REVISION
ProLine 2200 Precision Plasma Cutting System
Revision N
10/15/2012
Manual Part Number 718063
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.
REVISION
N
ProLine 2200 User’s Manual REV N
Revision History
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Description of Change
As released
10/14/04
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Section 4
Section 6
Schematic update
Section 4
Section 6
Section 2
Section 4
Section 6
Section 3
Section 4
Section 6
Section 4
Section 6
Section 4
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Section 4
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Section 4
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Section 4
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Section 6
• Section 4
• Section 6
• Section 2
• Section 6
• Section 6
• Changed to 24VDC Condor power supply
for gas valves.
• Changed inductor/resistor CTP sensor lead
filter inside RHF box to the ferrite core
filter.
• Added 2nd control transformer fuse and
labeled the fuses F1A and F1B.
• Changed the 200A H17 swirl ring from
277143 to 277259.
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 User’s Manual REV N
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Section 4
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Section 4
Section 4
Section 6
Changed coolant level switch location
Removed PAR, changed CR3
Section 4
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Added PAR relay in series with surge
injection circuit to schematic and parts list
• Section 4
Contents
Section 2
Section 3
Section 4
Section 5
Appendix A
Appendix B - deleted
Section 1, added references to Section 5.
Section 5, added chopper warning.
Added Quick-Disconnect Torch information
throughout manual.
Section 5, defective flow switch (25 blinks).
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10/25/2010
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08/01/2012
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10/15/2012
This documentation may not be copied, photocopied, reproduced, translated, or reduced to
any electronic medium or machine-readable format without explicit written permission from
Kaliburn.
4130 Carolina Commerce Parkway
Ladson, SC 29456 USA
(843) 695-4000 - Phone
(843) 695-4001- Fax
www.kaliburn.net
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
ProLine 2200 User’s Manual REV N
Limited Warranty
KALIBURN expressly warrants that this product shall be free from defects in materials
and workmanship, under proper and normal use for the intended function of such
equipment, for a period of one (1) year for the 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. There
are no warranties that extend beyond the description on the face hereof. All other
warranties, either expressed or implied, including any implied warranty of
merchantability or fitness for any particular purpose, are expressly excluded.
If this product or any component thereof is determined to be defective in manufacture,
KALIBURN will repair or replace the defective component or product. The buyer’s
remedies are limited to the return of the product for repair or replacement of any nonconforming product or part at the sole discretion of KALIBURN. No freight charges of
any kind are covered under this warranty. All returned goods shall be at the buyer’s risk
and expense. Beyond this remedy, KALIBURN will not be responsible for any special,
incidental or consequential damages or injury to the person or property of anyone by
reason of any defect in any equipment sold hereunder.
This warranty will be considered void if torches or torch
consumables manufactured by anyone other than KALIBURN
are incorporated into this product.
Returned Goods Procedure
KALIBURN utilizes a returned goods procedure that must be followed before returning
any items for repair, replacement, or restocking. This means that a returned goods
authorization number must be obtained prior to shipment to KALIBURN. It will be
necessary for the customer to provide a description, along with the stock number and
serial number, if applicable, of the item to be returned. In no case will KALIBURN
accept a returned shipment without the proper returned goods authorization number.
Electromagnetic Compatibility (EMC)
The 380V 50/60Hz and 415V 50/60Hz CE marked ProLine 2200 plasma cutting systems
are manufactured to comply with the European standards EN 60974-10 (Electromagnetic
compatibility (EMC) – Product standard for arc welding equipment). Information about
the EMC standard EN 50199 can be found in Appendix A.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
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 .....…….….………….…………………………………..………….. 1-3
Health Support Equipment ...…………………….……………………………….………...1-4
Safety Standards Booklet Index ...…………………….……………………………….…... 1-4
Section 2 Specifications ...….……...……………………………………………… 2-1
System Description ...……………………………………………………………………… 2-1
System Components ………………………………………………………………………. 2-2
Power Supply Specifications ……………………………………………………………… 2-2
Gas Console Specifications ...................……………………………………………………2-4
Remote High Frequency Console Specifications …………………………………………. 2-5
Torch Specifications ...…………………………………………………………………….. 2-6
Remote On/Off Control Specifications (Optional) ..………………………………………. 2-7
Hydrogen Manifold Specifications (Optional) ........………………………………………. 2-8
Airborne Noise Emissions ......…………………………………………………………….. 2-9
Section 3 Installation .....………………………………………………………… 3-1
Initial Inspection .......……………………………………………………………………… 3-1
System Interconnection .……………………………………………………………………3-2
Power Supply Installation .………………………………………………………………… 3-3
Remote High Frequency Installation ……………………………………………………… 3-3
Torch Installation ......……………………………………………………………………… 3-3
Primary Power Connection ...……………………………………………………………… 3-3
Power Supply Output Connections .......…………………………………………………… 3-5
RHF Console Ground Connection ....……………………………………………………… 3-6
Torch Leads to RHF Console Connections ..……………………………………………… 3-8
Torch Connections ....……………………………………………………………………… 3-10
Torch Head Connection…………………………………………………………………… 3-13
Gas Console Input Connections ....................……………………………………………… 3-14
Gas Console Output Connections .........................………………………………………… 3-15
CNC Machine Interface Connections ...…………………………………………………… 3-16
Torch Coolant Requirements ....…………………………………………………………… 3-17
Initial Filling of the Torch Coolant Reservoir…………………………………………… 3-18
Optional Remote On/Off Control Installation ......………………………………………… 3-19
Optional Hydrogen Manifold Installation .............…………………………………………3-19
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 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 ................……………………………………………………………………… 4-7
Cutting Charts ...........……………………………………………………………………… 4-8
Section 5 Maintenance and Troubleshooting ......................................... 5-1
Routine Maintenance ............……........................................................................................ 5-1
Replacing the Torch Coolant ................................................................................................ 5-3
230/460V 60 Hz Transformer Configurations ...................................................................... 5-4
Microprocessor Status LED’s ............................................................................................... 5-6
Microprocessor Sequence of Operation ................................................................................ 5-7
Troubleshooting Using the Control Panel Status LED’s ...................................................... 5-8
Troubleshooting Using the Microprocessor Error LED ....................................................... 5-9
General Troubleshooting ...................................................................................................... 5-10
Chopper Test Procedure ........................................................................................................5-11
Section 6 Parts List ................................................................................................. 6-1
Power Supply ........................................................................................................................ 6-1
Remote High Frequency Console ......................................................................................... 6-7
Torch and Torch Valve Assembly ........................................................................................ 6-9
Shielded Torch Leads ........................................................................................................... 6-10
Gas Hose Package ................................................................................................................. 6-11
Coolant and Power Leads ..................................................................................................... 6-12
Work Ground Cable .............................................................................................................. 6-13
Torch Consumables - Mild Steel Cutting, Copper Electrode................................................ 6-14
Torch Consumables - Mild Steel Cutting, Silver Electrode................................................. 6-15
Torch Consumables - Stainless Steel Cutting (Air), Copper Electrode................................ 6-16
Torch Consumables - Stainless Steel Cutting (Air), Silver Electrode................................... 6-17
Torch Consumables - Stainless Steel Cutting (H17), Copper Electrode.............................. 6-18
Torch Consumables - Aluminum Cutting, Copper Electrode............................................... 6-19
Torch Consumables - Aluminum Cutting, Silver Electrode................................................ 6-20
Torch Consumables - Marking, Copper Electrode............................................................... 6-21
Gas Console Without Integrated Inova ................................................................................. 6-22
Gas Console With Integrated Inova ...................................................................................... 6-23
Power Supply Microprocessor P.C. Board ........................................................................... 6-26
A.C. Detect P.C. Board ......................................................................................................... 6-27
Power Supply Relay P.C. Board ........................................................................................... 6-28
Power Supply I/O P.C. Board ............................................................................................... 6-29
Gas Console Relay P.C. Board ............................................................................................. 6-30
Remote On/Off Control Assembly (Optional) ......................................................................6-31
Remote On/Off Control Cable (Optional) ............................................................................ 6-32
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 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 .......................................................................................... A-2
Illustrations
Figure 2-1
Figure 2-2
Figure 2-3
Figure 2-4
Figure 2-5
Figure 3-1
Figure 3-2
Figure 3-3
Figure 3-4
Figure 3-5
Figure 3-6
Figure 3-7
Figure 3-8
Figure 4-1
Figure 4-2
Figure 5-1
Figure 5-2
Figure 5-3
Figure 5-4
Figure 6-1
Figure 6-2
Figure 6-3
Figure 6-4
Figure 6-5
Figure 6-6
Figure 6-7
Figure 6-8
Figure 6-9
Figure 6-10
Figure 6-11
Figure 6-12
Figure 6-13
Figure 6-14
Figure 6-15
Power Supply Dimensions ............................................................................ 2-3
Remote High Frequency Console Mounting Dimensions ............................ 2-5
Torch Dimensions ......................................................................................... 2-6
Remote On/Off Control Dimensions (Optional) ...........................................2-7
Hydrogen Manifold Dimensions (Optional) ................................................. 2-8
System Interconnection Diagram ..................................................................3-1
Primary Power Connections ......................................................................... 3-3
Power Supply Output Connections ............................................................... 3-6
Torch Leads to RHF Console Connections .................................................. 3-8
Torch Connections ........................................................................................ 3-11
Gas Console Input Connections .................................................................... 3-12
Gas Console Output Connections ................................................................. 3-13
Freezing Points of Aqueous Propylene Glycol Solutions ............................. 3-15
Front Panel Controls ..................................................................................... 4-1
Hydrogen Manifold Controls (Optional) ...................................................... 4-3
230V 60 Hz Transformer Configuration .......................................................5-4
460V 60 Hz Transformer Configuration .......................................................5-5
Chopper Diagnostics - Part 1 ........................................................................ 5-13
Chopper Diagnostics - Part 2 ........................................................................ 5-14
Power Supply Front View ............................................................................. 6-3
Power Supply Rear View .............................................................................. 6-4
Power Supply Left Side View .......................................................................6-5
Power Supply Right Side View .................................................................... 6-6
Remote High Frequency Console ................................................................. 6-8
Torch and Torch Valve Assembly ................................................................ 6-9
Shielded Torch Leads ................................................................................... 6-10
Gas Hose Package ......................................................................................... 6-11
Coolant and Power Leads ............................................................................. 6-12
Work Ground Cable ...................................................................................... 6-13
Torch Consumables - Mild Steel Cutting, Copper Electrode....................... 6-14
Torch Consumables - Mild Steel Cutting, Silver Electrode......................... 6-15
Torch Consumables - Stainless Steel Cutting (Air), Copper Electrode........ 6-16
Torch Consumables - Stainless Steel Cutting (Air), Silver Electrode.......... 6-17
Torch Consumables - Stainless Steel Cutting (H17), Copper Electrode...... 6-18
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 User’s Manual REV N
Figure 6-16
Figure 6-17
Figure 6-18
Figure 6-19
Figure 6-20
Figure 6-21
Figure 6-22
Figure 6-23
Figure 6-24
Figure 6-25
Figure 6-26
Figure 6-27
Figure 6-28
Figure 6-29
Torch Consumables - Aluminum Cutting, Copper Electrode........................ 6-19
Torch Consumables - Aluminum Cutting, Silver Electrode......................... 6-20
Torch Consumables – Marking, Copper Electrode ...................................... 6-21
Gas Console - Exterior .................................................................................. 6-24
Gas Console - Interior ................................................................................... 6-25
Power Supply Microprocessor P.C. Board ................................................... 6-26
A.C. Detect P.C. Board ................................................................................. 6-27
Power Supply Relay P.C. Board ................................................................... 6-28
Power Supply I/O P.C. Board ....................................................................... 6-29
Gas Console Relay P.C. Board ..................................................................... 6-30
Remote On/Off Control Assembly (Optional) .............................................. 6-31
Remote On/Off Control Cable (Optional) .................................................... 6-32
Hydrogen Manifold Assembly (Optional) .................................................... 6-33
Hydrogen Manifold Interface Cable (Optional) ........................................... 6-34
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.
Safety
ProLine 2200 User’s Manual REV N
Section 1 Safety
General Precautions
Whereas plasma cutting has been used safely for years, it does require certain precautions
to ensure the safety of the operator and other people around the equipment. It is
management’s responsibility to see that the following safety information is provided to
each person who will operate, observe, perform maintenance, or work in close proximity
to this piece of equipment.
Installation, 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.
circuitry for operation. Fatal shock hazard does exist. Exercise extreme caution
while working on the system.
Ultraviolet Radiation Protection
Plasma cutting produces ultraviolet radiation similar to a welding arc. This ultraviolet
radiation can cause skin and eye burns. For this reason, it is essential that proper
protection be worn. The eyes are best protected by using safety glasses or a welding
helmet with an AWS No. 12 shade or ISO 4850 No. 13 shade, which provides protection
up to 400 amperes. All exposed skin areas should be covered with flame-retardant
clothing. The cutting area should also be prepared in such a way that ultraviolet light
does not reflect. Walls and other surfaces should be painted with dark colors to reduce
reflected light. Protective screens or curtains should be installed to protect additional
workers in the area from ultraviolet radiation.
Noise Protection
The ProLine 2200 system generates high noise levels while cutting. Depending on the
size of the cutting area, distance from the cutting torch, and arc current cutting level,
acceptable noise levels may be exceeded. Proper ear protection should be used as
defined by local or national codes. See Section 2 for noise emission levels.
Toxic Fume Prevention
Care should be taken to ensure adequate ventilation in the cutting area. Some materials
give off toxic fumes that can be harmful or fatal to people in the vicinity of the cutting
area. Also, some solvents decompose and form harmful gases when exposed to
ultraviolet radiation. These solvents should be removed from the area prior to cutting.
Galvanized metal can produce harmful gases during the cutting process. Ensure proper
ventilation and use breathing equipment when cutting these materials.
Certain metals coated with or containing lead, cadmium, zinc, beryllium, and mercury
produce harmful toxins. Do not cut these metals unless all people subjected to the fumes
wear proper air breathing equipment.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-1
Safety
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:
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A wall-mounted disconnect should be installed and fused according to local
and national electrical codes. The disconnect should be located as close as
possible to the power supply so it can be turned off in case of an emergency.
The primary power cord should have a 600 volt minimum rating in order to
protect the operator. In addition, it should be sized according to local and
national electrical codes. Inspect the primary power cord frequently. Never
operate the ProLine system if the power cord is damaged in any way.
Make sure the primary power ground wire is connected to the input power
ground stud on the ProLine power supply. Make sure the connection is
securely tightened.
Make sure the positive output (work ground) of the ProLine power supply is
connected to a bare metal area on the cutting table. A driven ground rod
should be placed no further than five feet from this connection. Make sure
this ground point on the cutting table is used as the star ground point for all
other ground connections.
Inspect the torch leads frequently. Never use the system if the leads are
damaged in any way.
Do not stand in wet, damp areas when operating or performing maintenance
on the system.
Wear insulated gloves and shoes while operating or performing maintenance
on the system.
Make sure the ProLine system is switched off at the wall disconnect before
servicing the power supply or torch.
Never change torch consumable parts unless the ProLine system is switched
off at the wall disconnect.
Do not attempt to remove any parts from beneath the torch when cutting.
Remember that the workpiece forms the current path back to the power
supply.
Never bypass the safety interlock devices.
Before removing any of the ProLine covers, switch the system off at the wall
disconnect. Wait at least five (5) minutes before removing any cover. This
will give the capacitors inside the unit time to discharge. See Section 5 for
additional safety precautions.
Never operate the ProLine system without all of the covers in place. See
Section 5 for additional safety precautions.
Preventive maintenance should be performed daily to avoid possible safety
hazards.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-2
Safety
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. All flammable liquids should be at least 40 feet
away from the cutting area, preferably stored in a metal cabinet. Plasma cutting should
never be attempted on containers that contain flammable materials. Make sure that fire
extinguishers are readily accessible in the cutting area.
Make sure that the cutting area is properly ventilated when using oxygen as a cutting gas.
