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1. Figure 3 4 Torch Leads to RHF Console Connections 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 3 8 Installation ProLine 2150 User s Manual REV M 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 e 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 e Route the torch leads through the torch handle Note that the threaded end of the torch handle mates with the torch base e Route the Shield Gas Hose through the torch h
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 24 Operation ProLine 2150 User s Manual REV M Aluminum 100 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277286 277284 277282 q 9 OND D J s 7 i L L Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277151 277283 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 158 105 155 250 300 095 3 8 25 94 26 0 162 90 180 275 400 098 1 2 165 70 195 300 500 100 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 158 2710 3 8 6 3 300 2 4 10 25 94 26 0 162 2210 4 6 7 0 500 2 5 12 165 1890 4 9 7 4 Use an arc transfer height
3. 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 26 Operation ProLine 2150 User s Manual REV M Mild Steel Marking 10 Amps Nitrogen Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277145 277120 277190 p x 9 OMD gt D a a Ss Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277152 277140 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Marking Initial Pierce Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Time in psi psi psi psi volts ipm in in msec All Thicknesses 28 28 28 2 145 250 ATT 100 0 Metric Material Preflow Plasma Shield Postflow Arc Travel Marking Initial Pierce Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Time 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
4. 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 22 Operation ProLine 2150 User s Manual REV M Aluminum 50 Amps Air Plasma Nitrogen Shield i Copper Electrode Shield Cap Nozzle Electrode 277122 277131 277150 s 7 ZT Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277142 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 050 135 180 050 400 100 080 063 25 74 19 1 138 140 065 i 150 082 080 143 90 075 150 200 085 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 5 137 3870 1 5 2 5 150 2 1 25 74 19 1 2 0 142 2360 1 8 3 7 200 2 2 Use an arc transfer height ignition height of 100 2 5 mm 1
5. Attachment Ring f oa Indicator Torch Head ere Circle 5 08 129 Figure 2 3 Torch Dimensions 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 Specifications ProLine 2150 User s Manual REV M Remote On Off Control Specifications Optional Stock Number arenei th tutte dues ee as 277079 TSUN cans tie eea ade ore art Pid e iota ee e eas 2 0 in 51 mm Widths nania n a td ctl meas a ea 5 455 in 139 mm DG piles ecteterSaaeiessieeticigls aia a i E EEEN 4 4 in 112 mm Weight ose eds e aos sth N ie sae R Aa 1 5 lb 7 kg PLASMA POWER OFF PLASMA POWER ON 2 00 51 4 40 112 3 643 93 3 175 81 _ 4 6 32 PRESS NUT Cm eM 156 4 mm DIA A75 12 515 13 375 10 4 425 112 5 455 139 Figure 2 4 Remote On Off Control Dimensions 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 2 7 Specifications ProLine 2150 User s Manual REV M Hydrogen Manifold Specifications Optional Stock NUMDET atire sit atte eet esr eee 150098
6. SO HE SY Se Re OFA FF O Figure 4 2 Hydrogen Manifold Controls Optional Inlet Pressure Gauge a Displays the H17 incoming supply pressure Outlet Pressure Regulator 2 Adjusts the H17 outlet pressure Outlet Pressure Gauge G Displays the H17 outlet pressure 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 3 Operation ProLine 2150 User s Manual REV M 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 For 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 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
7. 1p Be R eN 800 90 e 1 2 3 7 Figure 3 3 Power Supply Output Connections 3 6 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 Installation ProLine 2150 User s Manual REV M Torch Leads to RHF Console Connections Perform the following steps to connect the torch leads to the RHF console See Figure 3 4 for additional information Note When making hose connections only tighten the brass fittings enough to make water or gas seals The fittings are subject to damage if over tightened Braided Shield e 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 e 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 gro
8. e 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 e 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 e 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 e Inspect the torch leads frequently Never use the system if the leads are damaged in any way e Do not stand in wet damp areas when operating or performing maintenance on the system e Wear insulated gloves and shoes while operating or performing maintenance on the system e Make sure the ProLine system is switched off at the wall disconnect before servicing the power supply or torch e Never change torch consumable parts unless the ProLine system is switched off at the wall disconnect e 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 e Never bypass the safety i
9. 3 3 Installation ProLine 2150 User s Manual REV M Power Supply Output Connections Perform the following steps to connect the output of the power supply to the RHF console and the work table See Figure 3 3 for additional information Power Supply Electrode Lead 1 Route one end of the 1 0AWG Power Supply Electrode Lead through the upper strain relief on the rear of the power supply and connect it to the Electrode terminal 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 Q 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 G 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 1 Connect the RHF Console Control Cable plug labeled P16 to the connector labeled P1
10. 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 2150 User s Manual REV M Stainless Steel 30 Amps Air Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode 277121 277137 Outer Cap Retaining Cap Swirl Ring 277154 277110 277138 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Air Air Voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 20 036 200 020 71 100 065 18 048 165 30 80 30 14 035 050 16 060 74 125 500 068 14 075 75 90 025 070 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Air Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 71 4855 0 6 100 30 80 30 14 1 3 1 7 1 5 73 3260 0 9 200 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 Regula
11. 10 150 2805 4 7 7 0 600 12 25 75 70 0 153 2330 5 1 7 4 35 16 160 1510 5 6 8 3 800 20 170 1030 6 2 9 0 1200 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 21 Operation ProLine 2150 User s Manual REV M Aluminum 30 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277145 277120 277130 q 9 OD D J s 7 i L L Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277140 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 040 150 100 100 065 050 30 92 20 2 135 120 030 063 90 150 200 070 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 1 3885 2 5 100 1 7 30 92 20 2 135 0 8 1 5 2520 3 4 200 1 8
12. LED 24 PLASMA e LED 12 MOTION After a transferred cutting arc is established the following LED s will go out e LED 14 HOLD OUT e LED 27 HIGH FREQ e LED 4PREFLOW e 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 5 Maintenance and Troubleshooting ProLine 2150 User s Manual REV M 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 e RHF Door LED Extinguishes when the RHF door switch opens Check the RHF door switch and associated wiring e Gas Console LED Extinguishes when the preflow outlet plasma outlet or shield inlet pressures are low e 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 operat
13. 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 2150 User s Manual REV M Stainless Steel 100 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277286 277284 277282 a D Li 7 Si J Outer Cap Retaining Cap Swirl Ring 277154 277151 277283 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 141 100 135 225 400 092 3 8 25 94 35 0 147 80 170 250 500 09s 1 2 154 55 210 300 600 i Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 140 2595 3 2 5 6 400 2 3 10 25 94 35 0 148 1935 4 4 6 5 600 2 4 12 152 1540 5 0 7 3 Use an arc transfer height ignition height of 200 5 1 mm 1 Revised on 01 18 2011 This informatio
14. eee 75 lb 34 kg Weight without integrated Inova height control 60 lb 27 kg Gas Supply Requirements Plasma gas types Mild SGN dG inuuna ater aieet ete coat a aat Oxygen or Air Stainless Steel eat e ee eas soe e N a aaa Air or H17 optional Shield gas types MildSteel mennan EE ERES Oxygen or Air Stainless Steels uiiirana n a a a i ai ty Air or Nitrogen Alumin esd sors anene a a i a a E Air or Nitrogen PrefloWw gas type seresdiseeiscshassapiasneantedeademrsvaiads addenda ER A Air or Nitrogen Plasma gas flow rate maximum CPV GCM Or AIT nen mninre a e A AE NTER 30 scfh 850 liters hour i E O E tes E E EAE TS E E E 30 scfh 850 liters hour Shield gas flow rate maximum ROU A ees ce Saccee Ne actos astese tse Stason weed es O deus Maeda 19 scfh 538 liters hour AIP OF INTO BER is ast co ea hiteas oily ena i yale Sinetron ais 87 scfh 2464 liters hour Preflow gas flow rate MaxiMUM eeceeeeeeteeeeeeteeeeeeeeee 25 scfh 708 liters hour Inlet gas pressures rated maximum ORG Gi ara ahaa lade etn alt ken a a at 120 psi 8 3 bar 150 psi 10 3 bar NITOSI eara ciBecce ature Move uohasceaen A E 120 psi 8 3 bar 150 psi 10 3 bar P o rst aces eae AE unduamaunsias aaihna EEEE A 120 psi 8 3 bar 150 psi 10 3 bar aera ene aa ee a er Peer re eee eee 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
15. 2 Pressure regulator 125 psi 7 500061 1 Pressure regulator 15 psi 8 708115 1 Gas test run switch 9 708116 1 Gas test run switch knob 10 500568 1 Fan 11 501147 1 Fan guard filter 12 709002 3 Receptacle 14 position 13 709003 5 Receptacle 9 position 14 709001 2 Receptacle 4 position 15 709229 1 Fuse 1 5 amp 16 709010 3 Fuse Holder 17 709179 1 Terminal block 10 position 18 709192 1 Terminal block marker strip 10 position 19 277060 1 Gas console relay p c board 20 706053 1 Transformer 24VAC 21 707001 1 Line filter 22 709004 4 Receptacle 24 position 23 501145 7 Manifold 24 708097 2 Pressure switch 80 200 psi 25 708077 1 Solenoid valve 30 706003 1 Transformer 20VAC 31 709191 1 Terminal block 4 position 32 709190 1 Terminal block marker strip 4 position 33 110900 1 Inova H Bridge p c board 230VAC 34 110200 1 Inova microprocessor p c board 35 110705 1 Inova power distribution p c board 230VAC 36 709207 1 Receptacle 7 position 37 709084 1 Ground lug 38 709012 1 Fuse 3 amp 39 709210 1 Fuse 6 amp 40 277081 9 Inova insulating washer top 41 277082 9 Inova insulating bushing bottom 42 708030 1 Pressure switch 10 psi 43 708046 1 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 E
