Kaliburn FineLine 200PC User manual

FineLine 200PC User’s Manual
FineLine 200PC High Density Plasma Cutting System
With Automatic Gas Console
Revision H
7/12/07
Manual Part Number 718059
455 Fleming Road
Charleston, SC 29412 USA
[phone] – Toll Free
[phone] – Phone
[phone] – Fax
www.kaliburn.net

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FineLine 200PC User’s Manual
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 FineLine 200PC
torch and leads and three (3) years for the FineLine 200PC power supply and
automatic 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 non-conforming product or part at the sole discretion of
KALIBURN. No freight charges of any kind are covered under this warranty.
All returned goods shall be at the 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.

FineLine 200PC User’s Manual
Electromagnetic Compatibility (EMC)
The 380V 50Hz and 415V 50Hz FineLine 200PC plasma cutting systems are
manufactured to comply with the European standards EN 60974 (Arc welding
equipment – Part 1: Welding power sources) and EN 50199 (Electromagnetic
compatibility (EMC) – Product standard for arc welding equipment). Information
about the EMC standard EN 50199 can be found in Appendix B.

FineLine 200PC User’s Manual
TABLE OF CONTENTS
Section 1 Safety..……………………………………..…………………………….1-1
General Precautions .…………………………………………………..……….…..………1-1
Ultraviolet Radiation Protection ..………………………………………………………….1-1
Noise Protection .……………………………………………………..…………………….1-1
Toxic Fume Prevention ...…………………………………………………………..………1-1
Electric Shock Prevention ...……………………………………………………….….……1-2
Fire Prevention ...…………………….………………………………….………………….1-3
Explosion Prevention .....…….….………….…………………………………..…………..1-3
Health Support Equipment ...…………………….……………………………….………...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
Automatic Gas Console Specifications .……………………………………………………2-4
Remote High Frequency Console Specifications …………………………………………. 2-5
Torch Specifications ...…………………………………………………………………….. 2-6
Airborne Noise Emissions ......…………………………………………………………….. 2-7
Section 3 Installation.....…………………………………………………………3-1
Initial Inspection .......……………………………………………………………………… 3-1
System Interconnection .……………………………………………………………………3-1
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
Automatic Gas Console Input Connections ..………………………………………………3-13
Automatic Gas Console Output Connections .......…………………………………………3-14
CNC Machine Interface Connections ...……………………………………………………3-15
Torch Coolant Requirements ....……………………………………………………………3-15
Filling the Torch Coolant Reservoir .………………………………………………………3-17
Section 4 Operation………………………………………………………………4-1
Power Supply Front Panel Controls ..………………………………………………………4-1
Automatic Gas Console Keypad ...…………………………………………………………4-3
Automatic Gas Console Help Prompt ...……………………………………………………4-4
Automatic Gas Console Status Screen ..……………………………………………………4-5

FineLine 200PC User’s Manual
Setting up a Cut .........………………………………………………………………………4-5
Making a Cut .................……………………………………………………………………4-11
Cut Quality ................………………………………………………………………………4-11
Consumable Life .......………………………………………………………………………4-12
Cutting Charts ...........………………………………………………………………………4-13
Section 5 Automatic Gas Console Advanced Functions..................5-1
Altering the Current Set Point .............................................................................................. 5-1
Setting the Pierce Delay Time .............................................................................................. 5-2
Altering Gas Types ...............................................................................................................5-3
Altering Gas Pressures ..........................................................................................................5-4
Altering Arc Voltage Control and X/Y Machine Parameters ...............................................5-5
Saving a User Created Cutting Condition .............................................................................5-6
Gas Purge ..............................................................................................................................5-6
Maintenance Screen ..............................................................................................................5-7
Viewing Messages ................................................................................................................5-8
Viewing Cut Errors ...............................................................................................................5-9
Pressure Diagnostics .............................................................................................................5-13
Setting the Default Delay Parameter .....................................................................................5-14
Restoring Factory Default Cutting Conditions .....................................................................5-15
Measurement System ............................................................................................................5-16
Communication Node ...........................................................................................................5-17
Inova Parameter Transmit .....................................................................................................5-18
Viewing Serial Communication ............................................................................................5-19
Configuring the Optional Hydrogen Manifold .....................................................................5-20
Setting an Arc Off Delay ...................................................................................................... 5-21
Software Updates ..................................................................................................................5-22
Section 6 Serial Communication....................................................................6-1
Initializing the FineLine System ...........................................................................................6-1
Transmitting Parameters to the FineLine System .................................................................6-1
Communication Error Checking ...........................................................................................6-2
Default Cutting Parameters ...................................................................................................6-2
Troubleshooting Serial Communication ...............................................................................6-3
RS-422 Serial Commands .....................................................................................................6-4
Section 7 Maintenance and Troubleshooting .........................................7-1
Routine Maintenance ............……........................................................................................7-1
Replacing the Torch Coolant ................................................................................................7-3
230/460V 60 Hz Transformer Configurations ......................................................................7-4
Microprocessor Status LED’s ...............................................................................................7-6
Microprocessor Sequence of Operation ................................................................................7-7
Troubleshooting Using the Control Panel Status LED’s ......................................................7-8
Troubleshooting Using the Automatic Gas Console Messages Screen ................................7-9
General Troubleshooting ...................................................................................................... 7-10