Explosion Prevention
The ProLine 2200 system uses compressed gases. Use proper techniques when handling
compressed gas cylinders and other compressed gas equipment. Observe the following
guidelines to protect against explosion:
• Never operate the ProLine system in the presence of explosive gases or other
explosive materials.
• Never cut pressurized cylinders or any closed container.
• When using a water table and cutting aluminum under water or with water
touching the underside of the aluminum plate, hydrogen gas is produced. This
hydrogen gas may collect under the plate and explode during the cutting process.
Make sure the water table is properly aerated to help prevent the accumulation of
hydrogen gas.
• Handle all gas cylinders in accordance with safety standards published by the U.S.
Compressed Gas Association (CGA), American Welding Society (AWS),
Canadian Standards Association (CSA), or other local or national codes.
• Compressed gas cylinders should be maintained properly. Never attempt to use a
cylinder that is leaking, cracked, or has other signs of physical damage.
• All gas cylinders should be secured to a wall or rack to prevent accidental knock
over.
• If a compressed gas cylinder is not being used, replace the protective valve cover.
• Never attempt to repair compressed gas cylinders.
• Keep compressed gas cylinders away from intense heat, sparks, or flames.
• Clear the compressed gas cylinder connection point by opening the valve
momentarily prior to installing a regulator.
• Never lubricate compressed gas cylinder valves or pressure regulators with any
type of oil or grease.
• Never use a compressed gas cylinder or pressure regulator for any purpose other
than which it is intended.
• Never use a pressure regulator for any gas other than which it is intended.
• Never use a pressure regulator that is leaking or has other signs of physical
damage.
• Never use oxygen hoses and pressure regulators for any gas other than oxygen.
• Never use any gas hose that is leaking or has other signs of physical damage.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-3
Safety
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. Observe the following guidelines to
minimize exposure to these electric and magnetic fields:
•
•
•
•
Stay as far away from the ProLine power supply, torch, torch leads, and remote
high frequency console as possible.
Route the torch leads as close as possible to the work ground cable.
Never place your body between the torch leads and work ground cable. Keep the
work ground cable and the torch leads on the same side of your body.
Never stand in the center of a coiled up set of torch leads or work ground cable.
Safety Standards Booklet Index
For further information concerning safety practices to be exercised with plasma arc
cutting equipment, please refer to the following publications:
1. AWS Standard AWN, Arc Welding and Cutting Noise, obtainable from the
American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
2. AWS Standard C5.2, Recommended Practices for Plasma Arc Cutting, obtainable
from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
3. AWS Standard FSW, Fire Safety in Welding and Cutting, obtainable from the
American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
4. AWS Standard F4.1, Recommended Safe Practices for Preparation for Welding
and Cutting of Containers and Piping, obtainable from the American Welding
Society, 550 NW LeJeune Road, Miami, FL 33126.
5. AWS Standard ULR, Ultraviolet Reflectance of Paint, obtainable from the
American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
6. AWS / ANSI Standard Z49.1, Safety in Welding, Cutting, and Allied Processes,
obtainable from the American Welding Society, 550 NW LeJeune Road, Miami,
FL 33126.
7. ANSI Standard Z41.1, Standard For Men’s Safety-Toe Footwear, obtainable from
the American National Standards Institute, 11 West 42nd Street, New York, NY
10036.
8. ANSI Standard Z49.2, Fire Prevention in the Use of Cutting and Welding
Processes, obtainable from the American National Standards Institute, 11 West
42nd Street, New York, NY 10036.
9. ANSI Standard Z87.1, Safe Practices For Occupation and Educational Eye and
Face Protection, obtainable from the American National Standards Institute, 11
West 42nd Street, New York, NY 10036.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
1-4
Safety
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.
12. NFPA Standard 51, Oxygen - Fuel Gas Systems for Welding, Cutting, and Allied
Processes, obtainable from the National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.
13. NFPA Standard 51B, Cutting and Welding Processes, obtainable from the
National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.
14. NFPA Standard 70, National Electrical Code, obtainable from the National Fire
Protection Association, 1 Batterymarch Park, Quincy, MA 02269.
15. CGA booklet P-1, Safe Handling of Compressed Gases in Containers, obtainable
from the Compressed Gas Association, 1725 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202.
16. CGA booklet P-14, Accident Prevention in Oxygen-Rich and Oxygen-Deficient
Atmospheres, obtainable from the Compressed Gas Association, 1725 Jefferson
Davis Highway, Suite 1004, Arlington, VA 22202.
17. CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from the
Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004,
Arlington, VA 22202.
18. CSA Standard W117.2, Safety in Welding, Cutting, and Allied Processes,
obtainable from Canadian Standards Association, 178 Rexdale Boulevard,
Toronto, Ontario M9W lR3, Canada.
19. Canadian Electrical Code Part 1, Safety Standard for Electrical Installations,
obtainable from the Canadian Standards Association, 178 Rexdale Boulevard,
Toronto, Ontario M9W 1R3, Canada.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
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1-5
Safety
ProLine 2200 User’s Manual REV N
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Specifications
ProLine 2200 User’s Manual REV N
Section 2 Specifications
System Description
The ProLine 2200 is a microprocessor controlled, 200 amp, 100% duty cycle high current
density plasma cutting and marking system. It utilizes a precision, dual gas torch that is
capable of cutting mild steel from gauge to 2" thick and stainless steel from gauge to 11/2” thick. The maximum piercing capacity is 1” thick material. The ProLine 2200 is
equipped with a manually operated gas console with pressure readouts for all gases. All
gas inlets and outlets are connected to the rear of the gas console. 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
gas and either air or nitrogen is used for the shielding gas. Air or nitrogen is used for the
preflow and postflow gases.
When cost is of greater concern than cut quality, the
system can be configured to use clean, dry, oil-free shop air for all gas types.
The ProLine 2200 is technologically advanced to produce the highest quality cuts while
maximizing consumable life. The torch is water-cooled and consumables are machined
to exacting dimensions and checked with the latest computerized measuring systems. Six
nozzle sizes (30, 50, 70, 100, 150 and 200 amps) are available to produce excellent cut
quality throughout the cutting range.
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2-1
Specifications
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).
The ProLine 2200 consists of the following components:
Standard Components
• Power Supply
• Gas Console
• Remote High Frequency (RHF) Console
• RHF Console Control Cable
• Torch and Handle Assembly
• Torch Lead Set
• Torch Solenoid Valve Assembly
• Torch Solenoid Valve Control Cable
• Water and Power Leads
• Gas Hose Package
• Work Ground Lead
• System Manual
• Consumable Spare Parts Kit (see Section 6 for details)
Optional Components
• Remote On/Off Control Assembly
• Hydrogen Manifold Assembly
Power Supply Specifications
Stock Number:
208 VAC, 3Ø, 60Hz .............................................277411
230/460 VAC, 3Ø, 60Hz ..................................... 277412
380 VAC, 3Ø, 50/60Hz ....................................... 277415
415 VAC, 3Ø, 50/60Hz ....................................... 277414
575 VAC, 3Ø, 60Hz .............................................277413
Input Current at Maximum Output:
208 VAC, 3Ø, 60Hz .............................................115 amps
230/460 VAC, 3Ø, 60Hz ..................................... 104/52 amps
380 VAC, 3Ø, 50/60Hz ....................................... 63 amps
415 VAC, 3Ø, 50/60Hz ....................................... 58 amps
575 VAC, 3Ø, 60Hz .............................................42 amps
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2-2
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 ................................................................... 30 in (762 mm)
Height (including gas console) ............................ 48 in (1219 mm)
Depth .................................................................... 43 in (1092 mm)
Weight (including gas console) ................................ 700 lb (317 kg)
Torch Cooling System:
Discharge pressure ............................................... 150 psi (10.2 bar)
Flow rate .............................................................. 1 gal/min (3.8 liters/min)
Coolant fluid ........................................................ Propylene glycol/deionized water
Coolant tank capacity ...........................................3.2 gal (12 liters)





























Figure 2-1 Power Supply Dimension
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2-3
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)
Depth ..................................................................................... 23.8 in (605 mm)
Weight (with integrated Inova height control) ......................75 lb (34 kg)
Weight (without integrated Inova height control) ................ 60 lb (27 kg)
Gas Supply Requirements
Plasma gas types:
Mild Steel ...................................................... Oxygen or Air
Stainless Steel ............................................... Air or H17 (optional)
Aluminum ..................................................... Air
Shield gas types:
Mild Steel ...................................................... Oxygen or Air
Stainless Steel ............................................... Air or Nitrogen
Aluminum ..................................................... Air or Nitrogen
Preflow gas type ...................................................Air or Nitrogen
Plasma gas flow rate (maximum):
Oxygen or Air ............................................... 40 scfh (1132 liters/hour)
H17 ................................................................ 36 scfh (1019 liters/hour)
Shield gas flow rate (maximum):
Oxygen .......................................................... 19 scfh (538 liters/hour)
Air or Nitrogen ..............................................150 scfh (4245 liters/hour)
Preflow gas flow rate (maximum) ....................... 25 scfh (708 liters/hour)
Inlet gas pressures (rated / maximum)
Oxygen .......................................................... 120 psi (8.3 bar) / 150 psi (10.3 bar)
Nitrogen ........................................................ 120 psi (8.3 bar) / 150 psi (10.3 bar)
Air ................................................................. 120 psi (8.3 bar) / 150 psi (10.3 bar)
H17 ................................................................ 120 psi (8.3 bar) / 150 psi (10.3 bar)
Oxygen and nitrogen should be supplied with a purity of at least 99.5%. H17
should be supplied with a purity of at least 99.995%. A potential fire hazard
exists when cutting with oxygen. Flashback arrestors must be supplied to
prevent a possible fire from propagating back to the gas supplies. Ensure that
oxygen lines remain free from contaminants such as oil and grease. The mixture
of such contaminants with oxygen presents an additional fire hazard. Compressed
air must be clean, dry, and oil-free and may be supplied from compressed
cylinders or from an air compressor. Be aware that shop air systems are prone to
oil and moisture contamination. If shop air is used, it must be cleaned to ISO
8573.1: Class 1.4.1. Specify dry air when using compressed cylinders. Breathing
quality air contains moisture and must not be used. 1/4” (inside diameter) hoses
are required for all inlet gas connections. Mating connectors are supplied with the
unit. Quick-connect fittings must not be used.
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2-4
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 .................................................... .025 in (.635 mm)
Figure 2-2 Remote High Frequency Console Mounting Dimensions
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2-5
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]
1.99
[51]
Torch Base
1.87 [47]
Alignment Indicator
(Slot)
Attachment Ring
Alignment Indicator
(Small Circle)
Torch Head
5.08 [129]
Figure 2-3 Torch Dimensions
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2-6
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)


Figure 2-4 Remote On/Off Control Dimensions (Optional)
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2-7
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)
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2-8
Specifications
ProLine 2200 User’s Manual REV N
Airborne Noise Emissions
The ProLine 2200 system generates high noise levels while cutting. Depending
on the size of the cutting area, distance from the cutting torch, and arc current
cutting level, acceptable noise levels may be exceeded. Proper ear protection
should be used as defined by local or national codes. The following chart gives
the noise levels generated by the ProLine 2200 when operating at 200 amps, 135
arc volts. The measurements were made with a sound level meter.
Distance From Torch
A-Weighted Sound
Pressure Level
C-Weighted Sound
Pressure Level
1 meter horizontal / 1.6 meters
above the workpiece
110 dB
107 dB
The maximum noise level is 127 dB at a distance of 3 inches (76.2 mm) from the
torch while cutting at 200 amps, 135 arc volts.
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2-9
Specifications
ProLine 2200 User’s Manual REV N
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2-10
Installation
ProLine 2200 User’s Manual REV N
Section 3 Installation
Initial Inspection
All systems undergo full testing before being shipped from KALIBURN. In the unlikely
event that one of your components is defective or missing, please contact KALIBURN so
a replacement item can be sent to you. Also, KALIBURN has taken special care in
packaging your ProLine 2200 system. If your system was damaged during shipment, you
will have to file a claim with the shipping company. Next, it will be necessary to contact
KALIBURN so replacement parts can be ordered. If you need additional assistance,
please contact KALIBURN.
System Interconnection
The ProLine 2200 system interconnection diagram, Figure 3-1, will assist you in
identifying cables and hoses upon receipt of your system. Electrical cables are marked
with the appropriate plug number or letter and can be identified on the diagram. The
Inova arc voltage control is also shown to assist in its hookup.
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3-1
Installation
ProLine 2200 User’s Manual REV N


     
Figure 3-1 System Interconnection Diagram
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3-2
Installation
ProLine 2200 User’s Manual REV N
Power Supply Installation
The ProLine power supply should be lifted by a forklift or pallet jack. In order to prevent
damaging the power supply, the forks should be of adequate length to protrude on the far
side of the power supply. The proper location of the power supply will provide
dependable service and reduce periodic maintenance time. Choose a location that will
provide unrestricted air movement into and out of the power supply. Maintain at least 24
inches of space on all sides of the unit. The location should subject the power supply to
the least amount of dust, dirt, moisture, and corrosive vapors. The surface on which the
power supply is located should have a grade of no greater than 10º to eliminate the risk of
toppling over. The power supply must be cleaned as often as necessary to prevent the
accumulation of metallic dust inside the unit. See Figure 2-1 for power supply
dimensions.
Remote High Frequency Console Installation
The Remote High Frequency (RHF) Console should be mounted in a convenient location
that is away from other electronic control devices. The high voltage, high frequency
signal generated inside the unit can interfere with the operation of certain control
systems. The RHF console is usually mounted on the gantry of the cutting machine or on
the cutting table. 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. The positioner must be rigid to ensure cut quality and
a torch collision sensor is highly recommended. See Figure 2-3 for torch mounting
dimensions.
Primary Power Connection
** Before connecting primary power, check the data plate to verify the voltage
required by the ProLine power supply **
A primary disconnect switch, switching all ungrounded supply conductors, should be
provided for each ProLine power supply. The disconnect switch should be located as
close as possible to the power supply so it can be turned off quickly in case of an
emergency. The disconnect switch should be equipped with time delay fuses only.
The magnetic inrush current of the power supply will cause fast acting fuses to blow.
The disconnect switch should be sized according to local and national codes. The rating
must meet or exceed the continuous rating of the fuses used. See the following chart for
recommended fuse sizes:
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3-3
Installation
ProLine 2200 User’s Manual REV N
3 Phase
Input Voltage
(VAC)
208V 60Hz
230V 60Hz
380V 50/60Hz
415V 50/60Hz
460V 60Hz
575V 60Hz
Input Current
at Maximum Output
(amps)
115
104
63
58
52
42
Recommended
Time-Delay Fuse Size
(amps)
170
150
90
80
75
60
Use a Type SO power cable to connect the primary power to the ProLine power supply.
The power cable should have a 600 volt minimum rating and should be sized according
to local and national codes. Route the power cable through the lower strain relief on the
rear of the power supply and connect it to the input terminal block TB5 as shown in
Figure 3-2. TB5 is located on the base of the power supply behind the left side cover. Be
sure to connect the primary ground cable to the ground stud on the input terminal
block.
L1
L2
L3
GND
Figure 3-2 Primary Power Connections
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3-4
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 1
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.
2. Route the other end of the Power Supply Electrode Lead through the strain relief
on the RHF console and connect it to the cathode manifold.
Power Supply Nozzle Lead 2
1. Route one end of the #10AWG Power Supply Nozzle Lead through the upper
strain relief on the rear of the power supply and connect it to the Nozzle terminal.
2. Route the other end of the Power Supply Nozzle Lead through the strain relief on
the RHF console and connect it to the Pilot terminal on the RHF console printed
circuit board.
Power Supply CTP Sensor Lead 3
1. Route the end of the #14AWG Power Supply CTP Sensor Lead with the ring
terminal through the middle strain relief on the rear of the power supply and
connect it to the CTP terminal.
2. Route the end of the Power Supply CTP Sensor Lead with the fast-on terminal
through the strain relief on the RHF console and connect it to the CTP sensor lead
filter assembly.
RHF Console Control Cable 4
1. Connect the RHF Console Control Cable plug labeled P16 to the connector
labeled P16 on the rear of the power supply.