16. 277306 45 45 ft 13 7 m 277306 50 50 ft 15 2 m 277306 55 55 ft 16 8 m 277306 60 60 ft 18 3 m 277306 65 65 ft 19 8 m 277306 70 70 ft 21 3 m 277306 75 75 ft 22 9 m 277306 80 80 ft 24 4 m 277306 85 85 ft 25 9 m 277306 90 90 ft 27 4 m 277306 95 95 ft 29 0 m 277306 100 100 ft 30 5 m POWER SUPPLY ELECTRODE LEAD Lig O POWER SUPPLY NOZZLE LEAD POWER SUPPLY CTP SENSOR LEAD OS e LEFT HAND POWER SUPPLY COOLANT RETURN HOSE LEFT HAND J mm ii RIGHT HAND POWER SUPPLY COOLANT SUPPLY HOSE RIGHT HAND 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 2150 User s Manual REV M Work Ground Cable Part Number Length 2773 18 10 10 ft 3 0 m 277318 15 15 ft 4 6 m 2773 18 20 20 ft 6 1 m 2773 18 25 25 ft 7 6 m 2773 18 30 30 ft 9 1 m 2773 18 35 35 ft 10 7 m 2773 18 40 40 ft 12 2 m 2773 18 45 45 ft 13 7 m 2773 18 50 50 ft 15 2 m 2773 18 55 55 ft 16 8 m 2773 18 60 60 ft 18 3 m 2773 18 65 65 ft 19 8 m 2773 18 70 70 ft 21 3 m 2773 18 75 75 ft 22 9 m 2773 18 80 80 ft 24 4 m 2773 18 85 85 ft 25 9 m 2773 18 90 90 ft
17. Amps Oxygen Plasma Air Shield Copper Electrode Shield Cap Nozzle Electrode 277117 277293 277292 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277151 277152 277139 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in Retaining Cap 277151 1 4 118 165 105 200 300 r 3 8 20 74 30 0 123 125 135 250 400 1 2 125 90 140 300 500 130 Retaining Cap 277152 5 8 127 70 446 325 600 130 3 4 130 55 350 1000 135 1 20 74 45 0 134 40 150 400 1 25 145 25 200 1500 140 1 5 155 15 225 a Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm Retaining Cap 277151 6 117 4305 2 6 4 9 300 49 10 20 74 30 0 123 3040 3 4 6 5 00 12 124 2485 3 5 7 3 3 3 Retaining Cap 277152 16 127 1760 56 8 3 1000 3 3 20 130 1340 9 0 3 4 25 20 74 45 0 133 1040 3 7 10 1 4506 32 145 625 5 1 8 9 3 6 38 154 385 5 6 8 9 Use an arc transfer height ignition height of 200 4 9 mm
18. 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 20 Operation ProLine 2150 User s Manual REV M Stainless Steel 150 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277117 277293 277292 Q Outer Cap Retaining Cap Swirl Ring 277154 277152 277139 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 145 150 160 250 400 125 3 8 150 115 180 275 500 1 2 25 75 70 0 155 85 210 300 600 130 5 8 160 60 220 325 800 3 4 168 45 240 350 1200 135 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 144 3910 4 0 6 3 400 39
19. Motion delay knob lock Current thumbwheel assembly Fan Guard Strain relief F2 fuse MDL 5A R9 2 ohm pilot arc resistor 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 2 Parts List ProLine 2150 User s Manual REV M BOO NX OOS SOG 2 72 C729 DA NANRANN RIN RNR R RR RNR RN Ee OH gi i K amp VVUVVVVVUV UV YV mn 5 8 A X2 T CH DE 784 i a y RF 1234667 8 91011121314 igs lclelclelclelclelelelelelelele Pe 9 9 9 9 9 9 9 9 9 9 9 9 9 1 8sshgghs iin of i EIN rl 15 3 6 be Front panel fan not shown item number 42 Figure 6 1 Power Supply Front 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 3 Parts List ProLine 2150 User s Manual REV M Figure 6 2 Power Supply Rear View This information is subject to t
20. Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Oxygen Oxygen Air Voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 20 036 120 105 080 100 062 18 048 121 97 090 16 060 125 78 110 065 14 075 35 85 6 2 126 65 105 200 i 12 105 127 55 11 120 129 50 070 120 125 300 10 135 131 40 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Oxygen Oxygen Air Voltage Speed Height Height Time 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 8 1 7 2 35 85 6 2 1615 200 126 2 7 2 5 1455 18 3 128 1285 2 9 3 1 300 i 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 2150 User s Manual REV M Mild Steel 50 Amps Oxygen Plasma Oxygen or Air Shield Copper Electrode Shield Cap Nozzle Electrode 277115 277122 277131 Torch Head Outer Cap
21. REV M Power Supply Relay P C Board Assembly 500348 m A a Ke PRESSURE K6 TEMPERATURE foe a mM fon N Zz N A gt z m Li N lt N o gt L 4 N t M So N zZ N m oO A x Zz lt m Figure 6 20 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 25 Parts List ProLine 2150 User s Manual REV M Power Supply I O P C Board Assembly 277452 ELECTRODE NOZZLE SHUNT POS WORK GROUND SHUNT NEG O O O O O C e a e INNERLOGIC INC BLANK PCB P N 200351 REV 0 ASSEMBLY P N 200352 Figure 6 21 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 26 Parts List ProLine 2150 User s Manual REV M Gas Console Relay P C Board Assembly 277060 ONT SINOTSSNNI 090442 N d ATaWASSYV 0 Ada 690222 N d 43d ANV1E gt mw D gt D gt gt Vas 24V NEU f a PWR LIGH ON AUX IN R12
22. Retaining Cap Swirl Ring 277154 277153 277140 277142 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Oxygen O or Air Air Voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in Cold Rolled Steel Oxygen Shield Swirl Ring 277140 12 105 123 70 120 100 075 11 120 25 74 12 1 126 60 125 135 200 078 10 135 128 50 135 Hot Rolled Steel Air Shield Swirl Ring 277142 14 075 200 100 075 12 105 106 190 100 135 125 180 25 74 19 1 200 080 10 135 110 170 110 3 16 113 105 440 200 300 085 1 4 117 75 i 225 400 087 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Oxygen Oz or Air Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm Cold Rolled Steel Oxygen Shield Swirl Ring 277140 2 5 121 1895 2 9 100 1 9 25 74 12 1 3 4 3 125 1555 3 1 200 2 0 Hot Rolled Steel Air Shield Swirl Ring 277142 2 5 4885 100 1 9 106 2 5 3 4 3 4660 200 2 0 25 74 19 1 5 113 2555 5 1 3 6 400 2 2 6 116 2075 5 5 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 t
23. 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 PREFLOW SHIELD POSTFLOW GAS TEST RUN NN ON Oe SoS Sere rererrrrs Figure 4 1 Front Panel Controls Power Off Button 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 Illuminates when 3 phase power is applied to the ProLine system DC Power Indicator Illuminates when then main contactor has been energized and D C current is flowing through the torch Motion Delay Potentiometer Used to delay the x y machine motion when piercing thicker materials The delay can be adjusted from 0 to 3 seconds 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 1 Operation ProLine 2150 User s Manual REV M Current Thumbwheel Used
24. 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 2150 User s Manual REV M 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 televisio
25. by opening the valve momentarily prior to installing a regulator e Never lubricate compressed gas cylinder valves or pressure regulators with any type of oil or grease e Never use a compressed gas cylinder or pressure regulator for any purpose other than which it is intended e Never use a pressure regulator for any gas other than which it is intended e Never use a pressure regulator that is leaking or has other signs of physical damage e Never use oxygen hoses and pressure regulators for any gas other than oxygen e 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 2150 User s Manual REV M Health Support Equipment The ProLine 2150 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 e Stay as far away from the ProLine power supply torch torch leads and remote high frequency console as possible e Route the t
26. 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 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 6 Operation ProLine 2150 User s Manual REV M 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 adjus
27. 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 2150 User s Manual REV M 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 Wh
28. 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 25 Operation ProLine 2150 User s Manual REV M Aluminum 150 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277117 277293 277292 Y 7 7 j ZT Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277152 277139 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 145 145 130 250 400 DE 3 8 155 115 185 275 500 i 1 2 25 75 50 1 165 90 230 300 600 130 5 8 65 325 800 135 170 250 3 4 45 350 1200 140 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 143 3770 3 1 6 3 400 32 10 156 2825 4 8 7 0 600 i 12 25 75 50 1 162 2430 5 5 7 4 3 3 16 170 1630 8 3 3 4 6 4 1200 20 170 990 9 0 3 6
29. 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 2150 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 60974 10 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 2150 User s Manual REV M TABLE OF CONTENTS Section I Safety caen cea isa Caen tenes EAA ETER E eeN 1 1 General Preca tiohS sikepan anenee teary R Oa IA EAT O EA ENa O a aus 1 1 Ultraviolet Radiation Protection iaiuiccscy cn cuecdeds Zeca evinnaiy ca oeeumrdtdv es vaniaes ees ch denote 1 1 RTA PLOle COM 542s hie oda hte iss sic elt teu anak Creda tteh E mat doit EE 1 1 Toxic F me Preventi 25 seu nanciuar geet cewiesn mean E T resins T T
30. propylene glycol and provides freezing protection down to 13 C 9 F The standard solution can be ordered in one gallon containers PN 500695 For operating temperatures below 13 C a 50 solution of industrial grade propylene glycol can be ordered in one gallon containers PN 500895 providing protection down to 36 C 33 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 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 3 16 Installation ProLine 2150 User s Manual REV M 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
31. 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 3 TR1 main transformer 230 460 V 60 Hz 30 TR1 main transformer 380 V 50 60 Hz 3 TR1 main transformer 415 V 50 60 Hz 3 TR1 main transformer 575 V 60 Hz 3 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 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 1 Parts List ProLine 2150 User s Manual REV M Item Number Part Number Qua
