 Chopper Diagnostics - Part 1

    Maintenance and Troubleshooting FineLine 200PC User’s Manual Figure 7-3 Chopper Diagnostics - Part 1 7-14...

  • Page 125: Figure 7-4 Chopper Diagnostics - Part 2

    Maintenance and Troubleshooting FineLine 200PC User’s Manual Figure 7-4 Chopper Diagnostics - Part 2 7-15...
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  • Page 127: Section 8 Parts List

    Parts List FineLine 200PC User’s Manual Section 8 Parts List Power Supply Note: See Figures 8-1 to 8-4. Item Number Part Number Quantity Description 708088 Off switch, red 708111 Off actuator, red 708090 On switch, green 708089 On actuator, green / illuminated...
  • Page 128 Parts List FineLine 200PC User’s Manual Item Number Part Number Quantity Description 500511 Coolant pump, 70 gph 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 129: Figure 8-1 Power Supply Front View

    Parts List FineLine 200PC User’s Manual Front panel fans not shown (item numbers 42 and 82) Figure 8-1 Power Supply Front View...

  • Page 130: Figure 8-2 Power Supply Rear View

    Parts List FineLine 200PC User’s Manual Figure 8-2 Power Supply Rear View...

  • Page 131: Figure 8-3 Power Supply Left Side View

    Parts List FineLine 200PC User’s Manual Figure 8-3 Power Supply Left Side View...

  • Page 132: Figure 8-4 Power Supply Right Side View

    Parts List FineLine 200PC User’s Manual Figure 8-4 Power Supply Right Side View...

  • Page 133: Remote High Frequency Console

    Parts List FineLine 200PC User’s Manual Remote High Frequency Console Note: See Figure 8-5. Item Number Part Number Quantity Description 715051 Coolant return fitting (left hand) 715050 Coolant supply fitting (right hand) 709227 Strain relief 710147 Lock nut 709001 4 pin receptacle...

  • Page 134: Figure 8-5 Remote High Frequency Console

    Parts List FineLine 200PC User’s Manual Figure 8-5 Remote High Frequency Console...

  • Page 135: Torch And Torch Valve Assembly

    Parts List FineLine 200PC User’s Manual Torch and Torch Valve Assembly Item Number Part Number Quantity Description 277475 Torch valve assembly (includes bracket) 500549 Torch valve bracket 820134 Torch handle 277000 Torch main body 500740 Torch solenoid plasma hose 820209...

  • Page 136: Shielded Torch Leads

    Parts List FineLine 200PC User’s Manual Shielded Torch Leads Part Number Length 200304-10 10 ft. (3.0 m) 200304-15 15 ft. (4.6 m) 200304-20 20 ft. (6.1 m) 200304-25 25 ft. (7.6 m) 200304-30 30 ft. (9.1 m) 200304-35 35 ft. (10.7 m) 200304-40 40 ft.

  • Page 137: Gas Hose Package

    Parts List FineLine 200PC User’s Manual Gas Hose Package Part Number Length 200317-20 20 ft. (6.1 m) 200317-25 25 ft. (7.6 m) 200317-30 30 ft. (9.1 m) 200317-35 35 ft. (10.7 m) 200317-40 40 ft. (12.2 m) 200317-45 45 ft. (13.7 m) 200317-50 50 ft.

  • Page 138: Coolant And Power Leads

    Parts List FineLine 200PC User’s Manual Coolant and Power Leads Part Number Length 200306-5 5 ft. (1.5 m) 200306-10 10 ft. (3.0 m) 200306-15 15 ft. (4.6 m) 200306-20 20 ft. (6.1 m) 200306-25 25 ft. (7.6 m) 200306-30 30 ft. (9.1 m) 200306-35 35 ft.

  • Page 139: Work Ground Cable

    Parts List FineLine 200PC User’s Manual Work Ground Cable Part Number Length 200318-10 10 ft. (3.0 m) 200318-15 15 ft. (4.6 m) 200318-20 20 ft. (6.1 m) 200318-25 25 ft. (7.6 m) 200318-30 30 ft. (9.1 m) 200318-35 35 ft. (10.7 m) 200318-40 40 ft.