2. Connect the RHF Console Control Cable plug labeled P1 to the connector labeled
P1 on the RHF console.
Power Supply Coolant Supply Hose 5
1. Connect one end of the Power Supply Coolant Supply Hose to the coolant supply
fitting on the rear of the power supply. Note that the coolant supply fitting has
right hand threads.
2. Connect the other end of the Power Supply Coolant Supply Hose to the coolant in
fitting on the RHF console. Note that the coolant in fitting has right hand threads.
Power Supply Coolant Return Hose 6
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.
2. Connect the other end of the Power Supply Coolant Return Hose to the coolant
out fitting on the RHF console. Note that the coolant out fitting has left hand
threads.
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3-5
Installation
ProLine 2200 User’s Manual REV N
Work Ground Lead 7
1. 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.
2. Connect the other end of the Work Ground Lead to the star ground point on the
cutting table. The star ground point is generally referred to as the common
ground point on the cutting table where all subsystems of the machine are
grounded. This point is then connected to a driven earth ground rod that should
be as close as possible to the star ground. The ground rod should have no other
wires connected to it. The ground rod should be at least 3/4 inches in diameter
and should be driven into the earth’s permanent moisture layer. The length of the
ground rod varies from installation to installation and should be installed
according to local and national codes. Refer to the National Electrical Code,
Article 250, Section H, Ground Electrode System for additional information.
RHF Console Ground Connection
8
Perform the following steps to connect the chassis of the RHF Console to the cutting
table. See Figure 3-3 for additional information.
1.
2.
Connect one end of the RHF Console Ground Lead to the ground stud on the RHF
console.
Connect the other end of the RHF Console Ground Lead to chassis ground on the
cutting table. Make sure that good metal-to-metal contact is made.
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3-6
Installation
ProLine 2200 User’s Manual REV N
 









Figure 3-3 Power Supply Output Connections
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3-7
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 34 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.
9
Braided Shield
• Remove the threaded ring from the brass shield connector on the end of the
braided shield. Route the torch leads through the opening in the RHF console and
push the shield connector through the hole until it is seated against the side of the
console.
• Slide the threaded ring over the torch leads, thread it onto the brass shield
connector, and tighten firmly. The shield connector should ground the braided
shield to the case of the RHF console in order to help reduce high frequency noise
emission. Using an ohmmeter, measure for zero ohms between the braided shield
and the ground stud located on the outside of the RHF console.
10
Torch Electrode/Coolant Supply Lead
• Connect the Torch Electrode/Coolant Supply Lead to the brass cathode manifold.
Note that the Torch Electrode/Coolant Supply Lead has right hand threads.
11
Torch Coolant Return Lead
• Connect the Torch Coolant Return Lead to the brass cathode manifold. Note that
the Torch Coolant Return Lead has left hand threads.
12
Torch Nozzle Lead
• Connect Torch Nozzle Lead to the angled bracket on the red standoff. Note that
the Torch Nozzle Lead has right hand threads.
13
Torch CTP Sensor Lead
• Connect the #18AWG Torch CTP Sensor Lead to the red standoff as shown.
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3-8
Installation
ProLine 2200 User’s Manual REV N
Figure 3-4 Torch Leads to RHF Console Connections
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3-9
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. The fittings are subject
to damage if over tightened. Also, use two wrenches when
tightening the torch fittings to avoid damaging the torch
Gas Hose Package/Torch Solenoid Control Cable Installation
• Route the Plasma, Shield, Preflow, and Postflow Gas Hoses and the Torch
Solenoid Control Cable from the power supply to the torch station. Note that
the Shield Gas Hose extends down inside the torch handle, so it should be
routed accordingly. Also, plug P12 on the Torch Solenoid Control Cable
attaches at the power supply and P15 attaches to the torch solenoid assembly.
Torch Handle Installation
• Route the torch leads through the torch handle. Note that the threaded end of
the torch handle mates with the torch base.
• Route the Shield Gas Hose through the torch handle.
• Route the 15” Torch Plasma Gas Hose through the torch handle. Note that the
larger fitting on the Torch Plasma Gas Hose mates with the torch base.
10
Torch Electrode/Coolant Supply Lead
• Connect the Torch Electrode/Coolant Supply Lead to the torch base as shown.
11
Torch Coolant Return Lead
• Connect the Torch Coolant Return Lead to the torch base as shown. Note that
the Torch Coolant Return Lead fitting has left hand threads.
12
Torch Nozzle Lead
• Connect the Torch Nozzle Lead to the torch base as shown.
13
Torch CTP Sensor Lead
• Connect the Torch CTP Sensor Lead to the torch base as shown.
14
Shield Gas Hose
• Connect the Shield Gas Hose to the torch base as shown.
Torch Plasma Gas Hose 15
• Connect the Torch Plasma Gas Hose to the torch base as shown.
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3-10
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).
• 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.
• Mount the torch handle/base/valves to the positioner. Note the alignment
indicators on the torch base (slot) and torch head (small circle). These aid in
aligning the quick-disconnect torch base and head and should be oriented so
they are clearly visible when the operator is changing heads.
Torch Plasma Gas Hose 16
• Connect the Torch Plasma Gas Hose to the solenoid outlet port as shown.
Preflow Gas Hose 17
• Connect the Preflow Gas Hose to the solenoid preflow inlet port as shown.
Note that the Preflow Gas Hose fitting has a left hand thread.
Plasma Gas Hose 18
• Connect the Plasma Gas Hose to the solenoid plasma inlet port as shown.
Postflow Gas Hose 19
• Connect the Postflow Gas Hose to the solenoid postflow inlet port as shown.
Torch Solenoid Control Cable 20
• Connect the Torch Solenoid Control Cable plug marked P15 to the torch
solenoid assembly as shown.
• Connect the Torch Solenoid Control Cable plug labeled P12 to the connector
labeled P12 on the rear of the power supply.
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3-11
Installation
ProLine 2200 User’s Manual REV N
Figure 3-5 Torch Connections
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3-12
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. Reminder: do not use an excessive amount of o-ring
lubricant.
2. Align the indicator on the torch head (small circle) with the one on the torch
base (slot).
3. Apply enough upward force to engage the threads while tightening the
attachment ring. Turn the attachment ring to the LEFT to tighten.
4. Keep tightening the attachment ring until it stops. As shown below, the
attachment ring will NOT cover the o-ring. This is only a visual indicator; no
seal is created. However, there should be no gap between the attachment ring
and the o-ring.
During the tightening process (after the initial install) a small amount of
coolant will collect in the torch head. It is normal for this coolant to discharge
between the o-ring on the torch base and the attachment ring while the system
is being pressurized. If coolant continues to discharge after the system is
pressurized, turn off the plasma power supply, remove the torch head and
inspect the o-rings for damage.
CORRECT
INCORRECT!
O-ring
O-ring
Correct
There is no
gap between
o-ring and
attachment
ring
Incorrect!
Gap is visible
between
o-ring and
attachment
ring
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3-13
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. Using quick-connect fittings to
connect and disconnect pressurized hoses may cause damage to the system.
Note: When making hose connections, only tighten the brass
fittings enough to make gas seals. The fittings are
subject to damage if over tightened.
21
Preflow Inlet
• Connect the proper preflow gas to the Preflow In port. See the cutting charts in
Section 4 for gas types.
22
Plasma Inlet
• Connect the proper plasma gas to the Plasma In port. See the cutting charts in
Section 4 for gas types.
23
Shield Inlet
• Connect the proper shield gas to the Shield In port. See the cutting charts in
Section 4 for gas types.
Figure 3-6 Gas Console Input Connections
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3-14
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.
24
Preflow Outlet
• Connect the preflow hose to the Preflow Out port as shown. Note that the
Preflow Out port has left hand threads.
25
Plasma Outlet
• Connect the plasma hose to the Plasma Out port as shown. Note that the Plasma
Out port has right hand threads.
26
Shield Outlet
• Connect the shield hose to the Shield Out port as shown. Note that the Shield Out
port has right hand threads.
27
Postflow Outlet
• Connect the postflow hose to the Postflow Out port as shown. Note that the
Postflow Out port has right hand threads.
Figure 3-7 Gas Console Output Connections
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3-15
Installation
ProLine 2200 User’s Manual REV N
CNC Machine Interface Connections
Perform the following steps to properly interface the ProLine 2200 system with a CNC
cutting machine. 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. The contacts should be rated for 12VDC - 10mA. If the ProLine 2200 is
ordered with the integrated Inova system, see below for interface information.
Arc Hold / IHS Complete Signal
• The ProLine 2200 requires a contact closure between P8 pins 10 and 11 to inhibit
arc starting even though a plasma start signal has been applied to the unit. When
the arc hold / IHS complete contacts are opened, the cutting arc is initiated. This
feature is used to decrease cycle time by allowing pre-cut gas and contact
sequencing to occur simultaneously with initial torch height positioning. The
contacts should be rated for 12VDC - 10mA. If the ProLine 2200 is ordered with
the integrated Inova system, see below for interface information.
Motion Output Signal
• The ProLine 2200 provides a maintained contact closure output between P8 pins 12
and 14 as long as a cutting arc is maintained between the torch and the workpiece.
The motion contacts are rated for .6A - 125VAC / .6A - 110VDC / 2A - 30VDC. If
the ProLine 2200 is ordered with the integrated Inova system, see below for
interface information.
Inova Connections (optional)
• When the ProLine 2200 is ordered with the integrated Inova torch height control
system, connect the Inova C cable between P8 on the rear of the power supply and
P3 on the Inova control panel. The C cable is used to interface the plasma start,
plasma hold, and machine motion signals between the Inova and the ProLine 2200.
Next, connect the Inova D cable between P7 on the rear of the power supply and P2
on the Inova control panel. The Inova D cable is used to interface the cutting arc
voltage and plate sensing circuit between the Inova and the ProLine 2200. Next,
connect the Inova E cable between the Work terminal on the ProLine power supply
and the Ground lug on the Inova control panel. Note that the E cable is not a safety
ground. It is part of the voltage feedback circuit used for arc voltage control. See
the Inova manual for details on x/y machine, operator’s remote, and positioner
interface.
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-16
Installation
ProLine 2200 User’s Manual REV N
Torch Coolant Requirements
Note: Refer to the supplier’s most current Material Safety Data Sheet for
information regarding safety, handling, and storage of
torch coolant.
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. The standard coolant solution consists of 25% industrial
grade propylene glycol and provides freezing protection down to -13º C (9º F).
The standard solution can be ordered in one-gallon containers, PN 500695. For
operating temperatures below -13º C, a 50% solution of industrial grade
propylene glycol can be ordered in one-gallon containers, PN 500895, providing
protection down to -36º C (-33º F).
Failure to use the proper propylene glycol solution may result in cooling
system and/or torch damage.
The torch coolant should be flushed out of the ProLine system every six months
and replaced with new coolant. The water filter/deionization cartridge should also
be changed at the same time. See Section 5 for details.
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3-17
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.
1. Remove the coolant reservoir cap and fill the reservoir with 2 gallons of
coolant solution.
2. Apply main power to the ProLine unit.
3. Depress and hold the green ON button on the ProLine control panel.
4. The coolant pump will begin pumping coolant fluid through the system. The
Coolant Flow LED will remain out until the coolant has filled the entire
system and begins flowing back into the tank. The coolant pump will turn off
if the coolant level drops below the minimum level inside the reservoir. If this
happens, add more coolant solution to the reservoir and return to Step 3.
5. When the Coolant Flow LED illuminates, release the green ON switch. The
ProLine system should remain energized and continue pumping coolant
through the system.
6. Locate the small red push-button on top of the coolant filter/deionization
cartridge. Depress and hold the button until no air is seen inside the clear
filter housing.
7. Fill the reservoir with coolant solution until the coolant gauge indicates full.
Coolant should be added to the system any time the level drops below half
full.
8. Check for coolant leaks at all hose connections inside the power supply, RHF
console, and at the torch.
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
3-18
Installation
ProLine 2200 User’s Manual REV N
Optional Remote On/Off Control Installation
Install the remote on/off control on the operator’s control station. The control has
four mounting holes and four #6-32 press nuts on the bottom for installation. See
Figure 2-4 for mounting dimensions. After the control has been mounted, connect
the Remote On/Off Control Cable between the plug on the rear of the remote
on/off control and the plug labeled Remote On/Off 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.
Optional Hydrogen Manifold Installation
The hydrogen manifold is designed to be installed on the top of the gas console
using the two left rear mounting holes of the gas console cover (as viewed from
the front of the power supply). Simply remove the cover of the hydrogen
manifold, remove the two left rear gas console cover screws, then reinstall the
cover screws after inserting them through the holes in the bottom of the hydrogen
manifold. After the manifold has been mounted, replace the hydrogen manifold
cover and connect the 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.
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3-19
Installation
ProLine 2200 User’s Manual REV N
BLANK PAGE
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3-20
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.





























Figure 4-1 Front Panel Controls
Power Off Button 1
Deenergizes the ProLine system and turns off the cooling fans and coolant pump.
Power On Button/Indicator 2
Energizes the ProLine system and turns on the cooling fans and coolant pump.
Illuminates to show that the system is energized.
AC Power Indicator 3
Illuminates when 3 phase power is applied to the ProLine system.
DC Power Indicator 4
Illuminates when then main contactor has been energized and D.C. current is flowing
through the torch.
Motion Delay Potentiometer 5
Used to delay the x/y machine motion when piercing thicker materials. The delay can be
adjusted from 0 to 3 seconds.
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-1
Operation
ProLine 2200 User’s Manual REV N
Current Thumbwheel 6
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 7
• RHF Door Indicator
Illuminates when the RHF console door is closed securely. Remains extinguished
when the RHF console door is open.
• Gas Console Indicator
Illuminates when the automatic gas console is operational. Remains extinguished
when there is a problem with the gas system. Check the message screen on the
automatic gas console for errors.
• 3 Phase Power Indicator
Illuminates when 3 phase power is satisfactory. Remains extinguished when there
is a problem with main 3 phase power to the system.
• Coolant Flow Indicator
Illuminates when the coolant flow through the system is satisfactory. Remains
extinguished when the coolant flow through the system is restricted.
• Coolant Level Indicator
Illuminates when the coolant level inside the reservoir is satisfactory. Remains
extinguished when coolant must be added to the system.
• 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.
Preflow Gas Control 8
Displays the preflow gas inlet and outlet pressures and provides a preflow gas outlet
pressure regulator.
9
Plasma Gas Control
Displays the plasma gas inlet and outlet pressures and provides a plasma gas outlet
pressure regulator.
Shield Gas Control 10
Displays the shield gas inlet and outlet pressures and provides a shield gas outlet pressure
regulator.
Postflow Gas Control 11
Displays the postflow gas inlet and outlet pressures and provides a postflow gas outlet
pressure regulator.
Gas Test/Run Switch 12
In the test modes, the selected gas solenoids are energized so the gas pressures can be
properly adjusted prior to cutting. Test mode also allows the operator to manually purge
the gas lines as required, i.e. after switching to a different type of gas. In the Run mode,
all gas solenoids are controlled by the microprocessor board.
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4-2
Operation
ProLine 2200 User’s Manual REV N
Optional Hydrogen Manifold Controls
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 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 1
Displays the H17 incoming supply pressure.
Outlet Pressure Regulator 2
Adjusts the H17 outlet pressure.
Outlet Pressure Gauge 3
Displays the H17 outlet pressure.
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4-3
Operation
ProLine 2200 User’s Manual REV N
Setting up a Cut
Note: When installing the torch parts, do not use an excessive amount of o-ring lubricant.
Also, ensure that the lubricant is placed only on the o-rings. Excess lubricant can interfere
with gas flow, cause starting problems, and shorten consumable life.
1.
Turn off the primary power to the unit.
2.
Using the cutting charts found in the rear of this section, determine the proper torch
parts and cutting conditions for the material being cut.
3.