32. 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 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 2150 gas console to the Hydrogen Out port on the H17 manifold Do not route H17 through the ProLine 2150 gas console Note Always turn the system off prior
33. 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 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 4 Operation ProLine 2150 User s Manual REV M 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 mi
34. troubleshoot accordingly released Faulty latch relay on relay p c board Faulty relay p c board Faulty microprocessor p c board Relay CR1 defective EOR No arc at the torch 1 Incorrect torch consumables installed 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 6 Damaged or loose torch lead connections 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 5 8 Maintenance and Troubleshooting ProLine 2150 User s Manual REV M Problem Possible Cause 7 Shorted torch or torch leads Check the continuity between the Electrode lead and the Nozzle lead to make sure they are not shorted 8 Open torch or torch leads Check the continuity from the Electrode lead to the torch electrode and the Nozzle lead to the l
35. 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 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 3 17 Installation ProLine 2150 User s Manual REV M 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
36. 0024 500018 279013 279112 279113 500740 716012 277056 277086 277087 1 p pk pk pk pi ON ee pd pk pd pd pask Torch valve assembly includes bracket Torch valve bracket Torch Handle Torch Base Torch Head Copper 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 Figure 6 6 Torch and Torch Valve Assembly 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 9 Parts List ProLine 2150 User s Manual REV M Shielded Torch Leads Part Number Length 277304 10 10 ft 3 0 m 277304 15 15 ft 4 6 m 277304 20 20 ft 6 1 m 277304 25 25 ft 7 6 m 277304 30 30 ft 9 1 m 277304 35 35 ft 10 7 m 277304 40 40 ft 12 2 m 277304 45 45 ft 13 7 m 277304 50 50 ft 15 2 m il a Figure 6 7 Shielded Torch Leads O This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provi
37. 11 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 2150 User s Manual REV M Stainless Steel 70 Amps H17 Plasma Nitrogen Shield Copper Electrode This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277150 277124 277132 9 ap Lis 7 Si J Outer Cap Retaining Cap Swirl Ring 277154 277113 277140 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 16 35 60 36 13 135 80 100 200 300 090 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 5 35 60 36 13 135 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 Ad
38. 20 20 ft 6 1 m 711800 25 25 ft 7 6 m 711800 30 30 ft 9 1 m 711800 35 35 ft 10 7 m 711800 40 40 ft 12 2 m 711800 45 45 ft 13 7 m 711800 50 50 ft 15 2 m 711800 55 55 ft 16 8 m 711800 60 60 ft 18 3 m 711800 65 65 ft 19 8 m 711800 70 70 ft 21 3 m 711800 75 75 ft 22 9 m 711800 80 80 ft 24 4 m 711800 85 85 ft 25 9 m 711800 90 90 ft 27 4 m 711800 95 95 ft 29 0 m 711800 100 100 ft 30 5 m Figure 6 24 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 29 Parts List ProLine 2150 User s Manual REV M Hydrogen Manifold Assembly Optional Item Number Part Number Quantity Description 1 708076 2 500570 3 708113 Not Shown 708097 Not Shown 709124 Pressure gauge 200 psi Pressure regulator 125 psi Pressure gauge 160 psi Pressure switch 80 200 psi Receptacle 9 pin ph pb p p pah HYDROGEN PLASMA INLET PRESSURE OUTLET PRESSURE C7 C Figure 6 25 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 an
39. 25 2010 SECTIONS UPDATES Contents Section 2 Section 3 Section 4 Section 5 Section 6 Appendix A Appendix B Deleted 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 2150 User s Manual REV M Rev ECO Author Date Description of Change Section 1 added references to Section 5 L Cee ete Section 5 added chopper warning Added Quick Disconnect Torch information M 10 15 2012 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 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 2150 User s Manual REV M Limited Warranty KALIBURN expressly warrants that this product shall be free from defects in materials and workmanship under p
40. 27 4 m 2773 18 95 95 ft 29 0 m 2773 18 100 100 ft 30 5 m o DIO 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 2150 User s Manual REV M Torch Consumables Mild Steel Cutting Copper Electrode Outer Shield Inner Noose Swirl Copper Torch Retaining Cap Cap Retaining Cap Ring Electrode Head 277154 277145 277153 277120 277140 277130 30A Om D 277140 277122 277142 277154 Q 50A a eran aisi armo omes ama omas gna aao 70A 9 O 877154277286 277151 277284 277283 277282 279150 100A 9 277151 277154 277117 277152 277293 277139 277292 150A 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 2150 User s Manual REV M Torch Consumables Stainless Steel Cutting Air Plasma Copper Electrode Outer Shield Inner Nozzle Swirl Copper Torch Retaining Cap Cap Retaining Cap Ring Electrode Head 27
41. 6 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 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 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 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 3 4 Installation ProLine 2150 User s Manual REV M Work Ground Lead 1 Route one end of the 1 OAWG 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
42. 7120 277140 277130 279150 Q 4 D 30A EE 27715 Q 4 277154 Q9 D gt DP 277154 277293 277139 277292 Q J j 7 i A LL g A 150A Figure 6 14 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 17 Parts List ProLine 2150 User s Manual REV M Torch Consumables Marking Copper Electrode Outer Shield Inner Nozzle Swirl Copper Retaining Cap Cap Retaining Cap Ring Electrode 277154 277145 277152 277120 277140 277190 Figure 6 15 Torch Consumables 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 2150 User s Manual REV M Gas Console Without Integrated Inova Assembly 277080 Note See Figures 6 16 and 6 17 Item Number Part Number Quantity Description 1 708076 4 Pressure gauge 200 psi 2 708075 1 Pressure gauge 100 psi 3 708113 2 Pressure gauge 160 psi 4 708114 1 Pressure gauge 15 psi 5 500562 1 Pressure
43. 7154 277144 277110 277121 277138 277137 279150 lt lt N 30A 9 D 277154 Q J j 7 i vA Sa 379150 277154 Q 150A Figure 6 12 Torch Consumables Stainless Steel Cutting Air 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 15 Parts List ProLine 2150 User s Manual REV M Torch Consumables Stainless Steel Cutting H17 Plasma Copper Electrode Outer Shield Inner Nozzle Swirl Copper Torch Retaining Cap Cap Retaining Cap Ring Electrode Head 277154 277150 277113 277124 277140 277132 279150 lt lt N 277133 277154 277135 Q Figure 6 13 Torch Consumables Stainless Steel Cutting H17 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 2150 User s Manual REV M Torch Consumables Aluminum Cutting Copper Electrode Outer Shield Inner Nessie Swirl Copper Torch Retaining Cap Cap Retaining Cap Ring Electrode Head 277154 277145 277153 27
44. 9001 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 l 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 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 7 Parts List ProLine 2150 User s Manual REV M QS OF O00 OW a se Figure 6 5 Remote High Frequency 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 6 8 Parts List ProLine 2150 User s Manual REV M Torch and Torch Valve Assembly Item Number Part Number Quantity Description Not shown Not shown Not shown Not shown 277475 500549 820134 279050 279150 820209 50
45. AR 6 20 Parts List ProLine 2150 User s Manual REV M PLASMA GAS TEST RUN RUN TEST PREFLOW TEST PLASMA TEST POSTFLOW Be eee POSTFLOW OUT SHIELD OUT PLASMA OUT PREFLOW OUT SHIELD IN PLASMA IN PREFLOW IN Figure 6 16 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 21 Parts List ProLine 2150 User s Manual REV M f th 42 bG He o ast 8 El A THIS gt Tt 88 Figure 6 17 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 locatio
46. B HV Output and its wiring to the Microprocessor PCB 9 If 300 VDC is not present at the output terminal block check the chopper status LED s when a start signal is applied a LED s 1 through 5 off go to step 10 b LED s 1 through 5 on LED 6 off go to step 11 c LED s 1 through 5 on LED 6 on LED 7 off go to step 12 d Only some of LED s 1 through 5 on 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 4 0 VDC to less than 1 VDC after the main contactor of the power supply is energized If 4 VDC is not present replace the chopper If no voltage change occurs check for approximately 4 0 VDC between P26 1 ground and P26 2 signal on the microprocessor p c board If 4 0 VDC is not present check continuity between P26 on the microprocessor p c board and P2 on the chopper p c board If 4 0 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
47. IOUS PAGE CHECK F2 AND WIRING REPAIR ON OFF CABLE REPLACE MICROPROCESSOR P C BOARD REPLACE 10VDC_AT CHOPPER P26 7 8 ASSEMBLY Cen Figure 5 2 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 13 Maintenance and Troubleshooting ProLine 2150 User s Manual REV M 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 5 14 Parts List Section 6 Parts List Power Supply Note See Figures 6 1 to 6 4 Item Number Part Number Quantity Description 1 ONDARRUN Wn 14 Not shown 32 33 34 35 708088 708111 708090 708089 501163 501164 501162 501161 707150 500557 706205 500559 706151 706150 706152 706153 706154 709086 709007 709058 709012 709011 709059 709076 709033 216450 709002 709001 709124 709061 709128 709060 500810 200092 200292 500518 708062 505024 500052 N Oe e e me N Nee UR eee UNR NO RK OO Bh LB ProLine 2150 User s Manual REV M Off switch red Off actuator red On
48. Line 2150 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 2150 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 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 3 15 Installation ProLine 2150 User s Manual REV M 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 2150 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
