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
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.
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
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.
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

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.
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

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.
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

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.
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

Safety ProLine 2200 User’s Manual REV N
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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.

Safety 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.
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.