If using a copper electrode, apply a small amount of o-ring lubricant to the two
o-rings on the electrode. Then, use the tool (P/N 277087) to tighten the electrode
into the torch head. If using a silver electrode, apply a small amount of o-ring
lubricant to the o-ring on the electrode. Then, use the tool (P/N 279061) to tighten
the silver electrode into the torch head.
4.
Apply a small amount of o-ring lubricant to the two o-rings on the swirl ring and
insert the swirl ring into the nozzle.
5.
Apply a small amount of o-ring lubricant to the two o-rings on the nozzle and push
the swirl ring/nozzle assembly into the torch head until it is seated properly.
6.
Inspect the threads on the torch base/head, copper inner retaining cap, and brass
outer cap and clean as necessary.
7.
Install a small amount of o-ring lubricant to the three o-rings on the torch head.
8.
Install the inner retaining cap onto the torch head. Tighten the cap firmly but do not
over tighten.
9.
Apply a small amount of o-ring lubricant to the shield cap o-ring and install the
shield cap into the brass outer cap. Note: Make sure the shield cap o-ring is seated properly
inside the outer cap.
10.
Install the outer cap onto the torch head and tighten firmly. Do not over tighten.
11.
Apply a small amount of o-ring lubricant on each of the seven o-rings on the top of the
torch head.
12.
Align the indicator on the torch head (small circle) with the one on the torch base (slot).
13.
Apply enough upward force to engage the threads while tightening the attachment ring.
Turn the attachment ring to the LEFT to tighten.
14.
Connect the correct preflow, plasma, and shield gas types to the gas inlet ports on
the rear of the gas console. When using H17 as the plasma gas, connect the H17 gas supply
to the Hydrogen In port on the H17 manifold and move the Plasma Out hose from the ProLine
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. If the Coolant Flow LED fails to illuminate after 10 seconds, see the
maintenance section for possible causes and solutions.
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-4
Operation
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.
17.
Set the Gas Test/Run switch to the Test Plasma position. Adjust both the plasma
and shield outlet pressures to their correct values as indicated in the cutting chart.
18.
Set the Gas Test/Run switch to the Test Postflow position and adjust the postflow
outlet pressure to the correct value as indicated in the cutting chart.
19.
Return the Gas Test/Run switch to the Run position.
20.
Adjust the Current thumbwheel to the value indicated in the cutting chart.
21.
Adjust the Motion Delay potentiometer to the value indicated in the cutting chart.
Gas Purge
After changing gas types, the gas lines must be purged in order to ensure that a dangerous
gas mixture does not exist. The gas console can be manually purged by setting the Gas
Test/Run switch to the three test modes for a minimum of 10 seconds each. NOTE: If
the Gas Test/Run switch is not set to test mode after power is restored to the system, the
gas console will perform an automatic purge prior to initiating a cut.
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-5
Operation
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:
• Two second gas preflow
• High frequency starting circuit energized
• Pilot arc initiation
• Transferred arc (cutting arc) established
• Motion output relay energized after Pierce Delay timer complete
2. Upon removal of the cycle start signal, the following sequence will take place:
• Cutting arc extinguished
• Motion output relay deenergized
• Gas postflow
Consumable Life
Use the following guidelines to maximize consumable parts life:
1. Use the recommended pierce height given in the cutting charts. A pierce height that
is too low will allow molten metal that is ejected during the piercing process to
damage the shield cap and nozzle. A pierce height that is too high will cause the pilot
arc time to be excessively long and will cause nozzle damage.
2. Make sure the arc extinguishes properly at the end of each cut. Program the lead-out
such that the arc is not lost before the lead-out is complete. The arc must remain
transferred to the workpiece throughout the turn-off sequence. A “popping” noise
can be heard if the arc extinguishes abnormally.
3. Make sure the torch does not touch the plate while cutting. Shield cap and nozzle
damage will result.
4. Use a chain cut when possible. Starting and stopping the torch is much more
detrimental to the consumables than making a continuous cut.
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4-6
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. The following guidelines should be useful in
determining which cutting parameter to adjust.
Note: Before making any parameter changes, verify that the torch is square to the workpiece.
Also, it is essential to have the correct torch parts in place and to ensure that they are in good
condition. Check the electrode for excessive wear and the nozzle and shield cap orifices for
roundness. Also, check the parts for any dents or distortions. Irregularities in the torch parts
can cause cut quality problems.
1. A positive cut angle (top dimension of piece smaller than the bottom dimension)
usually occurs when the torch standoff distance is too high, when cutting too fast, or
when excessive power is used to cut a given plate thickness.
2. A negative cut angle (top dimension of piece larger than the bottom dimension)
usually occurs when the torch standoff distance is too low or when the cutting speed
is too slow.
3. Top dross usually occurs when the torch standoff distance is too high.
4. Bottom dross usually occurs when the cutting speed is either too slow (slow-speed
dross) or too fast (high-speed dross). Low-speed dross is easily removed, while highspeed dross usually requires grinding or chipping off. When using oxygen as the
shielding gas, bottom dross can sometimes be removed by increasing the shield gas
pressure. However, increasing the shield pressure too much can cause cut face
irregularities (see below). Bottom dross also occurs more frequently as the metal
heats up. As more pieces are cut out of a particular plate, the more likely they are to
form dross.
5. When using oxygen as a shielding gas, cut face irregularities usually indicate that the
shield gas pressure is too high or the torch standoff distance is too low.
6. A concave cut face usually indicates that the torch standoff distance is too low or the
shield gas pressure is too high. A convex cut face usually indicates that the torch
standoff distance is too high or the shield gas pressure is too low.
7. Note that different material compositions have an effect on dross formation.
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-7
Operation
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.
Cutting Chart Index
Copper
Electrode
Silver
Electrode
Material
Process
Current
Plasma Gas
Shield Gas
Mild Steel
Mild Steel
Mild Steel
Mild Steel
Mild Steel
Mild Steel
Cutting
Cutting
Cutting
Cutting
Cutting
Cutting
30 Amps
50 Amps
70 Amps
100 Amps
150 Amps
200 Amps
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen
Oxygen or Air
Air
Air
Air
Air
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Stainless Steel
Cutting
Cutting
Cutting
Cutting
Cutting
Cutting
Cutting
Cutting
Cutting
Cutting
30 Amps
50 Amps
70 Amps
70 Amps
100 Amps
100 Amps
150 Amps
150 Amps
200 Amps
200 Amps
Air
Air
H17
Air
H17
Air
H17
Air
H17
Air
Air
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
4-15
4-16
4-17
4-18
4-19
4-20
4-21
4-22
4-23
4-24
4-35
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Cutting
Cutting
Cutting
Cutting
Cutting
Cutting
30 Amps
50 Amps
70 Amps
100 Amps
150 Amps
200 Amps
Air
Air
Air
Air
Air
Air
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
4-25
4-26
4-27
4-28
4-29
4-30
4-36
Mild Steel
Stainless Steel
Aluminum
Marking
Marking
Marking
10 Amps
10 Amps
10 Amps
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
Nitrogen
4-31
4-32
4-33
4-9
4-10
4-11
4-12
4-13
4-14
4-34
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-8
Operation
ProLine 2200 User’s Manual REV N
Mild Steel - 30 Amps – Oxygen Plasma / Oxygen Shield
Copper Electrode
Shield Cap
277145
Outer Cap
277154
Imperial
Material
Thickness
Nozzle
277120
Retaining Cap
277153
Electrode
277130
Swirl Ring
277140
Torch Head
279150
Preflow
Air
Plasma
Oxygen
Shield
Oxygen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
100
.062
(ga)
(in)
20
.036
120
105
.080
18
.048
121
97
.090
16
.060
125
78
14
.075
126
65
12
.105
127
55
11
.120
129
50
10
.135
131
40
Metric
35
85
6
2
.110
.105
200
.120
.125
300
.065
.070
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
Oxygen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
1
120
2615
2.0
100
1.6
1.5
124
2020
2.6
2
35
85
6
2
126
2.5
3
128
1615
1455
1285
2.8
2.7
2.9
3.1
200
300
1.7
1.8
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-9
Operation
ProLine 2200 User’s Manual REV N
Mild Steel - 50 Amps – Oxygen Plasma / Oxygen or Air Shield
Copper Electrode
Shield Cap
277115
Outer Cap
277154
Imperial
Material
Thickness
(ga)
(in)
Nozzle
277122
Electrode
277131
Retaining Cap
277153
Swirl Ring
277140 / 277142
Torch Head
279150
Preflow
Air
Plasma
Oxygen
Shield
O2 or Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
100
.075
200
.078
100
.075
200
.080
.200
300
.085
.225
400
.087
Cold-Rolled Steel – Oxygen Shield – Swirl Ring 277140
12
.105
11
.120
10
.135
25
74
12
1
123
70
.120
126
60
.125
128
50
.135
.135
Hot-Rolled Steel – Air Shield – Swirl Ring 277142
14
.075
12
.105
190
110
170
3/16
113
105
1/4
117
75
.125
10
.135
Metric
200
106
25
74
19
.100
180
1
.135
.110
.140
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
O2 or Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
100
1.9
200
2.0
Cold-Rolled Steel – Oxygen Shield – Swirl Ring 277140
2.5
3
25
74
12
1
121
1895
2.9
125
1555
3.1
3.4
Hot-Rolled Steel – Air Shield – Swirl Ring 277142
2.5
3
5
106
25
74
19
1
6
4885
4660
113
2555
116
2075
2.5
3.6
3.4
5.1
5.5
100
1.9
200
2.0
400
2.2
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-10
Operation
ProLine 2200 User’s Manual REV N
Mild Steel - 70 Amps – Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
277150
Outer Cap
277154
Imperial
Nozzle
277125
Electrode
277131
Retaining Cap
277153
Swirl Ring
277142
Torch Head
279150
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/8
3/16
1/4
35
25
80
40
2
3/8
Metric
110
190
113
130
116
120
122
75
.150
100
.200
200
.110
.225
300
.140
.250
400
.100
.080
.085
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
109
4995
3.6
100
113
3265
115
3105
3
5
35
25
6
80
40
2
2.5
2.7
5.1
5.5
300
2.0
2.2
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-11
Operation
ProLine 2200 User’s Manual REV N
Mild Steel - 100 Amps – Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
277286
Outer Cap
277154
Imperial
Nozzle
277284
Electrode
277282
Retaining Cap
277151
Swirl Ring
277283
Torch Head
279150
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
125
150
.090
.200
300
100
.130
.250
400
65
.155
.300
500
1/4
3/8
1/2
25
94
26
130
0
5/8
143
47
3/4
145
35
Metric
.185
.325
800
.350
1000
.090
.095
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
124
3950
2.1
4.9
300
2405
3.3
6.5
1850
3.7
7.3
6
10
12
25
94
26
130
0
16
143
1180
20
145
800
4.7
8.3
9.0
500
1000
2.3
2.4
* Use an arc transfer height (ignition height) of .200” (4.9 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-12
Operation
ProLine 2200 User’s Manual REV N
Mild Steel - 150 Amps – Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
277117
Outer Cap
277154
Imperial
Nozzle
277293
Electrode
277292
Retaining Cap
277151 / 277152
Swirl Ring
277139
Torch Head
279150
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
118
165
.105
.200
300
123
125
.135
.250
400
125
90
.140
.300
500
.130
.325
600
.130
.350
1000
.135
1500
.140
Retaining Cap 277151
1/4
3/8
20
74
30
0
1/2
.125
Retaining Cap 277152
5/8
127
3/4
70
.140
130
55
134
40
.150
1.25 **
145
25
.200
1.5 **
155
15
.225
1
Metric
20
74
45
0
.400
.350
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
300
Retaining Cap 277151
6
10
20
74
30
0
12
117
4305
2.6
4.9
123
3040
3.4
6.5
124
2485
3.5
7.3
500
3.2
3.3
Retaining Cap 277152
16
127
1760
20
130
1340
133
1040
3.7
10.1
32 **
145
625
5.1
8.9
38 **
154
385
5.6
8.9
25
20
74
45
0
3.6
8.3
1000
9.0
3.3
3.4
1500
3.6
* Use an arc transfer height (ignition height) of .200” (4.9 mm)
** Edge start recommended
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-13
Operation
ProLine 2200 User’s Manual REV N
Mild Steel - 200 Amps – Oxygen Plasma / Air Shield
Copper Electrode
Shield Cap
277274
Outer Cap
277154
Imperial
Nozzle
277289
Electrode
277291
Retaining Cap
277266
Swirl Ring
277143
Torch Head
279150
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/4
125
230
.040
.200
300
3/8
130
140
.090
.250
400
1/2
133
120
.115
.300
500
5/8
137
100
.130
.350
600
.152
3/4
140
75
.150
.400
800
.153
147
50
.175
.450
1000
155
25
.240
.500
1
20
82
58
0
1.25
1.5 **
165
17
.300
.350
1.75 **
175
12
.350
.350
2.0 **
185
7
.500
.500
Metric
1500
.150
.155
158
.160
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(mm)
(volts)
(mm/m)
(mm)
(mm)
(msec)
6
124
6100
.8
4.9
300
10
130
3480
2.3
6.5
12
132
3160
2.7
7.3
16
137
2515
3.3
8.9
20
141
1810
3.8
10.3
146
1310
4.3
11.3
25
20
82
58
0
32
155
610
6.1
12.7
38 **
164
435
7.5
8.9
45 **
175
295
9.2
9.2
50 **
183
195
12.2
12.2
500
3.8
800
1000
3.9
1500
4.0
4.1
* Use an arc transfer height (ignition height) of .200” (4.9 mm)
** Edge start recommended
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-14
Operation
ProLine 2200 User’s Manual REV N
Stainless Steel - 30 Amps – Air Plasma / Air Shield
Copper Electrode
Shield Cap
277144
Outer Cap
277154
Imperial
Material
Thickness
(ga)
(in)
20
.036
18
.048
16
.060
14
.075
Metric
Nozzle
277121
Electrode
277137
Retaining Cap
277110
Swirl Ring
277138
Torch Head
279150
Preflow
Air
Plasma
Air
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
200
.020
100
.065
71
30
80
30
14
165
.035
74
125
75
90
.025
.050
200
.068
.070
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
71
4855
0.6
73
3260
0.9
1
1.5
30
80
30
14
1.3
100
200
1.7
* Use an arc transfer height (ignition height) of .050” (1.3 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-15
Operation
ProLine 2200 User’s Manual REV N
Stainless Steel - 50 Amps – Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277149
Outer Cap
277154
Imperial
Material
Thickness
Nozzle
277123
Electrode
277137
Retaining Cap
277110
Swirl Ring
277142
Torch Head
279150
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
.035
.070
(ga)
(in)
14
.075
87
105
12
.105
88
75
11
.120
89
65
10
.135
90
55
3/16
94
50
.040
.080
300
1/4
100
40
.060
.125
400
.115
Metric
30
70
40
4
100
.105
200
.110
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
.9
1.8
2
87
2.5
3
30
70
40
4
2565
2080
88
1685
5
94
1235
1.0
2.1
6
98
1075
1.3
2.9
100
2.7
200
400
2.8
2.9
* Use an arc transfer height (ignition height) of .070” (1.8 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-16
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
277150
Outer Cap
277154
Imperial
Nozzle
277124
Electrode
277132
Retaining Cap
277113
Swirl Ring
277140
Material
Thickness
Preflow
Nitrogen
Plasma
H17
Shield
Nitrogen
Postflow
Nitrogen
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
3/16
35
60
36
13
135
80
Material
Thickness
Preflow
Nitrogen
Plasma
H17
Shield
Nitrogen
Postflow
Nitrogen
Arc
Voltage
Travel
Speed
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
5
35
60
36
13
135
Metric
Torch Head
279150
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.100
.200
300
.090
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm/m)
(mm)
(mm)
(msec)
(mm)
2030
2.5
5.1
300
2.3
H17=17.5% Hydrogen / 32.5% Argon / 50.0% Nitrogen
* Use an arc transfer height (ignition height) of .150” (3.8 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-17
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
277150
Outer Cap
277154
Imperial
Material
Thickness
(ga)
(in)
10
.135
3/16
1/4
Nozzle
277125
Electrode
277131
Retaining Cap
277153