49. REA S o 1 1 Electric shock Prevention eenaa a a E AE E E dane EAEE REARS 1 2 Fire Prevention eere nea a a E a a Ana E Aa a ATE EIA 1 3 Explosio PreventiOny si0 01205 2c cand an caw BAe leesi Scheel ou Araives Aare eise eas 1 3 Health Support E quipment enirere cpteeess gene ave T E ETEA E OREA 1 4 Safety Standards Booklet Index 0535 aes oo utsdoedeldeee anus OU NS Res 1 4 Section 2 Specifications 000000000 e cee ee nee 2 1 System ESCH PMO erresiren EE ale ONE R R torn AEA E SETARA EE ESDA E es 2 1 SystemC OmpOnents ee a A AR A Ea AE 2 2 Power Supply Specifications ssossseeessssssssssrrerreresssssssererrrreesssssssererereessss 2 2 Gas Console Specifications ses cnnienciiees oe ns neorneresessssseerrrrreessssssssrrerrrereeessssse 2 4 Remote High Frequency Console Specifications sssssssseseeeessessssssreerrrreessse 2 5 LOrehSPSCIHCALIONS 4 5 t ycunravanecrainiweddannounicawgeagietepacmedea thee HEE TE AARAA Ei D aS 2 6 Remote On Off Control Specifications Optional ccc cece cee eee cent eee ene sean ens 2 7 Hydrogen Manifold Specifications Optional 0 0 cece ccc e cence eee nett ene eeaeenees 2 8 Airborne NGISe PMISSIONS ceses nion Eee EEE EET esuico A gece ral ea aS 2 9 Section 3 Installation 223 eccsi cies eeretis tectesvisieletieotan eran tecnd tree 3 1 Initial Inspection sss ean teas leas tae Creu oat S tiene Dose R lee eae oa 3 1 System Interconnections onua E ET a ie elecia euvet TE iacioanc
50. RHF CONSOLE CONTROL CABLE NOVA REMOTE a CABLE_A Figure 3 1 System Interconnection Diagram 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 3 1 Installation ProLine 2150 User s Manual REV M 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 10 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 moun
51. 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 2150 User s Manual REV M Aluminum 70 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277125 277131 277150 Outer Cap ZH Torch Head Retaining Cap Swirl Ring 277154 277153 277142 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 080 130 250 050 150 100 080 1 8 135 160 070 175 3 16 145 80 100 200 200 25 80 25 2 085 1 4 150 50 060 250 300 3 8 155 40 075 275 400 090 1 2 162 30 115 300 500 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 2 129 6400 1 2 3 7 100 2 0 3 134 4420 1 7 4 3 5 145 1920 2 3 5 2 25 80 25 2 300 2 2 6 148 1440 1 7 6 1 10 156 975 2 0 7 0 500 2 3 12 160 820 2 6 7 4
52. Sh R5 Sm ON D12 Se DS j SI ops pay PWR LIGHT OFF SAQW ETA 9J ON OFF OFF WM W M WM 24V NEU vw Bet O3 s F Ogg ew WwW elAOW XNY 9441 yIAOW PTA ZAQW yids una NIN ill 440 4041 R14 D14 x Figure 6 22 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 27 Parts List ProLine 2150 User s Manual REV M 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 PLASMA POWER OFF PLASMA POWER ON Figure 6 23 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 28 Parts List ProLine 2150 User s Manual REV M Remote On Off Control Cable Optional Part Number Length 711800 10 10 ft 3 0 m 711800 15 15 ft 4 6 m 711800
53. TBS 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 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 10 Maintenance and Troubleshooting ProLine 2150 User s Manual REV M 8 If 300 VDC is not present at the output terminal block install a jumper wire between P28 7 amp 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 PC
54. TSUN cays tie eea ata orca tik erred toa aan ee ees a eaS 6 15 in 156 mm WVU esac eal acne as les tt sealed deta g tac ches e E 7 11 181 mm Dp ilceaasiste ecto Saaeiessitetictals ai a w batted Rawdon eaa 6 25 in 159 mm VY SHRINE oce reads e aces ett n ous Ra es acesse asec Arsen 6 0 lb 2 7 kg 7 a DA X HYDROGEN PLASMA INLET PRESSURE OUTLET PRESSURE d d 6 15 156 2 q d r r 5 43 138 6 25 159 41 10 Pas 250 6 DIA 55 14 6 05 154 p 1 Figure 2 5 Hydrogen Manifold Dimensions 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 2 8 Specifications ProLine 2150 User s Manual REV M Airborne Noise Emissions The ProLine 2150 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 2150 when operating at 150 amps 130 arc volts The measurements were made with a sound level meter Distance From Torch A Weighted Sound C Weighted Sound Pressure Level P
55. VAC 30 50 60HZ cscs coccctstvancestadetesievscevsaieccceseeivs 150415 AIS VAC 30 50 OOF eea iaiia 150414 S VAC 3O Bao I genre tire ee renee ere mare eee ere 150413 Input Current at Maximum Output 208 VAC 30 60HZ cccceisisicels eck At iat e ARE 74 amps 230 460 VAC 3 60HZ 21 005 Seiu Secu etugesis trees ae 67 34 amps 280 VAC 30 50 GUNZ s reinn ese Gaon ote eae 41 amps 41S VAG 30 50 60HZ usinisi 38 amps SID VAG BO GON Zra idee ec a a a a o 27 amps Open Circuit Voltage ee cave ates Gases Sue nd Wosncunseea ses es otecuavete 300 VDC Output Current drooping characteristic ccceeeeeeeeeeee 8 150 amps Maximum Output Voltage 0 eee cecceeeceeteeetteette cette ees 170 VDC D t Eyele Sir anete e a a aaa 100 25 5 kW Maximum Ambient Temperature cccceccceseceeseceeeeeeeees 104 F 40 C 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 Specifications Dimensions WTF eten e e duemuais aaa me onto anapansteseonauber eas 30 in 762 mm Height including gas console cecceesseesseeeteeeteeeeees 48 in 1219 mm Dep il cases e A a E AAS 43 in 1092 mm Weight including gas console cceccceceseceeeeeeeeeeteeeeneees 700 lb 317 kg Torch Cooling System Discharge press
56. W KALIBURN ProLine 2150 Precision Plasma Cutting System Revision M 10 15 2012 Manual Part Number 718082 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 2150 User s Manual REV M Revision History Rev ECO Author Date Description of Change As released 10 05 05 Cut chart update 10 26 05 Cut chart update Bil wy Dd 1 11 18 05 Parts list update gt 12 12 05 Cut chart update Parts list update 01 18 06 Added ISO spec and flashback arrestors to gas console specifications Corrected 220 240V coolant flow solenoid part number 03 02 06 Changed to 24VDC Condor power supply for gas valves 6 13 06 Changed inductor resistor CTP sensor lead filter inside RHF box to the ferrite core filter Added 2 control transformer fuse and labeled the fuses F1A and F1B 7 27 06 Cut chart updates 05 09 07 Changed coolant level switch location Removed PAR changed CR3 Cut chart updates Corrected regulator and gauge PN s for hydrogen manifold assembly 05 23 07 Cut chart updates 10 15 07 Added PAR relay in series with surge injection circuit to schematic and parts list Cut chart updates 10
57. andle e 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 Torch Electrode Coolant Supply Lead e Connect the Torch Electrode Coolant Supply Lead to the torch as shown Torch Coolant Return Lead GD e Connect the Torch Coolant Return Lead to the torch base as shown Note that the Torch Coolant Return Lead fitting has left hand threads Torch Nozzle Lead 12 e Connect the Torch Nozzle Lead to the torch base as shown Torch CTP Sensor Lead 13 e Connect the Torch CTP Sensor Lead to the torch base as shown Shield Gas Hose e Connect the Shield Gas Hose to the torch base as shown Torch Plasma Gas Hose 15 e Connect the Torch Plasma Gas Hose to the torch base as shown 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 3 9 Installation ProLine 2150 User s Manual REV M Torch to Torch Handle Installation e Thread the torch handle onto the torch base e Tighten the base to the handle using a pin style adjustable spanner wrench fits 2 diameter with 4 diameter pin e 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 e Mount t
58. arge brass body of the torch No spark between the spark gap 1 Improper spark gap Set gap to 015 381 electrodes 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 TRS 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 The arc will not transfer to the Loose work ground connection workpiece Pierce height too high 3 Incorrect damaged or worn consumables NOR Wrong consumables installed in torch Pressure regulator orifice clogged with dirt or debris Turn off primary power and turn regulator adjustment knob fully clockwise Gas pressures will not adjust properly NR Supply gas pressure s less than 150 psi Faulty pressure switch or associated wiring inside gas console Low pressure error NR 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 9 Maintenance and Troubleshooting ProLine 2150 User s Manual REV M Chopper Test Procedure Warning Only qualified maintenance personnel should perform the chopper test proced
59. ated when the contacts are opened The contacts should be rated for 12VDC 10mA If the ProLine 2150 is ordered with the integrated Inova system see below for interface information Arc Hold IHS Complete Signal e The ProLine 2150 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 2150 is ordered with the integrated Inova system see below for interface information Motion Output Signal e The ProLine 2150 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 12SVAC 6A 110VDC 2A 30VDC If the ProLine 2150 is ordered with the integrated Inova system see below for interface information Inova Connections optional e When the ProLine 2150 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 Pro
60. 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 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 2150 User s Manual REV M FUSES CORRECT AS NECESSARY CHECK CON1 AND WIRING CHOPPER OK SEE NEXT PAGE Figure 5 1 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 12 Maintenance and Troubleshooting ProLine 2150 User s Manual REV M FROM PREV
61. ccisec eau E a a e e tewel atone notes 22 lb 10 kg Spark gap distance wewuccsche st awaiecas einai eta tatoos 025 in 635 mm 6 00 203 H T a e I 4 312 8 mm 13 50 343 12 75 324 12 00 305 l I Te ej Lee 10 00 254 I O 5 1 3 3 f 3 6 Jl COOLANT OUT PONER LENS COOLANT IN P1 aN GROUND PN am BA Figure 2 2 Remote High Frequency Console Mounting Dimensions 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 Specifications ProLine 2150 User s Manual REV M Torch Specifications Stock Number Toreh Handle srren inneni aE 820134 Torch SB ASC gcc aides eked iat ealinlecraWiedecannestbonncansies 279050 Torch Head Copper Electrode ceceeeeeee 279150 Weight Valves Handle Base and Head cc cceee 6 2 lb 2 8 kg D MAC Valves oB 3 40 86 op IH Mad INN D Torch Handle 9 20 234 Tl Ble 10 Torch Base 1 87 47 Alignment Indicator pa Slot
62. d Steel 100A Stainless Air 100A Aluminum 277126 3 Nozzle 100A Stainless H17 277293 5 Nozzle 150A Mild Steel 150A Stainless Air 150A Aluminum 271297 3 Nozzle 150A Stainless H17 277145 3 Shield Cap 30A Mild Steel 30A Aluminum 277144 3 Shield Cap 30A Stainless Air 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 Part Number 277149 277115 277150 277286 277146 277117 277298 277138 277140 277142 277283 277141 277139 277110 277153 277151 277152 277113 277266 716012 500024 500018 820209 Quantity 3 NNNe ProLine 2150 User s Manual REV M Description 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 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 Swi