FineLine 200PC User’s Manual
Chopper Test Procedure ........................................................................................................7-12
Section 8 Parts List.................................................................................................8-1
Power Supply ........................................................................................................................8-1
Remote High Frequency Console .........................................................................................8-7
Torch and Torch Valve Assembly ........................................................................................8-9
Shielded Torch Leads ........................................................................................................... 8-10
Gas Hose Package .................................................................................................................8-11
Coolant and Power Leads ..................................................................................................... 8-12
Work Ground Cable ..............................................................................................................8-13
Torch Consumables - Mild Steel Cutting ............................................................................. 8-14
Torch Consumables - Stainless Steel Cutting (Air Plasma) .................................................8-15
Torch Consumables - Stainless Steel Cutting (H17 Plasma) ................................................8-16
Torch Consumables - Aluminum Cutting .............................................................................8-17
Torch Consumables - Marking ............................................................................................. 8-18
Automatic Gas Console ........................................................................................................ 8-19
Power Supply Microprocessor P.C. Board ...........................................................................8-22
A.C. Detect P.C. Board .........................................................................................................8-23
Relay P.C. Board ...................................................................................................................8-24
Power Supply I/O P.C. Board ...............................................................................................8-25
Automatic Gas Console I/O P.C. Board ............................................................................... 8-26
Automatic Gas Console Interface P.C. Board ...................................................................... 8-27
Consumable Spare Parts Kit ................................................................................................. 8-28
Appendix A Propylene Glycol MSDS.........................................................A-1
Appendix B Electromagnetic Compatibility (EMC).........................B-1
Background ...........................................................................................................................B-1
Installation and Use ...............................................................................................................B-1
Assessment of Area ...............................................................................................................B-2
Methods of Reducing Emissions .......................................................................................... B-2
Appendix C Hydrogen Manifold (Optional) .......................................... C-1
Description ............................................................................................................................C-1
Specifications ........................................................................................................................C-1
Installation .............................................................................................................................C-2
Operation ...............................................................................................................................C-4
Parts List ............................................................................................................................... C-5
Hydrogen Manifold Microprocessor P.C. Board ..................................................................C-6
Dip Switch Settings .............................................................................................................. C-7
Illustrations
Figure 2-1 Power Supply Dimensions ............................................................................2-3
Figure 2-2 Remote High Frequency Console Mounting Dimensions ............................2-5