Swirl Ring
277142
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
132
120
134
100
140
25
80
25
2
3/8
Metric
Torch Head
279150
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.060
.150
200
.070
.200
300
75
.090
.225
400
148
50
.120
.250
500
.085
.090
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
131
3210
1.4
3.3
200
25
80
25
2
134
2445
1.8
5.1
138
2050
2.1
5.5
3
5
6
400
2.2
2.3
* Use an arc transfer height (ignition height) of .150” (3.3 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-18
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
277146
Outer Cap
277154
Imperial
Nozzle
277126
Electrode
277133
Retaining Cap
277113
Swirl Ring
277141
Material
Thickness
Preflow
Nitrogen
Plasma
H17
Shield
Nitrogen
Postflow
Nitrogen
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
138
115
140
100
152
65
3/16
1/4
28
67
46
13
3/8
Metric
Torch Head
279150
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.105
.200
300
.100
.125
.225
400
.180
.250
500
.105
Material
Thickness
Preflow
Nitrogen
Plasma
H17
Shield
Nitrogen
Postflow
Nitrogen
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
28
67
46
13
5
6
138
2865
2.7
5.1
139
2625
3.0
5.5
400
2.5
2.7
H17=17.5% Hydrogen / 32.5% Argon / 50.0% Nitrogen
* Use an arc transfer height (ignition height) of .200” (5.1 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-19
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
277286
Outer Cap
277154
Imperial
Nozzle
277284
Electrode
277282
Retaining Cap
277151
Swirl Ring
277283
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
141
100
147
80
154
55
1/4
3/8
25
94
35
0
1/2
Metric
Torch Head
279150
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.135
.225
400
.092
.170
.250
500
.210
.300
600
.095
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
140
2595
3.2
5.6
400
2.3
25
94
35
0
148
1935
4.4
6.5
152
1540
5.0
7.3
600
2.4
6
10
12
* Use an arc transfer height (ignition height) of .200” (5.1 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-20
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
277298
Outer Cap
277154
Imperial
Nozzle
277297
Electrode
277135
Retaining Cap
277266
Swirl Ring
277139
Material
Thickness
Preflow
Nitrogen
Plasma
H17
Shield
Nitrogen
Postflow
Nitrogen
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
Torch Head
279150
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(ipm)
(in)
(in)
(msec)
1/4
95
.250
.250
400
3/8
75
.150
.275
500
60
.165
.300
600
5/8
50
.185
.325
800
3/4
40
.250
.350
1200
.145
1/2
Metric
25
81
75
13
165
.135
.140
Material
Thickness
Preflow
Nitrogen
Plasma
H17
Shield
Nitrogen
Postflow
Nitrogen
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
1845
3.8
7.0
1610
4.1
7.4
1260
4.7
8.3
800
940
6.9
9.0
1200
10
12
16
25
81
75
155
13
20
167
600
3.4
3.6
3.7
H17=17.5% Hydrogen / 32.5% Argon / 50.0% Nitrogen
* Use an arc transfer height (ignition height) of .200” (5.1 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-21
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
277117
Outer Cap
277154
Imperial
Nozzle
277293
Electrode
277292
Retaining Cap
277152
Swirl Ring
277139
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
Torch Head
279150
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(volts)
(ipm)
(in)
(in)
(msec)
1/4
145
150
.160
.250
400
3/8
150
115
.180
.275
500
155
85
.210
.300
600
5/8
160
60
.220
.325
800
3/4
168
45
.240
.350
1200
.135
1/2
Metric
25
75
70
0
.125
.130
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
400
6
144
3910
4.0
6.3
10
150
2805
4.7
7.0
153
2330
5.1
7.4
16
160
1510
5.6
8.3
800
20
170
1030
6.2
9.0
1200
12
25
75
70
0
3.2
600
3.3
3.4
* Use an arc transfer height (ignition height) of .200” (5.1 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-22
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
277274
Outer Cap
277154
Imperial
Nozzle
277287
Electrode
277135
Retaining Cap
277266
Swirl Ring
277259
Material
Thickness
Preflow
Nitrogen
Plasma
H17
Shield
Nitrogen
Postflow
Nitrogen
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
Torch Head
279150
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(volts)
(ipm)
(in)
(in)
(msec)
3/8
156
80
.195
.250
500
1/2
148
75
.130
.300
600
155
60
.190
.350
800
3/4
160
50
.200
.400
1200
1.0
170
35
.240
.450
1500
.160
5/8
Metric
37
68
85
13
.150
.155
Material
Thickness
Preflow
Nitrogen
Plasma
H17
Shield
Nitrogen
Postflow
Nitrogen
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
10
154
2010
4.7
6.5
12
149
1935
3.6
7.3
600
3.8
16
37
68
85
13
155
1515
4.8
8.9
20
161
1215
5.2
10.3
25
169
915
6.0
11.3
800
1500
3.9
4.1
H17=17.5% Hydrogen / 32.5% Argon / 50.0% Nitrogen
* Use an arc transfer height (ignition height) of .200” (5.1 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-23
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
277274
Outer Cap
277154
Imperial
Nozzle
277289
Electrode
277291
Retaining Cap
277266
Swirl Ring
277143
Torch Head
279150
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
(in)
(psi)
(psi)
(psi)
(psi)
(in)
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(volts)
(ipm)
1/4
130
200
3/8
133
150
1/2
140
110
.115
146
75
.150
.350
800
153
60
.190
.400
1200
5/8
3/4
20
82
58
0
.070
(in)
(msec)
.200
400
.250
500
.300
600
1.0
158
40
.210
.450
1.25 **
170
20
.250
.350
1.50 **
180
10
.275
.350
Metric
.150
.152
.155
.160
1500
.165
.175
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(mm)
(volts)
(mm/m)
(mm)
(mm)
(msec)
6
129
5220
1.8
4.9
400
10
134
3655
1.9
6.5
12
138
3020
2.6
7.3
16
146
1890
3.8
8.9
153
1450
4.8
10.3
20
20
82
58
0
25
157
1050
5.2
11.3
32 **
170
495
6.4
8.9
38 **
179
260
6.9
8.9
3.8
600
800
1500
3.9
4.1
4.2
4.4
* Use an arc transfer height (ignition height) of .200” (4.9 mm)
** Edge start recommended
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-24
Operation
ProLine 2200 User’s Manual REV N
Aluminum - 30 Amps – Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277145
Outer Cap
277154
Imperial
Nozzle
277120
Electrode
277130
Retaining Cap
277153
Swirl Ring
277140
Torch Head
279150
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
30
92
20
2
135
.100
100
.065
.150
200
.070
.040
.050
150
.063
Metric
120
.030
90
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
2.5
100
1.7
3.4
200
1.8
1
1.5
30
92
20
2
135
3885
2520
0.8
* Use an arc transfer height (ignition height) of .100” (2.5 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-25
Operation
ProLine 2200 User’s Manual REV N
Aluminum - 50 Amps – Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277150
Outer Cap
277154
Imperial
Nozzle
277122
Electrode
277131
Retaining Cap
277153
Swirl Ring
277142
Torch Head
279150
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
135
180
.050
100
.080
25
74
19
1
138
140
.065
150
.082
143
90
.075
.150
200
.085
.050
.063
.080
Metric
.100
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
137
3870
1.5
2.5
150
2.1
142
2360
1.8
3.7
200
2.2
1.5
2.0
25
74
19
1
* Use an arc transfer height (ignition height) of .100” (2.5 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-26
Operation
ProLine 2200 User’s Manual REV N
Aluminum - 70 Amps – Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277150
Outer Cap
277154
Imperial
Nozzle
277125
Electrode
277131
Retaining Cap
277153
Swirl Ring
277142
Torch Head
279150
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
.080
130
250
.050
.150
1/8
135
160
.070
.175
100
.080
145
80
.100
.200
200
150
50
.060
.250
300
3/8
155
40
.075
.275
400
1/2
162
30
.115
.300
500
3/16
1/4
Metric
25
80
25
2
.085
.090
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
100
2.0
300
2.2
500
2.3
2
129
6400
1.2
3.7
3
134
4420
1.7
4.3
145
1920
2.3
5.2
148
1440
1.7
6.1
10
156
975
2.0
7.0
12
160
820
2.6
7.4
5
6
25
80
25
2
* Use an arc transfer height (ignition height) of .150” (3.7 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-27
Operation
ProLine 2200 User’s Manual REV N
Aluminum - 100 Amps – Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277286
Outer Cap
277154
Imperial
Nozzle
277284
Electrode
277282
Retaining Cap
277151
Swirl Ring
277283
Torch Head
279150
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
158
105
.155
.250
300
.095
25
94
26
0
162
90
.180
.275
400
.098
165
70
.195
.300
500
.100
1/4
3/8
1/2
Metric
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
158
2710
3.8
6.3
300
2.4
162
2210
4.6
7.0
165
1890
4.9
7.4
500
2.5
6
10
25
94
26
0
12
* Use an arc transfer height (ignition height) of .250” (6.3 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-28
Operation
ProLine 2200 User’s Manual REV N
Aluminum - 150 Amps – Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277117
Outer Cap
277154
Imperial
Nozzle
277293
Electrode
277292
Retaining Cap
277152
Swirl Ring
277139
Torch Head
279150
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
1/4
145
145
.130
.250
400
3/8
155
115
.185
.275
500
165
90
.230
.300
600
.130
.325
800
.135
.350
1200
.140
1/2
25
75
50
1
5/8
170
3/4
Metric
65
45
.250
.125
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(mm)
(volts)
(mm/m)
(mm)
(mm)
(msec)
6
143
3770
3.1
6.3
400
10
156
2825
4.8
7.0
5.5
7.4
12
25
75
50
1
162
2430
16
170
1630
20
170
990
6.4
8.3
9.0
600
1200
3.2
3.3
3.4
3.6
* Use an arc transfer height (ignition height) of .250” (6.3 mm)
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-29
Operation
ProLine 2200 User’s Manual REV N
Aluminum - 200 Amps – Air Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277274
Outer Cap
277154
Imperial
Nozzle
277289
Electrode
277291
Retaining Cap
277266
Swirl Ring
277143
Torch Head
279150
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
(in)
150
190
.135
.250
300
145
.140
.275
400
.300
500
.350
600
1/4
3/8
1/2
5/8
155
20
82
58
0
160
3/4
1.0 **
Metric
110
95
.135
65
.150
175
35
.200
.400
.150
.155
800
.160
1000
.170
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
149
4955
3.3
6.3
300
3545
3.5
7.0
6
10
12
16
155
20
82
58
0
2995
3.4
160
2380
20
162
1575
3.9
25 **
174
940
5.0
7.4
3.8
500
8.9
800
10.2
1000
3.9
4.1
4.3
* Use an arc transfer height (ignition height) of .250” (6.3 mm)
** Edge start recommended
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-30
Operation
ProLine 2200 User’s Manual REV N
Mild Steel Marking - 10 Amps – Nitrogen Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277145
Outer Cap
277154
Imperial
Nozzle
277120
Retaining Cap
277152
Material
Thickness
Preflow
(Air)
(in)
(psi)
(psi)
All Thicknesses
28
28
Metric
Electrode
277190
Swirl Ring
277140
Plasma
Shield
(Nitrogen) (Nitrogen)
Torch Head
279150
Postflow
(Air)
Arc
Voltage
Travel
Speed
Marking
Height
Initial
Height
Motion
Delay
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
28
2
145
250
.177
.100
0
Postflow
(Air)
Arc
Voltage
Travel
Speed
Marking
Height
Initial
Height
Motion
Delay
Material
Thickness
Preflow
(Air)
Plasma
Shield
(Nitrogen) (Nitrogen)
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
All Thicknesses
28
28
28
2
145
6350
4.5
2.5
0
1. Revised on 10/12/07
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-31
Operation
ProLine 2200 User’s Manual REV N
Stainless Steel Marking - 10 Amps – Nitrogen Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277145
Outer Cap
277154
Imperial
Nozzle
277120
Retaining Cap
277152
Material
Thickness
Preflow
(Air)
(in)
(psi)
(psi)
All Thicknesses
28
28
Metric
Electrode
277190
Swirl Ring
277140
Plasma
Shield
(Nitrogen) (Nitrogen)
Torch Head
279150
Postflow
(Air)
Arc
Voltage
Travel
Speed
Marking
Height
Initial
Height
Motion
Delay
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
28
2
145
250
.177
.100
0
Postflow
(Air)
Arc
Voltage
Travel
Speed
Marking
Height
Initial
Height
Motion
Delay
Material
Thickness
Preflow
(Air)
Plasma
Shield
(Nitrogen) (Nitrogen)
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
All Thicknesses
28
28
28
2
145
6350
4.5
2.5
0
1. Revised on 10/12/07
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-32
Operation
ProLine 2200 User’s Manual REV N
Aluminum Marking - 10 Amps – Nitrogen Plasma / Nitrogen Shield
Copper Electrode
Shield Cap
277145
Outer Cap
277154
Imperial
Nozzle
277120
Retaining Cap
277152
Material
Thickness
Preflow
(Air)
(in)
(psi)
(psi)
All Thicknesses
28
28
Metric
Electrode
277190
Swirl Ring
277140
Plasma
Shield
(Nitrogen) (Nitrogen)
Torch Head
279150
Postflow
(Air)
Arc
Voltage
Travel
Speed
Marking
Height
Initial
Height
Motion
Delay
(psi)
(psi)
(volts)
(ipm)
(in)
(in)
(msec)
28
2
145
250
.177
.100
0
Postflow
(Air)
Arc
Voltage
Travel
Speed
Marking
Height
Initial
Height
Motion
Delay
Material
Thickness
Preflow
(Air)
Plasma
Shield
(Nitrogen) (Nitrogen)
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
All Thicknesses
28
28
28
2
145
6350
4.5
2.5
0
1. Revised on 10/12/07
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-33
Operation
ProLine 2200 User’s Manual REV N
Mild Steel - 200 Amps – Oxygen Plasma / Air Shield
Silver Electrode
Shield Cap
277274
Outer Cap
277154
Imperial
Nozzle
279489
Electrode
279440
(yellow o-ring)
Retaining Cap
277266
Swirl Ring
279443
Torch Head
279160
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(volts)
(ipm)
(in)
(in)
(msec)
1/4
125
230
.040
.200
300
3/8
130
140
.090
.250
400
1/2
133
120
.115
.300
500
5/8
137
100
.130
.350
600
.152
3/4
140
75
.150
.400
800
.153
147
50
.175
.450
1000
155
25
.240
.500
1
20
82
58
0
1.25
1.5 **
165
17
.300
.350
1.75 **
175
12
.350
.350
2.0 **
185
7
.500
.500
Metric
1500
.150
.155
158
.160
Material
Thickness
Preflow
Air
Plasma
Oxygen
Shield
Air
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
300
6
124
6100
.8
4.9
10
130
3480
2.3
6.5
12
132
3160
2.7
7.3
16
137
2515
3.3
8.9
20
141
1810
3.8
10.3
146
1310
4.3
11.3
25
20
82
58
0
32
155
610
6.1
12.7
38 **
164
435
7.5
8.9
45 **
175
295
9.2
9.2
50 **
183
195
12.2
12.2
500
3.8
800
1000
3.9
1500
4.0
4.1
* Use an arc transfer height (ignition height) of .200” (4.9 mm)
** Edge start recommended
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-34
Operation
ProLine 2200 User’s Manual REV N
Stainless Steel - 200 Amps – Air Plasma / Nitrogen Shield
Silver Electrode
Shield Cap
277274
Outer Cap
277154
Imperial
Nozzle
279489
Electrode
279440
(yellow o-ring)
Retaining Cap
277266
Swirl Ring
279443
Torch Head
279160
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
(in)
(psi)
(psi)
(psi)
(psi)
(in)
(volts)
(ipm)
1/4
130
200
3/8
133
150
1/2
140
110
146
153
5/8
3/4
20
82
58
0
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
.200
400
.250
500
.115
.300
600
75
.150
.350
800
60
.190
.400
1200
.070
1.0
158
40
.210
.450
1.25 **
170
20
.250
.350
1.50 **
180
10
.275
.350
Metric
.150
.152
.155
.160
1500
.165
.175
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(mm)
(volts)
(mm/m)
(mm)
(mm)
(msec)
6
129
5220
1.8
4.9
400
10
134
3655
1.9
6.5
12
138
3020
2.6
7.3
16
146
1890
3.8
8.9
153
1450
4.8
10.3
20
20
82
58
0
25
157
1050
5.2
11.3
32 **
170
495
6.4
8.9
38 **
179
260
6.9
8.9
3.8
600
800
1500
3.9
4.1
4.2
4.4
* Use an arc transfer height (ignition height) of .200” (4.9 mm)
** Edge start recommended
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-35
Operation
ProLine 2200 User’s Manual REV N
Aluminum - 200 Amps – Air Plasma / Nitrogen Shield
Silver Electrode
Shield Cap
277274
Outer Cap
277154
Imperial
Nozzle
279489
Electrode
279440
(yellow o-ring)
Retaining Cap
277266
Swirl Ring
279443
Torch Head
279160
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
(in)
(psi)
(psi)
(psi)
(psi)
(volts)
(ipm)
150
190
145
.140
1/4
3/8
1/2
5/8
155
20
82
58
0
160
3/4
1.0 **
Metric
110
95
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(in)
(in)
(msec)
(in)
.135
.250
300
.275
400
.300
500
.350
600
.135
65
.150
175
35
.200
.400
.150
.155
800
.160
1000
.170
Material
Thickness
Preflow
Air
Plasma
Air
Shield
Nitrogen
Postflow
Air
Arc
Voltage
Travel
Speed
Cutting
Height
Pierce
Height
Pierce
Time
Kerf
Width
(mm)
(psi)
(psi)
(psi)
(psi)
(volts)
(mm/m)
(mm)
(mm)
(msec)
(mm)
149
4955
3.3
6.3
300
3545
3.5
7.0
6
10
12
16
155
20
82
58
0
2995
3.4
160
2380
20
162
1575
3.9
25 **
174
940
5.0
7.4
3.8
500
8.9
800
10.2
1000
3.9
4.1
4.3
* Use an arc transfer height (ignition height) of .250” (6.3 mm)
** Edge start recommended
1. Revised on 01/18/2011
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
4-36
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.