63. de to the ProLine 2150 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 2150 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
64. ded 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 2150 User s Manual REV M Gas Hose Package Part Number Length 277317 20 20 ft 6 1 m 277317 25 25 ft 7 6 m 277317 30 30 ft 9 1 m 277317 35 35 ft 10 7 m 277317 40 40 ft 12 2 m 277317 45 45 ft 13 7 m 277317 50 50 ft 15 2 m 277317 55 55 ft 16 8 m 277317 60 60 ft 18 3 m 277317 65 65 ft 19 8 m 277317 70 70 ft 21 3 m 277317 75 75 ft 22 9 m 277317 80 80 ft 24 4 m 277317 85 85 ft 25 9 m 277317 90 90 ft 27 4 m 277317 95 95 ft 29 0 m 277317 100 100 ft 30 5 m PLASMA GAS HOSE PREFLOW GAS HOSE fT E i SHIELD GAS HOSE GT POSTFLOW GAS HOSE TORCH SOLENOID CONTROL CABLE EL 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 Coolant and Power Leads ProLine 2150 User s Manual REV M Part Number Length 277306 5 5 ft 1 5 m 277306 10 10 ft 3 0 m 277306 15 15 ft 4 6 m 277306 20 20 ft 6 1 m 277306 25 25 ft 7 6 m 277306 30 30 ft 9 1 m 277306 35 35 ft 10 7 m 277306 40 40 ft 12 2 m
65. e regulator Shield Gas Control Displays the shield gas inlet and outlet pressures and provides a shield gas outlet pressure regulator Postflow Gas Control aD Displays the postflow gas inlet and outlet pressures and provides a postflow gas outlet pressure regulator Gas Test Run Switch 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 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 2 Operation ProLine 2150 User s Manual REV M 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 2150 gas console Ay A HYDROGEN PLASMA INLET PRESSURE OUTLET PRESSURE SPR
66. ear 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 2150 User s Manual REV M 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 Elect
67. ecetecceteceeeeeeeeeeseeenneens 5 6 Troubleshooting Using the Microprocessor Error LED 00 cc ce eccceseceeeceeeeeeeeeeeeeeenteeneeneees 5 7 General TrOuBIESNOGtIG i Maas atiaane Aone coda Lis sae REE Gia teeta decd Aaa eet 5 8 Chopper Test Proced te oj5023 45 covisiesfansuteasazes i AEEA EERE Eae 5 10 Section 6 Parts List ec cn nigel ai ha dete anh eae he 6 1 Power Supply rasina nre e a sana reodoaduce gh Sec shesia dav Eaa E EATA E EEES 6 1 Remote High Frequency Console 2 5 c 006s a svvetsvaccasecandncvacdasecs anv beaenaveduas casrduebassdassstvdaesuidess 6 7 Torch and Torch Valve Assembly 2 c cccd2sey so ceas ccvaceusceaacec occas ves dcses saataces pe eeaciseeteeastartenenaaes 6 9 Shielded Forch Meads as is csc tus tees ea oe Cae iat a aaa Sieg Sam ace a toa ae cat 6 10 yds HOSE PACKAGE risana in A E sansa tavaksqece EE E oe ea wa peace 6 11 Coolant and Power Leads ieron aa a a i a ad 6 12 Work Ground Cable rece ne hl eet Sani a au Aca tae ia E cent eS a aa 6 13 Torch Consumables Mild Steel Cutting Copper Electrode cecceceesceeeseeesseeeteeeeeeeees 6 14 Torch Consumables Stainless Steel Cutting Air Plasma Copper Electrode 0 6 15 Torch Consumables Stainless Steel Cutting H17 Plasma Copper Electrode 6 16 Torch Consumables Aluminum Cutting Copper Electrode cceeccceesscesseeeteceteeeeeeeenees 6 17 Torch Consumables Marking Copper Electrode cccceccesceesceeseeescece
68. ed to exacting dimensions and checked with the latest computerized measuring systems Five nozzle sizes 30 50 70 100 and 150 amps are available to produce excellent cut quality throughout the cutting range The degree of protection provided by the ProLine 2150 system is IP21S and as such is intended only for indoor use It is not suitable for use in rain or snow The Proline 2150 system is tested in accordance with CISPR 11 EMC classification Group 2 ISM Class 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 2 1 Specifications ProLine 2150 User s Manual REV M System Components The ProLine 2150 consists of the following components Standard Components e 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 e Remote On Off Control Assembly e Hydrogen Manifold Assembly Power Supply Specifications Stock Number 208 VAC 30 CONIZ iici aieri 150411 230 4600 VAC BO OOF terse oie tit a ate elas tat 150412 380
69. eeceeeeeeeeeeseeesseenes 6 18 Gas Console Without Integrated Inova ess sce seveces snccsseseccensssaderts ts casesseonstosstsdubesvbeeditieisdesseceans 6 19 Gas Console With Integrated Inova as ocs ss0dsschhiees Geass eataansdedpbieetdacsacieanddaxdineeandeatenaaagiess 6 20 Power Supply Microprocessor P C Board ia ciscscacesciengtadtisteyeens Wiassdlnngtiae aad 6 23 AC Detect PC Board e525 cagrs ceions aae e e erating Gao ou aca rae ae eae 6 24 Power supply Relay PAC Bonds syt bs saoeiieand oh kat unas deta ti enckacsrephsnatetea tae i a 6 25 Power oupply VO P C Band essen to gee onre seid ects Madera EE E E rate a 6 26 Gas Console Relay P C Board vcs Saige tos eras dccedeaes Sagecsos ss usb es uedanes ase nasaatsncceos auee a betectaaeauoks 6 27 Remote On Off Control Assembly Optional ccceccceeseessceesseceteceeeeeeeeeeseecaecneeneeeenaaes 6 28 Remote On Off Control Cable Optional c ceecccccecsseceseceeeeeeeeeeseeceaeceeeeeeeesseecsaeeneeeesees 6 29 Hydrogen Manifold Assembly Optional ccccecscesssecsseceseceeeeeeseecaecesecseeeenseecsaeeneenaes 6 30 Hydrogen Manifold Interface Cable Optional 0 0 0 ceeceesceeseeeeeceeeceeeceeseecaeeneeeeeeennees 6 31 Consumable Spare Parts Kit ry vans cs tay Seccarcle sede aceatsvs a ceen egattanteowa bo esas tetuera cc teesen Netategatcees 6 32 This information is subject to the controls of the Export Administration Regulations EAR This information shall not be provided
70. electrode removed inspect the cooling tube in the torch head for damage For a copper electrode the torch head uses cooling tube P N 277007 If replacement is required use tool P N 200109 0S 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 2150 User s Manual REV M 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 handl
71. ere 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 2150 User s Manual REV M 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 out
72. 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 2150 User s Manual REV M Electric Shock Prevention The ProLine 2150 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 e 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
73. 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 Perform the following steps to connect the chassis of the RHF Console to the cutting table See Figure 3 3 for additional information 1 Connect one end of the RHF Console Ground Lead to the ground stud on the RHF console 2 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 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 3 5 Installation ProLine 2150 User s Manual REV M T i
74. he EAR 4 10 Operation ProLine 2150 User s Manual REV M Mild Steel 70 Amps Oxygen Plasma Air Shield Outer Cap Copper Electrode Shield Cap Nozzle Electrode 277125 277131 277150 Torch Head i Retaining Cap Swirl Ring 277154 277153 277142 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 8 35 110 190 150 100 100 080 3 16 113 130 200 200 25 80 2 1 4 40 116 120 110 225 300 ggz 3 8 122 75 140 250 400 i Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 3 35 109 4995 3 6 100 2 5 2 0 5 25 80 2 113 3265 5 1 40 300 6 115 3105 2 7 5 5 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 2150 User s Manual REV M Mild Steel 100 Amps Oxygen P
75. he 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 2150 User s Manual REV M ceecee 69 Figure 6 3 Power Supply Left Side 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 5 Parts List ProLine 2150 User s Manual REV M Figure 6 4 Power Supply Right Side 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 6 Parts List ProLine 2150 User s Manual REV M Remote High Frequency Console Note See Figure 6 5 Item Number Part Number Quantity Description l 715051 2 Coolant return fitting left hand 2 715050 1 Coolant supply fitting right hand 3 709227 1 Strain relief 5 70
76. he 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 e Connect the Torch Plasma Gas Hose to the solenoid outlet port as shown Preflow Gas Hose e 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 e Connect the Plasma Gas Hose to the solenoid plasma inlet port as shown Postflow Gas Hose e Connect the Postflow Gas Hose to the solenoid postflow inlet port as shown Torch Solenoid Control Cable e 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 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 3 10 Installation ProLine 2150 User s Manual REV M a il g k RN RRR i A 7 WAXY RY WAY OO Ee ye Figure 3 5 Torch Connections This information i
77. his 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 2150 User s Manual REV M Figure 6 22 Gas Console Relay P C Board ee ceeeccesceseeseeseeceeceseceeeaeeeeeeeeeaeenaeeneeess 6 27 Figure 6 23 Remote On Off Control Assembly Optional 0 ccceeeecceeeseceteceteeeeeeeeeees 6 28 Figure 6 24 Remote On Off Control Cable Optional oe ee eeeceeseeeeeeeteeeeteeeteeeees 6 29 Figure 6 25 Hydrogen Manifold Assembly Optional 0 0 0 ceseecceseceseceeeeneeeeeeeeeeeeeaee 6 30 Figure 6 26 Hydrogen Manifold Interface Cable Optional 00 0 ee eeeeeeseceteeneeereeeeees 6 31 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 2150 User s Manual REV M 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 ma
78. iion riesite kiraia 6 10 Figure 6 8 Gras Hose Package onner iera ea e a e a a EGE 6 11 Figure 6 9 Coolant and Power Leads oiecsensiessiieienen eian a 6 12 Figure 6 10 Work Ground Cable s ssessessesessssseesssseseestsseseseseesesseseesesseseestsseesesseseesessese 6 13 Figure 6 11 Torch Consumables Mild Steel Cutting Copper Electrode 6 14 Figure 6 12 Torch Consumables Stainless Steel Cutting Air Copper Electrode 6 15 Figure 6 13 Torch Consumables Stainless Steel Cutting H17 Copper Electrode 6 16 Figure 6 14 Torch Consumables Aluminum Cutting Copper Electrode 06 6 17 Figure 6 15 Torch Consumables Marking Copper Electrode ccceeeeeceeseesteeeteeees 6 18 Figure 6 16 Gas Console Exterior ssisiscuvadasss cans cescieisshbnsotaaeesedses sseVeueane situnbebadenwe ascheaisasd 6 21 Figure 6 17 Gas Console Interior ssssseessesesessessessesseessesstssresseestesresseeseestesseeseesersseesse 6 22 Figure 6 18 Power Supply Microprocessor P C Board s sssssessesssssressessreseesseeseesressee 6 23 Fioure 621 9 AC Detect P C Board orinis iinn an a E 6 24 Figure 6 20 Power Supply Relay P C Board s sssessssessessssssesssesessseesresessseesseserssressessess 6 25 Figure 6 21 Power Supply I O P C Board ssessseeseesessssessessssesesessseesesessseesseserssressesess 6 26 This information is subject to the controls of the Export Administration Regulations EAR T