FineLine 200PC User’s Manual
Figure 2-3 Torch Dimensions .........................................................................................2-6
Figure 3-1 System Interconnection Diagram ..................................................................3-2
Figure 3-2 Primary Power Connections ......................................................................... 3-4
Figure 3-3 Power Supply Output Connections ...............................................................3-7
Figure 3-4 Torch Leads to RHF Console Connections .................................................. 3-9
Figure 3-5 Torch Connections ........................................................................................3-12
Figure 3-6 Automatic Gas Console Input Connections ..................................................3-13
Figure 3-7 Automatic Gas Console Output Connections ...............................................3-14
Figure 3-8 Freezing Points of Aqueous Propylene Glycol Solutions .............................3-16
Figure 4-1 Front Panel Controls .....................................................................................4-2
Figure 4-2 Automatic Gas Console Keypad ...................................................................4-3
Figure 4-3 Help Prompt ..................................................................................................4-4
Figure 4-4 Status Screen .................................................................................................4-5
Figure 4-5 Selecting Material Substance ........................................................................4-6
Figure 4-6 Setting Material Thickness ........................................................................... 4-7
Figure 4-7 Selecting Process .......................................................................................... 4-8
Figure 4-8 Torch Parts ....................................................................................................4-9
Figure 4-9 Voltage Screen ..............................................................................................4-10
Figure 5-1 Altering the Current Set Point .......................................................................5-1
Figure 5-2 Setting the Pierce Delay Time ...................................................................... 5-2
Figure 5-3 Altering Gas Types .......................................................................................5-3
Figure 5-4 Altering Gas Pressures ..................................................................................5-4
Figure 5-5 Altering Arc Voltage Control and X/Y Machine Parameters .......................5-5
Figure 5-6 User Created Cutting Conditions ..................................................................5-6
Figure 5-7 Maintenance Screen ......................................................................................5-7
Figure 5-8 Message Screen .............................................................................................5-8
Figure 5-9 Cut Errors Screen ..........................................................................................5-9
Figure 5-10 Error Selection Screen .................................................................................. 5-10
Figure 5-11 Actual Cut Errors Screen ..............................................................................5-11
Figure 5-12 Pressure Diagnostics Screen .........................................................................5-13
Figure 5-13 Default Pierce Delay Screen .........................................................................5-14
Figure 5-14 Restore Factory Defaults Screen ...................................................................5-15
Figure 5-15 Measurement System Selection Screen ........................................................5-16
Figure 5-16 Communication Node Selection Screen ....................................................... 5-17
Figure 5-17 Inova Parameter Transmit Screen .................................................................5-18
Figure 5-18 View Serial Communication Screen .............................................................5-19
Figure 5-19 Configure Hydrogen Manifold Screen ..........................................................5-20
Figure 5-20 Set Arc Off Delay Screen ............................................................................. 5-21
Figure 7-1 230V 60 Hz Transformer Configuration .......................................................7-5
Figure 7-2 460V 60 Hz Transformer Configuration .......................................................7-5
Figure 7-3 Chopper Diagnostics - Part 1 ........................................................................7-14
Figure 7-4 Chopper Diagnostics - Part 2 ........................................................................7-15
Figure 8-1 Power Supply Front View .............................................................................8-3
Figure 8-2 Power Supply Rear View ..............................................................................8-4
Figure 8-3 Power Supply Left Side View .......................................................................8-5
Figure 8-4 Power Supply Right Side View .................................................................... 8-6

FineLine 200PC User’s Manual
Figure 8-5 Remote High Frequency Console .................................................................8-8
Figure 8-6 Torch and Torch Valve Assembly ................................................................8-9
Figure 8-7 Shielded Torch Leads ................................................................................... 8-10
Figure 8-8 Gas Hose Package .........................................................................................8-11
Figure 8-9 Coolant and Power Leads ............................................................................. 8-12
Figure 8-10 Work Ground Cable ......................................................................................8-13
Figure 8-11 Torch Consumables - Mild Steel Cutting .....................................................8-14
Figure 8-12 Torch Consumables - Stainless Steel Cutting (Air Plasma) .........................8-15
Figure 8-13 Torch Consumables - Stainless Steel Cutting (H17 Plasma) ........................8-16
Figure 8-14 Torch Consumables - Aluminum Cutting .....................................................8-17
Figure 8-15 Torch Consumables – Marking .....................................................................8-18
Figure 8-16 Gas Console - Exterior ..................................................................................8-20
Figure 8-17 Gas Console - Interior ...................................................................................8-21
Figure 8-18 Power Supply Microprocessor P.C. Board ...................................................8-22
Figure 8-19 A.C. Detect P.C. Board .................................................................................8-23
Figure 8-20 Relay P.C. Board ...........................................................................................8-24
Figure 8-21 Power Supply I/O P.C. Board .......................................................................8-25
Figure 8-22 Automatic Gas Console I/O P.C. Board ....................................................... 8-26
Figure 8-23 Automatic Gas Console Interface P.C. Board .............................................. 8-27
Figure C-1 Hydrogen Manifold Mounting Dimensions ..................................................C-1
Figure C-2 Hydrogen Manifold Mounting Location .......................................................C-3
Figure C-3 Hydrogen Manifold Microprocessor P.C. Board ..........................................C-6

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