Use extreme caution when working near the power conversion module (i.e., chopper).
The large electrolytic capacitors store large amounts of energy even after power has
been removed from the system. Wait at least five minutes after turning off power, and
then use a voltmeter to verify that the capacitors are fully discharged before touching
the power conversion module.
Capacitor failure can injure and/or cause property damage. If troubleshooting
requires the system to be powered with the enclosure panels removed, remain clear of
the capacitors. Failure of a capacitor can result in a sudden release of stored energy
causing rupture of the capacitor case.
Routine Maintenance
Note: At minimum, these checks should be performed on a monthly basis. In
excessively dirty environments or in heavy usage situations, the checks should be
performed more frequently.
Power Supply
1. Remove the left, right, front, and rear panels of the power supply.
2. Using clean, dry, compressed air, blow out all accumulated dust inside the power
supply, including dust on p.c. boards and fans. Be sure to blow out the fan and heat
exchanger at the rear of the unit. In an excessively dirty environment, blow out the
unit on a weekly basis.
3. Verify that all torch lead and work ground connections are secure and free from
corrosion.
4. Verify that the primary three phase A.C. voltage connections are tight
5. Verify that all p.c. board connectors are installed securely.
6. Verify that the rear panel cable connectors are installed securely.
7. Verify that the gas console connectors are installed securely to the plugs on the
bottom of the gas console.
8. Check the torch coolant filter/deionization cartridge at the rear of the power supply
and replace if dirty.
9. Flush the cooling system every six months and replace the coolant and coolant
filter/deionization cartridge.
Gas Console
1. Remove the cover of the gas console.
2. Using clean, dry, compressed air, blow out all accumulated dust inside the unit. In
an excessively dirty environment, blow out the unit on a weekly basis.
3. Verify that all p.c. board connectors are installed securely.
4. Verify that all gas hose connectors are tight and that there are no leaks. Only tighten
the gas fittings enough to make a gas seal. The fittings are subject to damage if over tightened.
5. Inspect all gas hoses to ensure no damage exists. Immediately replace any damaged
gas hoses.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-1
Maintenance and Troubleshooting
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.
2. Verify that the braided shield of the torch leads is fastened securely to the brass
shield adapter that connects to the remote high frequency console. Also, make sure
the shield adapter is secured tightly to the high frequency console enclosure.
3. Inspect the braided shield for nicks or cuts and replace if necessary.
4. Remove the torch handle and verify that the connections at the torch base are
tightened securely. Only tighten the fittings enough to make a water or gas seal. The fittings
are subject to damage if over tightened.
5. Make sure the torch lead insulating sleeves are positioned to properly cover the brass
torch fittings at the torch base.
6. Inspect the outer sleeve on the torch base's electrode/coolant supply lead. If nicks,
cuts or holes are found, replace the torch base.
7. Remove the torch consumables from the torch head and inspect the o-rings on the
torch base. Replace any o-rings with cuts, nicks, abrasions, or any other signs of
wear. Faulty o-rings may cause gas or water leaks, which will affect cut quality.
8. With the electrode removed, inspect the cooling tube in the torch head for damage. If
using a copper electrode, the torch head uses cooling tube P/N 277007. If replacement
is required, use tool P/N 200109.
If using a silver electrode, the torch head uses cooling tube P/N 279117 and cooling tube
holder P/N 279116. Remove the cooling tube holder using tool P/N 277087 and inspect
the o-rings for damage. Apply a small amount of o-ring lubricant before re-installing in
the torch head.
9. Wipe any excess o-ring lubricant off of the torch base and head.
Remote High Frequency Console
1. Open the cover of the RHF console and verify that all leads and hoses are tightened
securely. Only tighten the fittings enough to make a water or gas seal. The fittings are subject to
damage if over tightened.
2. Check the spark gap electrodes for signs of wear. Replace electrodes that have
rounded faces. Use a clean feeler gauge and set the spark gap to .015” (.38 mm).
Work Ground
1. Verify that the work ground lead is securely fastened to the star ground on the
cutting table, and that the connection point is free from corrosion. Use a wire brush
to clean the connection point if necessary.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-2
Maintenance and Troubleshooting
ProLine 2200 User’s Manual REV N
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.
Note: When handling coolant, it is recommended that you wear nitrile gloves
and safety glasses.
1.
Remove primary power to the system.
2.
Remove the rear cover of the power supply to expose the cooling system.
3.
Remove the coolant reservoir cap/level gauge.
4.
Make sure that consumables are properly installed in the torch head and that
the torch head is installed on the torch base.
5.
Using a funnel to collect the coolant, unscrew the drain petcock on the
bottom of the coolant reservoir. Leave the funnel in place after the coolant
drains out of the reservoir.
6.
Remove the torch coolant supply hose from the rear of the power supply.
Note that the coolant supply hose has right hand threads.
7.
Blow compressed air (100 psi maximum) into the coolant supply hose. This
will clear the coolant out of the torch, torch leads, and heat exchanger. Note
that the coolant will be forced into the reservoir and will drain out of the
drain petcock.
8.
Unscrew the lower portion of the coolant filter housing and remove the
coolant filter/deionization cartridge.
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.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-3
Maintenance and Troubleshooting
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. To change the operating voltage for these systems, perform the following
procedures.
230V 60Hz Operation
For 230V operation, install a #4 AWG jumper wire from 0V to 0V on each primary
winding of the transformer (total of 3 wires). Install a second #4 AWG jumper wire from
230V to 230V on each primary winding of the transformer (total of 3 wires). Now install
a #4 AWG jumper wire 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. Connect the three phase primary power
from the main contactor to one of the 230V connections on each primary winding. See
Figure 5-1. Note When the primary voltage of TR1 is changed, the control transformer TR2 must also
be rewired for the correct service voltage. For 230V operation, connect the white wire of
control transformer TR2 to TB1-13 and the red/white wire to TB1-14.
Figure 5-1 230V 60 Hz Transformer Configuration
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-4
Maintenance and Troubleshooting
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. Connect the
three phase primary power from the main contactor to each of the 230V connections that
are without jumper wires. See Figure 5-2. Note When the primary voltage of TR1 is changed,
the control transformer TR2 must also be rewired for the correct service voltage. For 460V
operation, connect the white wire of control transformer TR2 to TB1-13 and the black
wire to TB1-14.
Figure 5-2 460V 60 Hz Transformer Configuration
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-5
Maintenance and Troubleshooting
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:
LED
LED 1 PAR
LED 2 CON
LED 3 SURGE
LED 4 PREFLOW
LED 5 LATCH
LED 6 AUX2 OUT
LED 7 PUMP
LED 8 START
LED 9 CHOPPER
LED 10 PAT
LED 11 TAC
LED 12 MOTION
LED 13 HOLD IN
Indication
Pilot arc relay energized
Main contactor energized
CR3 and K1 (I/O p.c. board) relays energized
Preflow gas valve 1 energized
Latch relay on the relay p.c. board energized
Shield gas valve GSV3 energized
Coolant pump relay CR5 energized
Plasma start signal applied to ProLine
Chopper energized
Pilot arc transistor energized
Transferred arc established from torch to workpiece
Motion relay energized
Arc hold input or IHS hold input enabled to keep
arc from igniting
LED 14 HOLD OUT
Hold relay energized / used for dual power supply
mode
LED 15 MAN CONSOLE Manual gas console attached
LED 16 5V uP PWR
5V microprocessor power supply satisfactory
LED 17 12V uP PWR
12V microprocessor power supply satisfactory
LED 18 ILK PWR
12V interlock power supply satisfactory
LED 19 ANALOG PWR 15V analog power satisfactory
LED 20 GAS PWR
24V gas solenoid power satisfactory
LED 21 OVER CURRENT Current output exceeded 200 amps / power down to
reset
LED 22 ERROR
Blinks on and off to display error codes
LED 23 GSV4
Postflow gas valve 4 energized
LED 24 PLASMA
Plasma gas valve 2 energized
LED 25 AUX OUT
Auxiliary output energized
LED 26 3 PHASE
Correct three phase power applied to chopper
LED 27 HIGH FREQ
High frequency transformer TR5 energized
LED 29 –15V
-15V analog power satisfactory
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-6
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
• LED 19 ANALOG PWR
• LED 20 GAS PWR
• LED 29 –15V
The following LED’s should illuminate when the ON button is depressed:
• LED 26 3 PHASE
• LED 7 PUMP
• LED 5 LATCH
The following LED’s should illuminate in sequence after a start signal is
received:
• LED 8 START
• LED 4 PREFLOW
• LED 6 AUX2 OUT
• LED 14 HOLD OUT
• LED 2 CON
• LED 9 CHOPPER
• LED 1 PAR
• LED 10 PAT
• LED 27 HIGH FREQ
• LED 11 TAC
• LED 24 PLASMA
• LED 12 MOTION
After a transferred cutting arc is established, the following LED’s will go
out:
• LED 14 HOLD OUT
• LED 27 HIGH FREQ
• LED 4 PREFLOW
• LED 10 PAT
When the start signal is removed, all of the cut cycle LED’s will extinguish
except for LED 23 GSV4, which will illuminate for approximately 3 seconds
and then go out.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-7
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.
•
•
•
•
•
•
RHF Door LED - Extinguishes when the RHF door switch opens. Check the
RHF door, switch, and associated wiring.
Gas Console LED - Extinguishes when the preflow outlet, plasma outlet, or
shield inlet pressures are low.
3 Phase Power LED - Extinguishes when there is a problem with the three
phase power being supplied to the chopper assembly. Verify that the primary
wall disconnect fuses are good and check the main transformer, main
contactor and A.C. Detect p.c. board for proper operation. Also, this LED
should turn on immediately when the green “ON” button is pressed. If not,
check P28-3 to P28-4 for 10 VDC first. This should drop to 0 VDC when the
ON button is pushed. If not, then check CR1 and associated wiring.
Coolant Flow LED - Extinguishes when there is a problem with the torch
coolant system. Check the coolant pump fuse F2 and verify that 230VAC is
present between TB3-13 and TB3-14. Also check for clogs in the coolant
leads and coolant filter/deionization cartridge.
Coolant Level LED - Extinguishes when the coolant level in the tank has
dropped below the required minimum level. Add more coolant to clear the
error.
Coolant Temperature LED - Extinguishes when the coolant temperature has
risen above the maximum operating temperature. Ensure that the heat
exchanger fan is running and that the heat exchanger is free from dust. Blow
out the heat exchanger and fan with clean, dry, oil-free compressed air. Leave
the unit running until the LED illuminates.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-8
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. The power supply microprocessor board displays
an error code by blinking LED22 on and off to indicate that an error has occurred.
The number of blinks can be counted to determine which error has occurred. The
following chart lists the errors and the corresponding number of blinks.
LED22 Number of Blinks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Error
No transferred arc (TAC) established
TAC lost before current slope up
TAC lost during current slope up
TAC lost while cutting
TAC lost during current slope down
Start signal applied prematurely or
while Gas Test/Run switch is in the
Run position
Start signal removed prematurely
Output voltage below 60V
Output voltage above 210V
Invalid current set point
Current feedback circuit open
TAC not established within 2 seconds
IHS or arc hold timed out
Pilot arc not established
Low current during cut
TAC sensed when start signal applied
Faulty AC phase
Low torch coolant flow
Gas console error
RHF door switch open
Low torch coolant level
High torch coolant temperature
Main contactor shorted
N/A
Defective Flow Switch
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5-9
Maintenance and Troubleshooting
ProLine 2200 User’s Manual REV N
General Troubleshooting
The following chart lists general troubleshooting guidelines for the ProLine system when
the status 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.
The primary system fuse F1 is located on the rear panel of the unit. All of the control
fuses are located behind the front panel of the unit beside the microprocessor p.c. board.
The automatic gas console fuse is located behind the right side panel of the system. Also
check all of the voltage LED’s on the system p.c. boards before performing any tests.
Problem
Front panel white A.C. power light will
not illuminate
1.
2.
3.
4.
Unit will not energize when the ON
button is pressed
1.
2.
3.
4.
Possible Cause
Primary disconnect fuse blown.
Fuse F1 or F4 blown.
White light or associated wiring bad.
Transformer TR2 or associated wiring bad.
RHF door open.
Low coolant level.
Fuse F4 blown.
Faulty ON switch or associated wiring. The
ON switch is normally open.
5. Faulty OFF switch or associated wiring. The
OFF switch is normally closed.
6. Relay CR1 coil open.
Power supply will not stay on when the
front panel ON button is pressed and
released
1. Check the control panel status LED’s and
troubleshoot accordingly.
2. Faulty latch relay on relay p.c. board.
3. Faulty relay p.c. board.
4. Faulty microprocessor p.c. board.
5. Relay CR1 defective.
No arc at the torch
1. Incorrect torch consumables installed.
2. Incorrect gas pressure settings.
3. Check the control panel status LED’s and
troubleshoot accordingly.
4. Check the spark gap assembly inside the RHF
console for proper arcing after a start signal is
applied. Open the RHF door and pull up on
the door interlock switch plunger to defeat the
interlock. If there is no spark, skip to the next
test.
5. Pilot arc resistor PAR or pilot arc transistor
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.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
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5-10
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.
Check the
8. Open torch or torch leads.
continuity from the Electrode lead to the torch
electrode and the Nozzle lead to the large brass
body of the torch.
No spark between the spark gap
electrodes
The arc will not transfer to the
workpiece
1. Improper spark gap. Set gap to .015” (.381
mm).
2. Worn spark gap electrodes. Clean electrodes
with 600 grit sandpaper and regap. Replace
electrodes that have a rounded face.
3. Bad high frequency transformer TR5. Check
for signs of arcing.
4. Check for 120VAC on the input side of filter
FL1 inside the RHF console after a start signal
has been given. If 120V is not present, check
associated wiring back to the power supply.
1. Loose work ground connection.
2. Pierce height too high.
3. Incorrect, damaged, or worn consumables.
Gas pressures will not adjust properly
1. Wrong consumables installed in torch.
2. Pressure regulator orifice clogged with dirt or
debris. Turn off primary power and turn
regulator adjustment knob fully clockwise.