79. ing 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 info
80. ion 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 e 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 e 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 e 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 6 Maintenance and Troubleshooting ProLine 2150 User s Manual REV M Troubleshooting Using the Microprocessor Error LED If all of the status LED s are illuminated but the ProLine system still has a prob
81. 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 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 7 Operation ProLine 2150 User s Manual REV M 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 Material Process Current Plasma Gas Shield Gas Copper Electrode Mild Stee
82. ively 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 Verify that the primary three phase A C voltage connections are tight Verify that all p c board connectors are installed securely Verify that the rear panel cable connectors are installed securely 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 Soe 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 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 0S 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 out
83. l Cutting Oxygen Mild Steel Cutting Oxygen or Air Mild Steel Cutting Air Mild Steel Cutting Air Mild Steel Cutting Air Stainless Steel Cutting Air Air Stainless Steel Cutting Air Nitrogen Stainless Steel Cutting Nitrogen Stainless Steel Cutting Air Nitrogen Stainless Steel Cutting Nitrogen Stainless Steel Cutting Air Nitrogen Stainless Steel Cutting Nitrogen Stainless Steel Cutting Air Nitrogen Aluminum Cutting Air Nitrogen Aluminum Cutting Air Nitrogen Aluminum Cutting Air Nitrogen Aluminum Cutting Air Nitrogen Aluminum Cutting Air Nitrogen Mild Steel Marking Nitrogen Nitrogen Stainless Steel Marking Nitrogen Nitrogen Aluminum Marking Nitrogen Nitrogen 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 2150 User s Manual REV M Mild Steel 30 Amps Oxygen Plasma Oxygen Shield Copper Electrode Shield Cap Nozzle Electrode 277120 277130 277145 2 VA SZ Torch Head Outer Cap Retaining Cap Swirl Ring 277154 277153 277140 279150 Imperial Material
84. lasma Air Shield Copper Electrode Shield Cap Nozzle Electrode 277286 277284 277282 2 S NA Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277151 277283 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 125 150 090 200 300 3 8 430 100 130 250 400 090 1 2 25 94 26 0 65 155 300 500 5 8 143 47 325 800 185 095 3 4 145 35 350 1000 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 6 124 3950 2 1 4 9 300 10 2405 3 3 6 5 2 3 130 500 12 25 94 26 0 1850 3 7 7 3 16 143 1180 8 3 4 7 1000 2 4 20 145 800 9 0 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 2150 User s Manual REV M Mild Steel 150
85. 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 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 Specifications ProLine 2150 User s Manual REV M Remote High Frequency Console Specifications Stock NumBetsg cuctin itt aig tus eae S 205500 Heighten ea a nears dan ieee os A oo MM WVU case escalate altel i latas ud a T E A ia taien T 13 5 in 343 mm DS pilates denina Os ease a sale eaten sadtees 10 in 25 mm NY STEIN e
86. lem 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 Error 1 No transferred arc TAC established 2 TAC lost before current slope up 3 TAC lost during current slope up 4 TAC lost while cutting 5 TAC lost during current slope down 6 Start signal applied prematurely or while Gas Test Run switch is in the Run position 7 Start signal removed prematurely 8 Output voltage below 60V 9 Output voltage above 185V 10 Invalid current set point 11 Current feedback circuit open 12 TAC not established within 2 seconds 13 IHS or arc hold timed out 14 Pilot arc not established 15 Low current during cut 16 TAC sensed when start signal applied 17 Faulty AC phase 18 Low torch coolant flow 19 Gas console error 20 RHF door switch open 21 Low torch coolant level 22 High torch coolant temperature 23 Main contactor shorted 24 N A 25 Defective Flow Switch 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 requiremen
87. ll 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 6 Specifications ProLine 2150 User s Manual REV M Section 2 Specifications System Description The ProLine 2150 is a microprocessor controlled 150 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 1 1 2 thick and stainless steel from gauge to 1 thick The maximum piercing capacity is 1 thick material The ProLine 2150 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 2150 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 2150 is technologically advanced to produce the highest quality cuts while maximizing consumable life The torch is water cooled and consumables are machin
88. ministration 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 2150 User s Manual REV M Stainless Steel 70 Amps Air Plasma Nitrogen Shield Copper Electrode This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277150 277125 277131 9 ome D lt E E7 Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277153 277142 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 10 135 132 120 060 150 200 085 3 16 134 100 070 200 300 i 25 80 25 2 1 4 140 75 090 225 400 090 3 8 148 50 120 250 500 l Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 3 131 3210 1 4 3 3 200 T 5 25 80 25 2 134 2445 1 8 5 1 400 6 138 2050 2 1 5 5 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 E
89. n Section 4 for gas types Plasma Inlet Q e Connect the proper plasma gas to the Plasma In port See the cutting charts in Section 4 for gas types Shield Inlet 3 e Connect the proper shield gas to the Shield In port See the cutting charts in Section 4 for gas types ou POSTFLOW SHIELD PLASMA PREFLOW SHIELD PLASMA PREWLOW OUT T IT OUT I OO oO e e REMOTE OTE ROGEN AUX E E CURRENT ON OFF FOLD our o P2 P3 PS P7 GROUND VOLT DIV __ POWER SUPPLY _RS 422 IN RS 422 OUT e e e 9 zag Figure 3 6 Gas Console Input Connections 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 3 13 Installation ProLine 2150 User s Manual REV M 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 Preflow Outlet 29 e Connect the preflow hose to the Preflow Out port as shown Note that the Preflow Out port ha
90. n 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 2150 User s Manual REV M Stainless Steel 150 Amps H17 Plasma Nitrogen Shield Copper Electrode This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277298 277297 277135 Q D m Li 7 iy J Outer Cap Retaining Cap Swirl Ring 277154 277266 277139 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 1 4 95 250 250 400 435 3 8 75 150 275 500 l 1 2 25 81 75 13 165 60 165 300 600 440 5 8 50 185 325 800 l 3 4 40 250 350 1200 145 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 10 1845 3 8 7 0 3 4 600 12 155 1610 4 1 7 4 25 81 75 13 3 6 16 1260 4 7 8 3 800 20 167 940 6 9 9 0 1200 3 7 H17 17 5
91. n outside the United States contrary to the requirements of the EAR 6 22 Parts List ProLine 2150 User s Manual REV M Power Supply Microprocessor P C Board Assembly 216450 2228855 aD Bi a sag 8 zen e ee og EO eso gW TT LEDI6 C Lene VR START LED 7 Lene 2V uP Oxy CHIPPER Lepie Jik vepio PAT R62 PWR LEDe3 Os LEDS LEDU JOR oge wO ia LEDAN LeDie Orr PWR MOTION LED21 LEDi3 IVER OQO s3 OXR r H ED2S UX Lepen LED Orme wan MANUAL CONSOLE INNERLOGIC INC BLANK PCB P N 200349 REV2 ASSEMBLY P N 200350 Figure 6 18 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 23 Parts List ProLine 2150 User s Manual REV M A C Detect P C Board Assembly 500810 v gt a m W 2 ASVHd OTPS O BLANK PCB P N 500809 REV 0 ASSEMBLY P N 500810 Figure 6 19 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 24 Parts List ProLine 2150 User s Manual
92. n 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
93. neeneenenaenes 3 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 2150 User s Manual REV M Section 4 Operation iis cides was aieiea esteem cilel uae 4 1 Power Supply Front Panel Controls sssssseeenerrsssssssseererreesssssssseererreressssssse 4 1 Optional Hydrogen Manifold Controls c occssincvanne scp soneeanen can seneuwcre rey anneanscunen eee 4 3 SCS UPA Ct ry ees ited shine sped EE TEE E EE A AT EEA EREA 4 4 ET RUE 1 E AAT A A E EE IS E E EAT 4 5 Making a C tar E a NEE T EEN AEE E EE TE EE 4 6 Consumable Lite siiscs ciccetnnenesersattoaiin EA E aa EE A a ETA arse aE Ea EER 4 6 C t Qualys ere ona a E E EEEa N ELA EaI 4 7 C tting Charts nieee orii a E ce aK A EEE E EEEE ATOE A S 4 8 Section 5 Maintenance and Troubleshooting 0000011111111111111 5 1 R tne Mati tetanic 2x oii atl a a a a a ei 5 1 Replacing the Torch Coolant s snssseessesesssessessessesseessesrssseeseesersstessessessressessesseesseeseesessee 5 3 Microprocessor tats LED Sesio tissues tanso baienn AAE AE rE PaA AERE EA KESEREK Sa 5 4 Microprocessor Sequence of Operation cccccsceessecsseceseceeeeeeseecseeceecseeeenseecsaeeneeseeeenseees 5 5 Troubleshooting Using the Control Panel Status LED S 0 cece cceccc
94. netic Compatibility EMC ProLine 2150 User s Manual REV M Appendix A Electromagnetic Compatibility EMC Background The 380V 50 60Hz and 415V 50 60Hz CE marked ProLine 2150 plasma cutting systems are manufactured to comply with the European standard EN 60974 10 Electromagnetic compatibility EMC Product standard for arc welding equipment The system has been tested in accordance with CISPR 11 EMC classification Group 2 ISM Class A 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