  • Page 140: Torch Consumables - Mild Steel Cutting

    Parts List FineLine 200PC User’s Manual Torch Consumables - Mild Steel Cutting Outer Cap Shield Cap Retaining Cap Nozzle Swirl Ring Electrode Torch body 277154 277145 277153 277120 277140 277130 277000 277140/ 277154 277115 277153 277122 277142 277131 277000 277154...

  • Page 141: Torch Consumables - Stainless Steel Cutting (Air Plasma)

    Parts List FineLine 200PC User’s Manual Torch Consumables - Stainless Steel Cutting (Air Plasma) Outer Cap Shield Cap Retaining Cap Nozzle Swirl Ring Electrode Torch body 277154 277144 277110 277121 277138 277137 277000 277154 277149 277110 277123 277142 277137 277000...

  • Page 142: Torch Consumables - Stainless Steel Cutting (H17 Plasma)

    Parts List FineLine 200PC User’s Manual Torch Consumables - Stainless Steel Cutting (H17 Plasma) Outer Cap Shield Cap Retaining Cap Nozzle Swirl Ring Electrode Torch body 277154 277150 277113 277124 277140 277132 277000 277154 277146 277113 277126 277141 277133 277000...

  • Page 143: Torch Consumables - Aluminum Cutting

    Parts List FineLine 200PC User’s Manual Torch Consumables - Aluminum Cutting Outer Cap Shield Cap Retaining Cap Nozzle Swirl Ring Electrode Torch body 277154 277145 277153 277120 277140 277130 277000 277154 277150 277153 277122 277142 277131 277000 277154 277150 277153...

  • Page 144: Torch Consumables - Marking

    Parts List FineLine 200PC User’s Manual Torch Consumables - Marking Outer Cap Shield Cap Retaining Cap Nozzle Swirl Ring Electrode Torch body 277154 277145 277152 277120 277140 277190 277000 Figure 8-15 Torch Consumables - Marking 8-18...

  • Page 145: Automatic Gas Console

    Parts List FineLine 200PC User’s Manual Automatic Gas Console (Assembly 200865) Note: See Figures 8-16 and 8-17. Item Number Part Number Quantity Description 500032 AGC decal / membrane switch 501146 AGC aluminum display panel 500860 AGC display window 710199 Aluminum standoff...

  • Page 146: Figure 8-16 Gas Console - Exterior

    Parts List FineLine 200PC User’s Manual QUICK DATA Figure 8-16 Gas Console - Exterior 8-20...

  • Page 147: Figure 8-17 Gas Console - Interior

    Parts List FineLine 200PC User’s Manual Figure 8-17 Gas Console – Interior 8-21...

  • Page 148: Power Supply Microprocessor P.c. Board

    Parts List FineLine 200PC User’s Manual Power Supply Microprocessor P.C. Board (Assembly 200450) Figure 8-18 Power Supply Microprocessor P.C. Board 8-22...

  • Page 149: A.c. Detect P.c. Board

    Parts List FineLine 200PC User’s Manual A.C. Detect P.C. Board (Assembly 500810) Figure 8-19 A.C. Detect P.C. Board 8-23...

  • Page 150: Relay P.c. Board

    Parts List FineLine 200PC User’s Manual Relay P.C. Board (Assembly 500348) Figure 8-20 Relay P.C. Board 8-24...

  • Page 151: Power Supply I/O P.c. Board

    Parts List FineLine 200PC User’s Manual Power Supply I/O P.C. Board (Assembly 277452) Figure 8-21 Power Supply I/O P.C. Board 8-25...

  • Page 152: Automatic Gas Console I/O P.c. Board

    Parts List FineLine 200PC User’s Manual Automatic Gas Console I/O P.C. Board (Assembly 201080) Figure 8-22 Automatic Gas Console I/O P.C. Board 8-26...

  • Page 153: Automatic Gas Console Interface P.c. Board

    Parts List FineLine 200PC User’s Manual Automatic Gas Console Interface P.C. Board (Assembly 505600) Figure 8-23 Automatic Gas Console Interface P.C. Board 8-27...