Low pressure error
1. Supply gas pressure(s) less than 150 psi.
2. Faulty pressure switch or associated wiring
inside gas 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.
5-11
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).
The large electrolytic capacitors store large amounts of energy even after power has
been removed from the system. Wait at least five minutes after turning off power, and
then use a voltmeter to verify that the capacitors are fully discharged before touching
the power conversion module.
Capacitor failure can injure and/or cause property damage. If troubleshooting
requires the system to be powered with the enclosure panels removed, remain clear of
the capacitors. Failure of a capacitor can result in a sudden release of stored energy
causing rupture of the capacitor case.
Note: A chopper troubleshooting flow chart can be found at the end of this section.
1.
Turn off all power to the ProLine power supply.
2.
Open the RHF console door and disconnect the black primary wires of the high
frequency transformer from the 120 VAC line filter. Close the RHF console
door to activate the door interlock switch.
3.
Remove the front and left side panels from the power supply to expose the output
terminal block and the microprocessor p.c. board.
4.
Remove the Electrode and Nozzle leads from the bottom connections of the
output terminal block (refer to Figure 3-3).
5.
Apply three phase power to the unit and check the primary power on the input
terminal block TB5 (refer to Figure 3-2).
6.
Depress the ON button to energize the ProLine system, and then apply a start
signal to the unit. Note that the unit will only energize for approximately two seconds each
time a start signal is applied. When making the following readings, be sure the red DC Power
light is illuminated on the front control panel of the unit. After applying the start signal,
check the three phase voltage input to the chopper at the diode bridge terminals
(three right side screws on the chopper assembly) for 208 VAC. If the voltage is
not present, check for primary voltage on the main contactor CON and on the
primary side of the power transformer.
7.
With a start signal applied, check for 300 VDC at the ProLine output terminal
block between Electrode and Work. If 300 VDC is present, the chopper is
working properly.
8. If 300 VDC is not present at the output terminal block, install a jumper wire
between P28-7 & P28-8 (ILK1). With a start signal applied, check for 300 VDC
at the Proline output terminal block between Electrode and Work. If 300 VDC is
present, the chopper is working properly. Check the I/O PCB (HV- Output) and
its wiring to the Microprocessor PCB.
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5-12
Maintenance and Troubleshooting
9.
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 & 5 off - go to step 10.
b) LED’s 4 & 5 on, LED 6 off - go to step 11.
c) LED’s 4 & 5 on, LED 6 on, LED 7 off - go to step 12.
d) Only LED 4 or LED 5 on (not both) - replace chopper.
e) All LEDs on – replace chopper.
10. Check the 120 VAC supply to the chopper between P1-1 and P1-3 on the
chopper p.c. board. If 120 V is present, replace the chopper. If 120 V is not
present, check fuse F3 and associated wiring.
11. Apply a start signal to the power supply and heck the DC voltage between P2-4
(ground) and P2-5 (signal) on the chopper p.c. board. This voltage should
change from approximately 15.5 VDC to less than 1 VDC after the main
contactor of the power supply is energized. If 15.5 VDC is not present, replace
the chopper. If no voltage change occurs, check for approximately 15.5 VDC
between P26-1 (ground) and P26-2 (signal) on the microprocessor p.c. board. If
15.5 VDC is not present, check continuity between P26 on the microprocessor
p.c. board and P2 on the chopper p.c. board. If 15.5 VDC is present at the
microprocessor p.c. board, replace the microprocessor.
12. Turn off primary power to the power supply. Disconnect P2 from the
chopper p.c. board and P26 from the microprocessor p.c. board. Check
continuity between P26-8 and P2-1 and between P26-7 and P2-2. Also check
that these wires are not shorted to each other. If the cable is OK, connect P26 to
the microprocessor p.c. board, but leave P2 disconnected from the chopper.
With power applied, give the power supply a start signal and check for
approximately 10 VDC between P26-7 (ground) and P26-8 (signal) when the
main contactor is energized.
If 10 VDC is not present, replace the
microprocessor p.c. board. If 10 VDC is present, turn all power off, reconnect
P2 to the chopper p.c. board, and repeat the test for 10 VDC between P2-2
(ground) and P2-1 (signal). If 10 VDC is present and LED 7 is not illuminated,
replace the chopper.
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-13
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.
5-14
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.
5-15
Maintenance and Troubleshooting
ProLine 2200 User’s Manual REV N
BLANK PAGE
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
5-16
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
1
2
3
4
5
6
7
8
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Not shown
32
33
34
35
36
37
708088
708111
708090
708089
501163
501164
501162
501161
707200
500557
706205
500559
706200
706201
706204
706203
706202
709086
709007
709058
709012
709011
709059
709076
709033
278450
709002
709001
709124
709061
709128
709060
500810
200092
200292
500518
708062
505024
500052
500513
500511
Quantity Description
1
1
1
1
2
2
1
1
1
1
1
4
4
9
1
2
1
3
1
1
3
1
1
2
2
1
1
1
1
1
1
1
1
1
1
Off switch, red
Off actuator, red
On switch, green
On actuator, green / illuminated
Light housing
Bulb
White lens
Red lens
L1 inductor
TR2 control transformer, 208/230/460 V / 60 Hz
TR2 control transformer, 575 V / 60 Hz
TR2 control transformer, 380/415 V / 50/60 Hz
TR1 main transformer, 208 V / 60 Hz / 3Ø
TR1 main transformer, 230/460 V / 60 Hz / 3Ø
TR1 main transformer, 380 V / 50/60 Hz / 3Ø
TR1 main transformer, 415 V / 50/60 Hz / 3Ø
TR1 main transformer, 575 V / 60 Hz / 3Ø
TB1 – TB4 terminal block marker strip, 14 position
TB1 – TB4 terminal block, 14 position
F2-F5, F7-F11 fuse holder
F10 fuse, AGC 3A fuse
F3/F4 fuse, AGC 5A
F8 fuse, AGC 2A
F7/F9/F11 fuse, AGC 1/2A
F5 fuse, AGC 1A
Microprocessor p.c. board assembly
P8/P12/P13, 14 socket receptacle
P7, 4 pin receptacle
P16, 9 socket receptacle
F1A/F1B fuse holder
F1A/F1B fuse, FNM 6.25A
Strain relief
A.C. detect p.c. board assembly
Coolant reservoir, without fittings or cap
Coolant reservoir assembly, with fittings and cap
Coolant reservoir cap/level gauge
LS1 coolant level switch
TS1 Coolant temperature switch
Pump motor, 1/3hp-230V-50/60 Hz
V-band clamp
Coolant pump, 70 gph
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-1
Parts List
Item Number
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
62
63
64
65
66
67
68
69
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
ProLine 2200 User’s Manual REV N
Part Number
708061
715084
708068
708059
500516
500514
200103
500509
500510
708117
500348
702048
708118
701165
500536
705011
709167
702075
277452
Contact factory
282130
709117
709228
706036
706041
706042
706043
280003
708103
708104
708105
709190
709191
740106
704050
200204
715052
701051
710190
710191
277070
500526
709227
709231
500525
701141
Quantity
1
1
1
1
2
1
1
1
1
1
1
1
2
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
1
1
1
1
1
1
2
2
1
2
1
Description
Solenoid valve, 220/240VAC
Check valve, coolant return
CON3 coolant pump relay
FS1 coolant flow switch
Fan, heat exchanger / front panel
Heat exchanger
Shunt
Coolant filter housing
Coolant filter/deionization cartridge
CON main contactor
Relay p.c. board assembly
EMI filter, 380/415 V units only
CR2/PAR relay
R7/R8, 3 ohm pilot arc resistor
PAT IGBT drive p.c. board assembly
PAT IGBT
TB5 3Ø power terminal block
PAT IGBT filter capacitor
I/O p.c. board assembly
Height control voltage divider p.c. board assembly
Chopper assembly
I/O terminal block (small)
I/O terminal block (large)
TR8 transformer, 241-4-36
TR7 transformer, 241-3-12
TR5 transformer, 241-4-12
TR3 transformer, 241-6-12
Power supply, 24VDC
CR1 relay
CR1 relay socket
CR1 hold-down clip
TB6 terminal block marker strip, 4 position
TB6 terminal block, 4 position
Bulb, power on switch
LED/lens, green
Fan, 120V
Drain petcock
Motion delay potentiometer
Motion delay knob
Motion delay knob lock
Current thumbwheel assembly
Fan Guard
Strain relief
F2 fuse, MDL 5A
Fan, front panel
R9, 2 ohm pilot arc resistor
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-2
Parts List
ProLine 2200 User’s Manual REV N












Front panel fans not shown (item numbers 42 and 85)
Figure 6-1 Power Supply Front View
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-3
Parts List
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.
6-4
Parts List
ProLine 2200 User’s Manual REV N




Figure 6-3 Power Supply Left Side View
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-5
Parts List
ProLine 2200 User’s Manual REV N
Figure 6-4 Power Supply Right Side View
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-6
Parts List
ProLine 2200 User’s Manual REV N
Remote High Frequency Console
Note: See Figure 6-5.
Item Number Part Number Quantity Description
1
715051
2
Coolant return fitting (left hand)
2
715050
1
Coolant supply fitting (right hand)
3
709227
1
Strain relief
5
709001
1
4 pin receptacle
6
707001
1
Line filter
7
706109
1
Transformer – 5000V, 20 mA
8
702069
1
Capacitor – 15 kV
9
708057
1
Door interlock switch
10
500014
1
Spark gap assembly
11
740039
3
Spark gap electrode
12
505043
1
High frequency inductor
13
740072
1
Standoff
14
800041
1
Busbar
15
500505
1
RHF console p.c. board assembly
16
715021
1
Coolant supply fitting (right hand)
17
500503
1
Cathode manifold
18
205010
1
CTP sensor lead filter assembly
19
200287
1
Transformer insulating plate
22
500098
1
Ground cable
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-7
Parts List
ProLine 2200 User’s Manual REV N
Figure 6-5 Remote High Frequency Console
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-8
Parts List
ProLine 2200 User’s Manual REV N
Torch and Torch Valve Assembly
Item Number Part Number Quantity Description
1
2
3
4
5
6
7
8
9
10
11
12
Not shown
Not shown
Not shown
Not shown
Not shown
277475
500549
820134
279050
279150
279160
820209
500024
500018
279013
279112
279113
500740
716012
277056
277086
277087
279061
1
1
1
1
1
1
1
1
1
1
6
1
1
1
1
1
1
Torch valve assembly (includes bracket)
Torch valve bracket
Torch Handle
Torch Base
Torch Head (Copper Electrode)
Torch Head (Silver Electrode)
O-ring (red)
O-ring (blue)
O-ring (red)
O-ring (red) - indicator only, not a seal
O-ring (red)
O-ring (red)
Torch solenoid plasma hose
O-ring lubricant
Nozzle removal tool
Electrode removal tool driver
Copper Electrode removal tool
Silver Electrode removal tool
Figure 6-6 Torch and Torch Valve Assembly
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non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-9
Parts List
ProLine 2200 User’s Manual REV N
Shielded Torch Leads
Part Number
277304-10
277304-15
277304-20
277304-25
277304-30
277304-35
277304-40
277304-45
277304-50
Length
10 ft. (3.0 m)
15 ft. (4.6 m)
20 ft. (6.1 m)
25 ft. (7.6 m)
30 ft. (9.1 m)
35 ft. (10.7 m)
40 ft. (12.2 m)
45 ft. (13.7 m)
50 ft. (15.2 m)
Figure 6-7 Shielded Torch Leads
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-10
Parts List
ProLine 2200 User’s Manual REV N
Gas Hose Package
Part Number
277317-20
277317-25
277317-30
277317-35
277317-40
277317-45
277317-50
277317-55
277317-60
277317-65
277317-70
277317-75
277317-80
277317-85
277317-90
277317-95
277317-100
Length
20 ft. (6.1 m)
25 ft. (7.6 m)
30 ft. (9.1 m)
35 ft. (10.7 m)
40 ft. (12.2 m)
45 ft. (13.7 m)
50 ft. (15.2 m)
55 ft. (16.8 m)
60 ft. (18.3 m)
65 ft. (19.8 m)
70 ft. (21.3 m)
75 ft. (22.9 m)
80 ft. (24.4 m)
85 ft. (25.9 m)
90 ft. (27.4 m)
95 ft. (29.0 m)
100 ft. (30.5 m)
Figure 6-8 Gas Hose Package
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-11
Parts List
ProLine 2200 User’s Manual REV N
Coolant and Power Leads
Part Number
277306-5
277306-10
277306-15
277306-20
277306-25
277306-30
277306-35
277306-40
277306-45
277306-50
277306-55
277306-60
277306-65
277306-70
277306-75
277306-80
277306-85
277306-90
277306-95
277306-100
Length
5 ft. (1.5 m)
10 ft. (3.0 m)
15 ft. (4.6 m)
20 ft. (6.1 m)
25 ft. (7.6 m)
30 ft. (9.1 m)
35 ft. (10.7 m)
40 ft. (12.2 m)
45 ft. (13.7 m)
50 ft. (15.2 m)
55 ft. (16.8 m)
60 ft. (18.3 m)
65 ft. (19.8 m)
70 ft. (21.3 m)
75 ft. (22.9 m)
80 ft. (24.4 m)
85 ft. (25.9 m)
90 ft. (27.4 m)
95 ft. (29.0 m)
100 ft. (30.5 m)
Figure 6-9 Coolant and Power Leads
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-12
Parts List
ProLine 2200 User’s Manual REV N
Work Ground Cable
Part Number
277318-10
277318-15
277318-20
277318-25
277318-30
277318-35
277318-40
277318-45
277318-50
277318-55
277318-60
277318-65
277318-70
277318-75
277318-80
277318-85
277318-90
277318-95
277318-100
Length
10 ft. (3.0 m)
15 ft. (4.6 m)
20 ft. (6.1 m)
25 ft. (7.6 m)
30 ft. (9.1 m)
35 ft. (10.7 m)
40 ft. (12.2 m)
45 ft. (13.7 m)
50 ft. (15.2 m)
55 ft. (16.8 m)
60 ft. (18.3 m)
65 ft. (19.8 m)
70 ft. (21.3 m)
75 ft. (22.9 m)
80 ft. (24.4 m)
85 ft. (25.9 m)
90 ft. (27.4 m)
95 ft. (29.0 m)
100 ft. (30.5 m)
Figure 6-10 Work Ground Cable
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-13
Parts List
ProLine 2200 User’s Manual REV N
Torch Consumables - Mild Steel Cutting
Copper Electrode
Outer
Retaining Cap
277154
Shield
Cap
277145
Inner
Nozzle
Retaining Cap
277153
277120
Swirl
Ring
277140
Copper
Electrode
277130
Torch
Head
279150
277154
277115
277153
277122
277140/
277142
277131
279150
277154
277150
277153
277125
277142
277131
279150
277154
277286
277151
277284
277283
277282
279150
277154
277117
277151/
277152
277293
277139
277292
279150
277154
277274
277266
277289
277143
277291
279150
30A
50A
70A
100A
150A
200A
Figure 6-11 Torch Consumables - Mild Steel Cutting, Copper Electrode
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-14
Parts List
ProLine 2200 User’s Manual REV N
Torch Consumables - Mild Steel Cutting
Silver Electrode
Outer
Retaining Cap
Shield
Cap
Inner
Retaining Cap
Nozzle
Swirl
Ring
277154
277274
277266
279489
279443
Silver
Electrode
279440
(yellow o-ring)
Torch
Head
279160
200A
Figure 6-12 Torch Consumables - Mild Steel Cutting, Silver Electrode
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-15
Parts List
ProLine 2200 User’s Manual REV N
Torch Consumables - Stainless Steel Cutting (Air Plasma)
Copper Electrode
Outer
Retaining Cap
277154
Shield
Cap
277144
Inner
Retaining Cap
277110
277121
Swirl
Ring
277138
Copper
Electrode
277137
Torch
Head
279150
277154
277149
277110
277123
277142
277137
279150
277154
277150
277153
277125
277142
277131
279150
277154
277286
277151
277284
277283
277282
279150
277154
277117
277152
277293
277139
277292
279150
277154
277274
277266
277289
277143
277291
279150
Nozzle
30A
50A
70A
100A
150A
200A
Figure 6-13 Torch Consumables - Stainless Steel Cutting (Air Plasma), Copper Electrode
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-16
Parts List
ProLine 2200 User’s Manual REV N
Torch Consumables - Stainless Steel Cutting (Air Plasma)
Silver Electrode
Outer
Retaining Cap
Shield
Cap
Inner
Retaining Cap
Nozzle
Swirl
Ring
277154
277274
277266
279489
279443
Silver
Electrode
279440
(yellow o-ring)
Torch
Head
279160
200A
Figure 6-14 Torch Consumables - Stainless Steel Cutting (Air Plasma), Silver Electrode
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-17
Parts List
ProLine 2200 User’s Manual REV N