95. 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 2150 User s Manual REV M Stainless Steel Marking 10 Amps Nitrogen Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277145 277120 277190 p x 9 ODS D f A a a Ss Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277152 277140 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Marking Initial Pierce Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Time in psi psi psi psi volts ipm in in msec All Thicknesses 28 28 28 2 145 250 177 100 0 Metric Material Preflow Plasma Shield Postflow Arc Travel Marking Initial Pierce Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Time 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 28 Operation ProLine 2150 User s Manual REV M Aluminum Marking 10 Amps Nitrogen Plasma Nitr
96. nterlock devices e 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 e Never operate the ProLine system without all of the covers in place See Section 5 for additional safety precautions e 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 2150 User s Manual REV M Fire Prevention When using the ProLine 2150 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 Note Make sure that the cutting area is properly ventilated when using o
97. ntity Description 36 500513 500511 708061 715084 708068 708059 500516 500514 150900 500509 500510 708110 500348 702048 708118 701165 500536 705011 709167 702075 277452 Contact factory 150004 709117 709228 706036 706041 706042 706043 280003 708103 708104 708105 709190 709191 740106 704050 200204 715052 701051 710190 710191 277070 500526 709227 709231 701141 1 N N OO NO e e aee N On Oo momo V band clamp Coolant pump 70 gph Solenoid valve 220 240V AC 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 3 power terminal block PAT IGBT filter capacitor VO p c board assembly Height control voltage divider p c board assembly Chopper assembly T O terminal block small T O terminal block large TR8 transformer 241 4 36 TR7 transformer 241 3 12 TRS transformer 241 4 12 TR3 transformer 241 6 12 Power supply 24VDC CRI relay CRI 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
98. oLine 2150 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 PROLINE POWER SUPPLY WITH INTEGRATED INOVA CABLE B fo HYDROGEN MANIFOLD OPTIONAL A HYDROGEN MANIFOLD INTERFACE CABLE iF D Pra GAS HOSE PACKAGE oO eo o E WaR Pa Aa gag E ieee REMOTE ON OFF CONTROL CABLE 2 A 7 gt REMOTE ON OFF OPTIONAL dl i a 3 INOVA POSITIONER Cc x a 3 CABLE D aS TORCH SOLENOID CONTROL CABLE CABLE C i POWER LEADS ey P15 eHe TORCH LEADS T RHF CONSOLE P16 FI f o o aciga oO EO rasa rover eos jy P12 P amp P7 eee Pi GROUND G e oe L2 mnan Eye H 77 Feel Ce COOLANT LEADS STAR WORK GROUND LEAD GROUND WORKPIECE Sg POWERS INET
99. ogen Shield Copper Electrode Shield Cap Nozzle Electrode 277145 277120 277190 p x 9 OMD gt D f A a a Ss Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277152 277140 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Marking Initial Pierce Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Time in psi si psi psi volts ipm in in msec All Thicknesses 28 28 28 2 145 250 177 100 0 Metric Material Preflow Plasma Shield Postflow Arc Travel Marking Initial Pierce Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Time 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 29 Operation ProLine 2150 User s Manual REV M 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 4 30 Maintenance and Trouble
100. 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 2150 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 2150 gas console Note that the cable has a key installed on the end that plugs into the 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 3 18 Operation ProLine 2150 User s Manual REV M
101. ons ceeceseeeseeseeeeeeeeeeeeeaeeneeenee 3 8 Figure 3 5 Torch AC ONMECHONS ais sca niniin nna a E E E ana G 3 11 Figure 3 6 Gas Console Input Connections ssssesssssesseeseeseesseesreseosseesreseesstesseseesseesee 3 12 Figure 3 7 Gas Console Output Connections ssssssssesseseesesseseessesetsessesetsesseseesseseesesse 3 13 Figure 3 8 Freezing Points of Aqueous Propylene Glycol Solutions 0 0 0 0 eee 3 15 Figure 4 1 Front Panel Contras siiaicctodecctettncsecemaaeeeas paces buosigecctia inanar eiiis 4 Figure 4 2 Hydrogen Manifold Controls Optional 00 0 0 eeseeseeseeeteeeeceeeceseeneeeaeeeneees 4 3 Figure 5 1 Chopper Diagnostics Part 1 cssccsdasco diescdete An noesebaee iors 5 11 Figure 5 2 Chopper Diagnostics Part 2 ci ecesedaccuacysises Migdaave seecasece suseadceDicce vs Seaabeitaes 5 12 Figure 6 1 Power Supply Front View cisicsuecewsciseis sewer ee as ena 6 3 Figure 6 2 Power Supply Rear View ic ciscinsisesdacaashsecctass ipcctyeistiavideslociashiuteestlaactasdind 6 4 Figure 6 3 Power Supply Left Side View desc ek ees tars nasactcolad nui kate nodadlin died cadens 6 5 Figure 6 4 Power Supply Right Side View 4 sect esi hesue des duende naka 6 6 Figure 6 5 Remote High Frequency Console ccc saavensaleccscesesces voscantvigecaseotsusnechdydundgevisd 6 8 Figure 6 6 Torch and Torch Valve Assembly o sccs5s5s 22yeqncenacasuassancecassaeeedesdaniondeoneusiasins 6 9 Figure 6 7 Shielded Torey Leads sii sicasccscices ssabccd i
102. or recommended fuse sizes 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 3 2 Installation ProLine 2150 User s Manual REV M 3 Phase Input Current Recommended Input Voltage at Maximum Output Time Delay Fuse Size VAC amps amps 208V 60Hz 74 100 230V 60Hz 67 90 380V 50 60Hz 4 60 415V 50 60Hz 38 50 460V 60Hz 34 50 575V 60Hz 2 40 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 an TB5 Location Disconnect Box Connections Strain Relief Figure 3 2 Primary Power Connections 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
103. orch leads as close as possible to the work ground cable e 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 e 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 249 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 Footw
104. ower supply remove the torch head and inspect the o rings for damage CORRECT INCORRECT V O ring T i TO i Correct Incorrect Thereisno Gap is visible gap between between O o ringand o ring and O attachment attachment ring ring 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 3 12 Installation ProLine 2150 User s Manual REV M 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 Preflow Inlet 1 e Connect the proper preflow gas to the Preflow In port See the cutting charts i
105. regulator 60 psi 6 500570 2 Pressure regulator 125 psi 7 500061 1 Pressure regulator 15 psi 8 708115 1 Gas test run switch 9 708116 1 Gas test run switch knob 10 500568 1 Fan 11 501147 1 Fan guard filter 12 709002 1 Receptacle 14 position 13 709003 2 Receptacle 9 position 14 709001 2 Receptacle 4 position 15 709229 1 Fuse 1 5 amp 16 709010 1 Fuse Holder 17 709179 1 Terminal block 10 position 18 709192 1 Terminal block marker strip 10 position 19 277060 1 Gas console relay p c board 20 706053 1 Transformer 24VAC 21 707001 1 Line filter 22 709004 1 Receptacle 24 position 23 501145 7 Manifold 24 708097 2 Pressure switch 80 200 psi 25 708077 1 Solenoid valve 42 708030 1 Pressure switch 10 psi 43 708046 1 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 19 Parts List ProLine 2150 User s Manual REV M Gas Console With Integrated Inova Imperial Assembly 277085 Metric Assembly 277090 Note See Figures 6 16 and 6 17 Item Number Part Number Quantity Description 1 708076 4 Pressure gauge 200 psi 2 708075 1 Pressure gauge 100 psi 3 708113 2 Pressure gauge 160 psi 4 708114 1 Pressure gauge 15 psi 5 500562 1 Pressure regulator 60 psi 6 500570
106. ressure Level 1 meter horizontal 1 6 meters 97 dB 94 dB above the workpiece The maximum noise level is 121 dB at a distance of 3 inches 76 2 mm from the torch while cutting at 150 amps 130 arc volts 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 9 Specifications ProLine 2150 User s Manual REV M 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 2 10 Installation ProLine 2150 User s Manual REV M 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 2150 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 Pr
107. rical Code obtainable from the National Fire Protection Association 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 IR3 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 non U S persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR 1 5 Safety ProLine 2150 User s Manual REV M BLANK PAGE This information is subject to the controls of the Export Administration Regulations EAR This information sha
108. rl Ring 100A Stainless H17 Swirl Ring 150A Mild Steel 150A Stainless 150A Aluminum Inner Retaining Cap 30 50A Stainless Air Inner Retaining Cap 30 50 70A Mild Steel 70A Stainless Air 30 50 70A Aluminum 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 O ring Lubricant Torch O ring blue lower Torch O ring red middle Torch O ring black upper 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 Part Number 277056 277086 277087 260105 277154 Quantity p SS ph pah ProLine 2150 User s Manual REV M Description 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 34 Electromag
109. rmation 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 2150 User s Manual REV M 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 LED 14 HOLD OUT LED 15 MAN CONSOLE LED 165V uP PWR LED 17 12V uP PWR LED 18 ILK PWR LED 19 ANALOG PWR LED 20 GAS PWR 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 Hold relay energized used for dual power supply mode Manual gas console attached 5V microprocessor power supply satisfactory 12V microprocessor power
110. roper and normal use for the intended function of such equipment for a period of one 1 year for the ProLine 2150 torch and leads and three 3 years for the ProLine 2150 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
111. s left hand threads Plasma Outlet Qs e Connect the plasma hose to the Plasma Out port as shown Note that the Plasma Out port has right hand threads Shield Outlet Qs e Connect theshield hose to the Shield Out port as shown Note that the Shield Out port has right hand threads Postflow Outlet D e Connect the postflow hose to the Postflow Out port as shown Note that the Postflow Out port has right hand threads POSTFLOW SHIELD PLASMA PREFLOW SHIELD PLASMA PREFLOW OUT OUT IT ol IN IN IN Figure 3 7 Gas Console Output Connections O o F 6 e M SEN RRE RENE ene eae d A Gite ees en 0o Meee eee en EOE 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 3 14 Installation ProLine 2150 User s Manual REV M CNC Machine Interface Connections Perform the following steps to properly interface the ProLine 2150 system with a CNC cutting machine See the system schematic for additional information Plasma Start Signal e The ProLine 2150 requires a contact closure between P8 pins 3 and 4 to commence the cutting sequence The cutting sequence is termin