  • Page 154: Consumable Spare Parts Kit

    Parts List FineLine 200PC User’s Manual 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 155 Parts List FineLine 200PC User’s Manual 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 50A Mild Steel...
  • Page 156 Parts List FineLine 200PC User’s Manual 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 157: Appendix A Propylene Glycol Msds

    Propylene Glycol MSDS FineLine 200PC User’s Manual Appendix A Propylene Glycol MSDS...
  • Page 158 Propylene Glycol MSDS FineLine 200PC User’s Manual...
  • Page 159 Propylene Glycol MSDS FineLine 200PC User’s Manual...
  • Page 160 Propylene Glycol MSDS FineLine 200PC User’s Manual...
  • Page 161 Propylene Glycol MSDS FineLine 200PC User’s Manual...
  • Page 162 Propylene Glycol MSDS FineLine 200PC User’s Manual...
  • Page 163 Propylene Glycol MSDS FineLine 200PC User’s Manual...
  • Page 164 Propylene Glycol MSDS FineLine 200PC User’s Manual...

  • Page 165: Appendix B Electromagnetic Compatibility (Emc

    Appendix B Electromagnetic Compatibility (EMC) Background The 380V 50Hz and 415V 50Hz FineLine 200PC plasma cutting systems are manufactured to comply with the European standard EN 50199 (Electromagnetic compatibility (EMC) – Product standard for arc welding equipment). The limits used in this standard are based on practical experience. However, the ability of...

  • Page 166: Assessment Of Area

    Electromagnetic Compatibility (EMC) FL-200PC User’s Manual 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;...
  • Page 167 Electromagnetic Compatibility (EMC) FL-200PC User’s Manual 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.
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  • Page 169: Appendix C Hydrogen Manifold (Optional

    Hydrogen Manifold (Optional) FineLine 200PC User’s Manual Appendix C Hydrogen Manifold (Optional) Description The hydrogen manifold can be used when cutting stainless steel at least 3/16” (4.75 mm) thick and a smooth, shiny cut surface finish is desired. When using the manifold, H17 (17.5% hydrogen / 32.5% argon / 50% nitrogen) must be...

  • Page 170: Installation

    The hydrogen manifold must be installed on the cooling system shelf of the FineLine 200PC power supply. The cooling system shelf is located at the rear of the unit as shown in Figure C-2. Use 1/4-20 bolts and 1/4” lock washers to secure the hydrogen manifold to the shelf.

  • Page 171: Figure C-2 Hydrogen Manifold Mounting Location

    Hydrogen Manifold (Optional) FineLine 200PC User’s Manual Figure C-2 Hydrogen Manifold Mounting Location...

  • Page 172: Operation

    Hydrogen Manifold (Optional) FineLine 200PC User’s Manual Operation The hydrogen manifold is fully integrated with the operating software of the FineLine automatic gas console. When an appropriate thickness stainless steel is selected, H17 will be selected for the plasma gas and nitrogen will be selected for the shield gas.

  • Page 173: Parts List

    Hydrogen Manifold (Optional) FineLine 200PC User’s Manual Parts List Item Number Part Number Quantity Description 709003 Receptacle, 9 position 709207 Receptacle, 7 position 706041 Transformer, 12V 704009 LED, panel mount 707006 Input power module 709033 Fuse, 1A 708076 Pressure gauge, 200 psi...

  • Page 174: Hydrogen Manifold Microprocessor P.c. Board

    Hydrogen Manifold (Optional) FineLine 200PC User’s Manual Hydrogen Manifold Microprocessor P.C. Board (Assembly 200285) Figure C-3 Hydrogen Manifold Microprocessor P.C. Board...

  • Page 175: Dip Switch Settings

    Hydrogen Manifold (Optional) FineLine 200PC User’s Manual Dip Switch Settings Dip Switch 1 (SW1): RS-422 Node Termination SW1-1 and SW1-2 should be switched on if the manifold is the last on a string of nodes. SW1-1 and SW1-2 should be switched off in all other manifolds on the network.

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