Torch Consumables - Stainless Steel Cutting (H17 Plasma)
Copper Electrode
Outer
Retaining Cap
277154
Shield
Cap
277150
Inner
Retaining Cap
277113
277124
Swirl
Ring
277140
Copper
Electrode
277132
Torch
Head
279150
277154
277146
277113
277126
277141
277133
279150
277154
277298
277266
277297
277139
277135
279150
277154
277274
277266
277287
277259
277135
279150
Nozzle
70A
100A
150A
200A
Figure 6-15 Torch Consumables - Stainless Steel Cutting (H17 Plasma), Copper Electrode
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-18
Parts List
ProLine 2200 User’s Manual REV N
Torch Consumables - Aluminum Cutting
Copper Electrode
Outer
Retaining Cap
277154
Shield
Cap
277145
Inner
Retaining Cap
277153
277120
Swirl
Ring
277140
Copper
Electrode
277130
Torch
Head
279150
277154
277150
277153
277122
277142
277131
279150
277154
277150
277153
277125
277142
277131
279150
277154
277286
277151
277284
277283
277282
279150
277154
277117
277152
277293
277139
277292
279150
277154
277274
277266
277289
277143
277291
279150
Nozzle
30A
50A
70A
100A
150A
200A
Figure 6-16 Torch Consumables - Aluminum Cutting, Copper Electrode
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-19
Parts List
ProLine 2200 User’s Manual REV N
Torch Consumables - Aluminum Cutting
Silver Electrode
Outer
Retaining Cap
Shield
Cap
Inner
Retaining Cap
Nozzle
Swirl
Ring
277154
277274
277266
279489
279443
Silver
Electrode
279440
(yellow o-ring)
Torch
Head
279160
200A
Figure 6-17 Torch Consumables - Aluminum Cutting, Silver Electrode
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-20
Parts List
ProLine 2200 User’s Manual REV N
Torch Consumables – Marking
Copper Electrode
Outer
Retaining Cap
277154
Shield
Cap
277145
Inner
Retaining Cap
277152
Nozzle
277120
Swirl
Ring
277140
Copper
Electrode
277190
Torch
Head
279150
Figure 6-18 Torch Consumables - Marking, Copper Electrode
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-21
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
1
708076
4
2
708075
1
3
708113
2
4
708114
1
5
500562
1
6
500570
2
7
500061
1
8
708115
1
9
708116
1
10
500568
1
11
501147
1
12
709002
1
13
709003
2
14
709001
2
15
709229
1
16
709010
1
17
709179
1
18
709192
1
19
277060
1
20
706053
1
21
707001
1
22
709004
1
23
501145
7
24
708097
2
25
708077
1
42
708030
1
43
708046
1
Description
Pressure gauge – 200 psi
Pressure gauge – 100 psi
Pressure gauge – 160 psi
Pressure gauge – 15 psi
Pressure regulator – 60 psi
Pressure regulator – 125 psi
Pressure regulator – 15 psi
Gas test/run switch
Gas test/run switch knob
Fan
Fan guard/filter
Receptacle, 14 position
Receptacle, 9 position
Receptacle, 4 position
Fuse, 1.5 amp
Fuse Holder
Terminal block, 10 position
Terminal block marker strip, 10 position
Gas console relay p.c. board
Transformer, 24VAC
Line filter
Receptacle, 24 position
Manifold
Pressure switch, 80-200 psi
Solenoid valve
Pressure switch, 10 psi
Pressure switch, 20-50 psi
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-22
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
1
708076
4
2
708075
1
3
708113
2
4
708114
1
5
500562
1
6
500570
2
7
500061
1
8
708115
1
9
708116
1
10
500568
1
11
501147
1
12
709002
3
13
709003
5
14
709001
2
15
709229
1
16
709010
3
17
709179
1
18
709192
1
19
277060
1
20
706053
1
21
707001
1
22
709004
4
23
501145
7
24
708097
2
25
708077
1
30
706003
1
31
709191
1
32
709190
1
33
110900
1
34
110200
1
35
110705
1
36
709207
1
37
709084
1
38
709012
1
39
709210
1
40
277081
9
41
277082
9
42
708030
1
43
708046
1
Description
Pressure gauge – 200 psi
Pressure gauge – 100 psi
Pressure gauge – 160 psi
Pressure gauge – 15 psi
Pressure regulator – 60 psi
Pressure regulator – 125 psi
Pressure regulator – 15 psi
Gas test/run switch
Gas test/run switch knob
Fan
Fan guard/filter
Receptacle, 14 position
Receptacle, 9 position
Receptacle, 4 position
Fuse, 1.5 amp
Fuse Holder
Terminal block, 10 position
Terminal block marker strip, 10 position
Gas console relay p.c. board
Transformer, 24VAC
Line filter
Receptacle, 24 position
Manifold
Pressure switch, 80-200 psi
Solenoid valve
Transformer, 20VAC
Terminal block, 4 position
Terminal block marker strip, 4 position
Inova H-Bridge p.c. board, 230VAC
Inova microprocessor p.c. board
Inova power distribution p.c. board, 230VAC
Receptacle, 7 position
Ground lug
Fuse, 3 amp
Fuse, 6 amp
Inova insulating washer (top)
Inova insulating bushing (bottom)
Pressure switch, 10 psi
Pressure switch, 20-50 psi
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-23
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. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-24
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.
6-25
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. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-26
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. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-27
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. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-28
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. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-29
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. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-30
Parts List
ProLine 2200 User’s Manual REV N
Remote On/Off Control Assembly (Optional)
Item Number Part Number Quantity Description
1
708087
1
Power Off actuator, red
2
708089
1
Power On actuator, green / illuminated
3
708090
2
Power On / Off switch, green
4
740106
1
Bulb, Power On switch
Not Shown
709124
1
Receptacle, 9 pin
Figure 6-26 Remote On/Off Control Assembly (Optional)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-31
Parts List
ProLine 2200 User’s Manual REV N
Remote On/Off Control Cable (Optional)
Part Number
711800-10
711800-15
711800-20
711800-25
711800-30
711800-35
711800-40
711800-45
711800-50
711800-55
711800-60
711800-65
711800-70
711800-75
711800-80
711800-85
711800-90
711800-95
711800-100
Length
10 ft. (3.0 m)
15 ft. (4.6 m)
20 ft. (6.1 m)
25 ft. (7.6 m)
30 ft. (9.1 m)
35 ft. (10.7 m)
40 ft. (12.2 m)
45 ft. (13.7 m)
50 ft. (15.2 m)
55 ft. (16.8 m)
60 ft. (18.3 m)
65 ft. (19.8 m)
70 ft. (21.3 m)
75 ft. (22.9 m)
80 ft. (24.4 m)
85 ft. (25.9 m)
90 ft. (27.4 m)
95 ft. (29.0 m)
100 ft. (30.5 m)
Figure 6-27 Remote On/Off Control 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. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-32
Parts List
ProLine 2200 User’s Manual REV N
Hydrogen Manifold Assembly (Optional)
Item Number Part Number Quantity Description
1
708076
1
Pressure gauge – 200 psi
2
500570
1
Pressure regulator – 125 psi
3
708113
1
Pressure gauge – 160 psi
Not Shown
708097
1
Pressure switch, 80-200 psi
Not Shown
709124
1
Receptacle, 9 pin
Figure 6-28 Hydrogen Manifold Assembly (Optional)
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-33
Parts List
ProLine 2200 User’s Manual REV N
Hydrogen Manifold Interface Cable (Optional)
Part Number
277089
Length
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. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-34
Parts List
ProLine 2200 User’s Manual REV N
Consumable Spare Parts Kit
(Part Number 282267)
Part Number
277130
Quantity
3
277137
2
277131
6
277132
2
277282
3
277133
2
277292
3
277291
3
277135
2
277120
5
277121
3
277122
5
277123
3
277125
5
277124
3
277284
5
277126
3
277293
5
277297
3
277289
5
Description
Electrode
30A Mild Steel - 30A Aluminum
Electrode
30/50A Stainless (Air)
Electrode
50/70A Mild Steel - 70A Stainless (Air) - 50/70A Aluminum
Electrode
70A Stainless (H17)
Electrode
100A Mild Steel - 100A Stainless (Air) - 100A Aluminum
Electrode
100A Stainless (H17)
Electrode
150A Mild Steel – 150A Stainless (Air) – 150A Aluminum
Electrode
200A Mild Steel - 200A Stainless (Air) - 200A Aluminum
Electrode
150/200 Stainless (H17)
Nozzle
30A Mild Steel - 30A Aluminum
Nozzle
30A Stainless (Air)
Nozzle
50A Mild Steel - 50A Aluminum
Nozzle
50A Stainless (Air)
Nozzle
70A Mild Steel - 70A Stainless (Air) - 70A Aluminum
Nozzle
70A Stainless (H17)
Nozzle
100A Mild Steel – 100A Stainless (Air) - 100A Aluminum
Nozzle
100A Stainless (H17)
Nozzle
150A Mild Steel – 150A Stainless (Air) – 150A Aluminum
Nozzle
150A Stainless (H17)
Nozzle
200A Mild Steel – 200A Stainless (Air) - 200A Aluminum
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-35
Parts List
ProLine 2200 User’s Manual REV N
Part Number
277287
Quantity
3
277145
3
277144
3
277149
3
277115
3
277150
3
277286
3
277146
3
277117
3
277298
3
277274
3
277138
1
277140
1
277142
1
277283
1
277141
1
277139
1
277143
1
277259
1
277110
1
277153
1
Description
Nozzle
200A Stainless (H17)
Shield Cap
30A Mild Steel - 30A Aluminum
Shield Cap
30A Stainless (Air)
Shield Cap
50A Stainless (Air)
Shield Cap
50A Mild Steel
Shield Cap
70A Mild Steel - 70A Stainless - 50/70A Aluminum
Shield Cap
100A Mild Steel - 100A Stainless (Air) - 100A Aluminum
Shield Cap
100A Stainless (H17)
Shield Cap
150A Mild Steel – 150A Stainless (Air) – 150A Aluminum
Shield Cap
150A Stainless (H17)
Shield Cap
200A Mild Steel - 200A Stainless – 200A Aluminum
Swirl Ring
30A Stainless (Air)
Swirl Ring
30/50A Mild Steel - 70A Stainless (H17) - 30A Aluminum
Swirl Ring
50/70A Mild Steel - 50/70A Stainless (Air) - 50/70A Aluminum
Swirl Ring
100A Mild Steel – 100A Stainless (Air) – 100A Aluminum
Swirl Ring
100A Stainless (H17)
Swirl Ring
150A Mild Steel – 150A Stainless – 150A Aluminum
Swirl Ring
200A Mild Steel – 200A Stainless (Air) - 200A Aluminum
Swirl Ring
200A Stainless (H17)
Inner Retaining Cap
30/50A Stainless (Air)
Inner Retaining Cap
30/50/70A Mild Steel - 70A Stainless (Air)
30/50/70A Aluminum
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-36
Parts List
ProLine 2200 User’s Manual REV N
Part Number
277151
Quantity
1
277152
1
277113
1
277266
1
716012
500024
500018
820209
277056
277086
277087
260105
277154
1
2
2
2
1
1
1
1
1
Description
Inner Retaining Cap
100A Mild Steel - 100A Stainless (Air) - 100A Aluminum
150A Mild Steel – 1/2” and below
Inner Retaining Cap
150A Mild Steel – 5/8” and above – 150A Stainless (Air)
150A Aluminum
Inner Retaining Cap
70/100A Stainless (H17)
Inner Retaining Cap
150A Stainless (H17)
200A Mild Steel – 200A Stainless – 200A Aluminum
O-ring Lubricant
Torch O-ring – blue, lower
Torch O-ring – red, middle
Torch O-ring – black, upper
Nozzle Removal Tool
Electrode Removal Tool Driver
Electrode Removal Tool Socket
Swirl Ring Removal Tool
Outer Retaining Cap
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
6-37
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.
6-38
Electromagnetic Compatibility (EMC)
ProLine 2200 User’s Manual REV N
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.
However, the ability of plasma cutting equipment to work in a compatible manner
with other radio and electronic systems is greatly influenced by the manner in
which it is installed and used. For this reason, it is important that the plasma
cutting equipment be installed and used in accordance with the information below
if electromagnetic compatibility is to be achieved.
Plasma cutting equipment is primarily intended for use in an industrial
environment. There may be potential difficulties in ensuring electromagnetic
compatibility in other environments.
Installation and Use
The user is responsible for installing and using the plasma cutting equipment
according to the manufacturer’s instructions. If electromagnetic disturbances are
detected then it shall be the responsibility of the user of the plasma cutting
equipment to resolve the situation with the technical assistance of the
manufacturer. In some cases this remedial action may be as simple as earthing
the plasma cutting circuit, see Note. In other cases it could involve constructing
an electromagnetic screen enclosing the plasma power source and the work,
complete with associated input filters. In all cases, electromagnetic disturbances
shall be reduced to the point where they are no longer troublesome.
Note: The plasma cutting circuit may or may not be earthed for safety reasons.
Changing the earthing arrangements should only be authorized by a person who is
competent to assess whether the changes will increase the risk of injury, e.g. by
allowing parallel plasma cutting current return paths which may damage the earth
circuits of other equipment. Further guidance is given in IEC 974-13 Arc welding
equipment – Installation and use.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
A-1
Electromagnetic Compatibility (EMC)
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,
below and adjacent to the plasma cutting equipment
b) radio and television transmitters and receivers
c) computer and other control equipment
d) safety critical equipment, e.g. guarding of industrial equipment
e) the health of the people around, e.g. the use of pacemakers and hearing aids
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment; the user shall ensure that
other equipment being used in the environment is compatible; this may
require additional protection measures
h) the time of day that plasma cutting or other activities are to be carried out
The size of the surrounding area to be considered will depend on the structure of
the building and other activities that are taking place. The surrounding area may
extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Plasma cutting equipment should be connected to the mains supply according to
the manufacturer’s recommendations. If interference occurs, it may be necessary
to take additional precautions such as filtering of the mains supply. Consideration
should be given to shielding the supply cable of permanently installed plasma
cutting equipment in metallic conduit or equivalent. Shielding should be
electrically continuous throughout its length. The shielding should be connected
to the plasma power source so that good electrical contact is maintained between
the conduit and the plasma power source enclosure.
Maintenance of the Plasma Cutting Equipment
The plasma cutting equipment should be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and covers should
be closed and properly fastened when the plasma cutting equipment is in
operation. The plasma cutting equipment should not be modified in any way
except for those changes and adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of arc striking and stabilizing devices
should be adjusted and maintained according to the manufacturer’s
recommendations.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
A-2
Electromagnetic Compatibility (EMC)
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. However, metallic components bonded to the
workpiece will increase the risk that the operator could receive a shock by
touching these metallic components and the electrode at the same time. The
operator should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to
earth because of its size and position, e.g. ship’s hull or building steelwork, a
connection bonding the workpiece to earth may reduce emissions in some, but not
all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment.
Where necessary, the connection of the workpiece to earth should be made by a
direct connection to the workpiece, but in some countries where direct connection
is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the
surrounding area may alleviate problems of interference. Screening of the entire
welding installation may be considered for special applications.
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
A-3
Electromagnetic Compatibility (EMC)
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.
A-4
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