Kaliburn ProLine 2200 User manual

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.
N
REVISION

ProLine 2200 User’s Manual REV N
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 History
Rev
ECO#
Author
Date
Description of Change
0 - - - As released
1 - - -
•Section 4
•Section 6
•
Schematic update
2 - - -
•Section 4
•Section 6
•
Section 2
3 - - 03/30/04 •
Section 4
•
Section 6
4 - - 06/02/04
•Section 3
•Section 4
• Section 6
5 - - 08/23/04 •Section 4
• Section 6
6 - - 10/14/04 •Section 4
7 - - 01/12/05
•Section 4
8 - - 9/30/05
•Section 4
9 - - 10/26/2005 •Section 4
10 - - - -
11 - - 11/18/05 •Section 6
A - - 12/12/05 •Section 4
•
Section 6
B - - 1/18/06 •Section 2
• Section 6
C - - 1/30/06 •Section 6
D - - •
Changed to 24VDC Condor power supply
for gas valves.
E - -
•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.

ProLine 2200 User’s Manual REV N
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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.
F - - •Section 4
G - - •Section 4
H - -
•Section 4
•Section 6
•Changed coolant level switch location
•
Removed PAR, changed CR3
I - -- •Section 4
J - - -
K - -
•Added PAR relay in series with surge
injection circuit to schematic and parts list
•
Section 4
L - - 10/25/2010
Contents
Section 2
Section 3
Section 4
Section 5
Appendix A
Appendix B - deleted
M 08/01/2012
Section 1, added references to Section 5.
Section 5, added chopper warning.
N 10/15/2012
Added Quick-Disconnect Torch information
throughout manual.
Section 5, defective flow switch (25 blinks).
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
[phone] - Phone
[phone]- Fax
www.kaliburn.net

ProLine 2200 User’s Manual REV N
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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.
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 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.
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.

ProLine 2200 User’s Manual REV N
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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.
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

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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

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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 Power Supply Dimensions ............................................................................2-3
Figure 2-2 Remote High Frequency Console Mounting Dimensions ............................ 2-5
Figure 2-3 Torch Dimensions .........................................................................................2-6
Figure 2-4 Remote On/Off Control Dimensions (Optional) ...........................................2-7
Figure 2-5 Hydrogen Manifold Dimensions (Optional) .................................................2-8
Figure 3-1 System Interconnection Diagram ..................................................................3-1
Figure 3-2 Primary Power Connections ......................................................................... 3-3
Figure 3-3 Power Supply Output Connections ...............................................................3-6
Figure 3-4 Torch Leads to RHF Console Connections .................................................. 3-8
Figure 3-5 Torch Connections ........................................................................................3-11
Figure 3-6 Gas Console Input Connections ....................................................................3-12
Figure 3-7 Gas Console Output Connections ................................................................. 3-13
Figure 3-8 Freezing Points of Aqueous Propylene Glycol Solutions .............................3-15
Figure 4-1 Front Panel Controls ..................................................................................... 4-1
Figure 4-2 Hydrogen Manifold Controls (Optional) ...................................................... 4-3
Figure 5-1 230V 60 Hz Transformer Configuration .......................................................5-4
Figure 5-2 460V 60 Hz Transformer Configuration .......................................................5-5
Figure 5-3 Chopper Diagnostics - Part 1 ........................................................................ 5-13
Figure 5-4 Chopper Diagnostics - Part 2 ........................................................................ 5-14
Figure 6-1 Power Supply Front View .............................................................................6-3
Figure 6-2 Power Supply Rear View ..............................................................................6-4
Figure 6-3 Power Supply Left Side View .......................................................................6-5
Figure 6-4 Power Supply Right Side View .................................................................... 6-6
Figure 6-5 Remote High Frequency Console ................................................................. 6-8
Figure 6-6 Torch and Torch Valve Assembly ................................................................ 6-9
Figure 6-7 Shielded Torch Leads ................................................................................... 6-10
Figure 6-8 Gas Hose Package .........................................................................................6-11
Figure 6-9 Coolant and Power Leads ............................................................................. 6-12
Figure 6-10 Work Ground Cable ......................................................................................6-13
Figure 6-11 Torch Consumables - Mild Steel Cutting, Copper Electrode....................... 6-14
Figure 6-12 Torch Consumables - Mild Steel Cutting, Silver Electrode......................... 6-15
Figure 6-13 Torch Consumables - Stainless Steel Cutting (Air), Copper Electrode........ 6-16
Figure 6-14 Torch Consumables - Stainless Steel Cutting (Air), Silver Electrode.......... 6-17
Figure 6-15 Torch Consumables - Stainless Steel Cutting (H17), Copper Electrode...... 6-18

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Figure 6-16 Torch Consumables - Aluminum Cutting, Copper Electrode........................6-19
Figure 6-17 Torch Consumables - Aluminum Cutting, Silver Electrode......................... 6-20
Figure 6-18 Torch Consumables – Marking, Copper Electrode ...................................... 6-21
Figure 6-19 Gas Console - Exterior ..................................................................................6-24
Figure 6-20 Gas Console - Interior ...................................................................................6-25
Figure 6-21 Power Supply Microprocessor P.C. Board ................................................... 6-26
Figure 6-22 A.C. Detect P.C. Board .................................................................................6-27
Figure 6-23 Power Supply Relay P.C. Board ................................................................... 6-28
Figure 6-24 Power Supply I/O P.C. Board .......................................................................6-29
Figure 6-25 Gas Console Relay P.C. Board ..................................................................... 6-30
Figure 6-26 Remote On/Off Control Assembly (Optional) ..............................................6-31
Figure 6-27 Remote On/Off Control Cable (Optional) .................................................... 6-32
Figure 6-28 Hydrogen Manifold Assembly (Optional) ....................................................6-33
Figure 6-29 Hydrogen Manifold Interface Cable (Optional) ........................................... 6-34

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1-1
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.

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1-2
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:
•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.

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1-3
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.

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1-4
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.

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1-5
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.

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1-6
BLANK PAGE

Specifications ProLine 2200 User’s Manual REV N
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2-1
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 1-
1/2” 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.

Specifications ProLine 2200 User’s Manual REV N
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-2
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

Specifications ProLine 2200 User’s Manual REV N
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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.
2-3
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

Specifications ProLine 2200 User’s Manual REV N
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-4
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.

Specifications ProLine 2200 User’s Manual REV N
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-5
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

Specifications ProLine 2200 User’s Manual REV N
This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
2-6
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)
Figure 2-3 Torch Dimensions
Torch Handle
9.20 [234]
1.99
[51]
Torch Head
5.08 [129]
Torch Base
1.87 [47]
Valves
3.40 [86]
Alignment Indicator
(Small Circle)
Attachment Ring
Alignment Indicator
(Slot)