112. s 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 3 11 Installation ProLine 2150 User s Manual REV M 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 0 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 p
113. shooting ProLine 2150 User s Manual REV M 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 excess
114. side the United States contrary to the requirements of the EAR 5 1 Maintenance and Troubleshooting ProLine 2150 User s Manual REV M 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 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 rear of 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
115. side the United States contrary to the requirements of the EAR A 4
116. supply satisfactory 12V interlock power supply satisfactory 15V analog power satisfactory 24V gas solenoid power satisfactory LED 21 OVER CURRENT Current output exceeded 150 amps power down to LED 22 ERROR LED 23 GSV4 LED 24 PLASMA LED 25 AUX OUT LED 26 3 PHASE LED 27 HIGH FREQ LED 29 15V reset Blinks on and off to display error codes Postflow gas valve 4 energized Plasma gas valve 2 energized Auxiliary output energized Correct three phase power applied to chopper High frequency transformer TRS energized 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 4 Maintenance and Troubleshooting ProLine 2150 User s Manual REV M Microprocessor Sequence of Operation The following LED s should illuminate after primary power is applied e LED 165V 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 e LED 263 PHASE e LED 7 PUMP e 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
117. ted 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 2150 torch must be installed on the positioner of an arc voltage control capable of maintaining the cutting arc voltage within 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 f
118. ted 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 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 high speed 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
119. teeass 3 1 Power supply Installations sccavecsurs E T EA are eae Be ee naa 3 2 Remote High Frequency Installation run c 05cceness eens eve nOnaseaeien eS 3 2 Toreh Installato aene eae a A tees oman a E E E a 3 2 Primary Power Comme ction fs taksrnssssa ideon n EEEE E O KE EES EEE 3 2 Power Supply Output Connecn Ons assests cp ahcondess hgatien tySai pape nace anise eageiatads 3 4 RHF Console Ground Connection sks oscaisacs sks aecestoneavs penanicaich ees oexegee deans peeenioids seases 3 5 Torch Leads to RHF Console Connections vrs cscccsixcaacdeseraninneiasscaatenas eda sereainnwiasss 3 7 Torch Connect Ons eienen a craw es ilien Cots EAA AE AEEA EEEE e EEA ATTE 3 9 Torch Head Connectioi snes ssssi inno E E KEI IEEE ES TEKEE EE TUSEN gio 3 12 Gas Console Input Connections ssssssssesee eese Gaerne oh ex esa wi Racers ddv hav ecnedaee O18 Gas Console Output Connections lt oacwad csssecantaveteSecdaccbaae sea deubirocseGesss Moaeeaasendenncedan 2 14 CNC Machine Interface Connections 2 7 0 045 02 vecuttpevesyanceneaced tesv ai etPouerncmerteaes 3 15 Torch Coolant Requirements lt 0 jieciu acca vases ods ca dwdins ee ae ies ped dee daldian ean elas 3 16 Initial Filling of the Torch Coolant Reservoir ccc cceceeeeneeeeee ene eneeeeneeneeaenes 3 17 Optional Remote On Off Control Installation 0 0 cece cece cence eee ne ee eee ene eneenens 3 18 Optional Hydrogen Manifold Installation 20 0 eee eee eee ne ene ee eee eneeee
120. tions 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 2150 User s Manual REV M Stainless Steel 50 Amps Air Plasma Nitrogen Shield Copper Electrode Shield Cap Nozzle Electrode 277149 277123 277137 aa 9 OMD D f la Y J H e ZY Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277110 277142 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width ga in psi psi psi psi volts ipm in in msec in 14 075 87 105 100 12 105 88 75 105 035 070 11 120 89 65 30 70 40 4 200 10 135 90 55 440 3 16 94 50 040 080 300 l 1 4 100 40 060 125 400 115 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 2 2565 87 100 2 5 2080 9 1 8 2 7 3 30 70 40 4 88 1685 200 5 94 1235 1 0 2 1 2 8 400 6 98 1075 1 3 2 9 2 9 Use an arc transfer height ignition height of 070 1 8 mm 1 Revised on 01 18 20
121. 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 2150 User s Manual REV M Appendix A Electromagnetic Compatibility EMC 00 0 A 1 BRAC I OU moranna a a a ea lah a ha Bes ah a Resta eke a ae tias A 1 Installations and USE ceesre a a a aE aa aE EEE A RT a A e arana tanani A 1 Assessment OT ATCA nerin ina n e AO a E E E E A A 2 Methods of Reducing Emissions lt factedacstecascoes ccatiets pester ainsaathepuesecuan nes comonasteccaveeeatevastvoussdanees A 2 Illustrations Figure 2 1 Power Supply Dimensions fc9 25s ccsdeaansischscs stesnces tase eo peceeoseases st eaten saan 2 3 Figure 2 2 Remote High Frequency Console Mounting Dimensions ceceeee 2 5 Figure 2 3 Torch DIMENSIONS 34 3 lt cesssseccrshgessegss dec tianteeevaiesdecaetecntqesndectesnsandurdecateas 2 6 Figure 2 4 Remote On Off Control Dimensions Optional ecceeeceeeeeteeeteeeeeeees 2 7 Figure 2 5 Hydrogen Manifold Dimensions Optional cceseeceeseceteeseeeteeeeeeeeeeeees 2 8 Figure 3 1 System Interconnection Diagram csscscsescesscesseseeeeessossescetsceseesseenees 3 1 Figure 3 2 Primary Power Connections lt s i5 s250 atsgcsdetecdneidceabans aexdonentede sav bevarsaatesbaeeeanys 3 3 Figure 3 3 Power Supply Output Connections ccccccceeeceeeceeeceeeeceseceeeeeeeeeeseeeaeens 3 6 Figure 3 4 Torch Leads to RHF Console Connecti
122. to set the output current of the ProLine 2150 The output current can be set to 10 30 50 70 100 and 150 amps Status Indicators e RHF Door Indicator Illuminates when the RHF console door is closed securely Remains extinguished when the RHF console door is open e 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 e 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 e Coolant Flow Indicator Illuminates when the coolant flow through the system is satisfactory Remains extinguished when the coolant flow through the system is restricted e Coolant Level Indicator Illuminates when the coolant level inside the reservoir is satisfactory Remains extinguished when coolant must be added to the system e 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 Displays the preflow gas inlet and outlet pressures and provides a preflow gas outlet pressure regulator Plasma Gas Control Displays the plasma gas inlet and outlet pressures and provides a plasma gas outlet pressur
123. ts of the EAR 5 7 Maintenance and Troubleshooting ProLine 2150 User s Manual REV M 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 Possible Cause Front panel white A C power light will 1 Primary disconnect fuse blown not illuminate 2 Fuse F1 or F4 blown 3 White light or associated wiring bad 4 Transformer TR2 or associated wiring bad 1 RHF door open 2 Low coolant level 3 Fuse F4 blown 4 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 Unit will not energize when the ON button is pressed Power supply will not stay on when the 1 Check the control panel status LED s and front panel ON button is pressed and
124. und stud located on the outside of the RHF console Torch Electrode Coolant Supply Lead e Connect the Torch Electrode Coolant Supply Lead to the brass cathode manifold Note that the Torch Electrode Coolant Supply Lead has right hand threads Torch Coolant Return Lead e Connect the Torch Coolant Return Lead to the brass cathode manifold Note that the Torch Coolant Return Lead has left hand threads Torch Nozzle Lead e Connect Torch Nozzle Lead to the angled bracket on the red standoff Note that the Torch Nozzle Lead has right hand threads Torch CTP Sensor Lead 13 e Connect the 18AWG Torch CTP Sensor Lead to the red standoff as shown 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 3 7 Installation ProLine 2150 User s Manual REV M Q S 10 4 11 iS u do J Lf h B 13 I m O ol JA LJ
125. ure 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
126. ure ssc2 cs ciucctecsaseguaniectectanetale de emradas 150 psi 10 2 bar FOW tateen ae a a A Ses dhaseo ase seites 1 gal min 3 8 liters min Coolant LUI erine nst enie atinse aa eN Coolant tank capacity ssessesessssessessesseessessrssressessreseesseese 3 2 gal 12 liters ProLine 2150 User s Manual REV M Propylene glycol deionized water 39 991 13 1 092 Figure 2 1 Power Supply Dimensions 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 3 Specifications ProLine 2150 User s Manual REV M Gas Console Specifications Stock Number without Inova height control 00 eee 277080 Stock Number with imperial Inova height control 277085 Stock Number with metric Inova height control 277090 PS Uo anara a a a eek nga ea clamped aa aahmuehes 9 in 229 mm SWAIN ars a seseies teatro cs sitesiteaey deste te hczs ict E 25 in 635 mm Depth Aa eects erase E A Ea etanbocucens 23 8 in 605 mm Weight with integrated Inova height control
127. xport 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 2150 User s Manual REV M Stainless Steel 100 Amps H17 Plasma Nitrogen Shield Copper Electrode This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277146 277126 277133 5 lt p MA ZT Outer Cap Retaining Cap Swirl Ring Torch Head 277154 277113 277141 279150 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Time Width in psi psi psi psi volts ipm in in msec in 3 16 138 115 105 200 300 100 1 4 28 67 46 13 140 100 125 225 400 105 3 8 152 65 180 250 500 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Pierce Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Time Width mm psi psi psi psi volts mm m mm mm msec mm 5 138 2865 2 7 5 1 2 5 28 67 46 13 400 6 139 2625 3 0 5 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
128. xture 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 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 5 Operation ProLine 2150 User s Manual REV M 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 e 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 e Cutting arc extinguished e Motion output relay deenergized e Gas postflow Consumable Life Use the following guidelines to maximize consumable parts life 1 Use the recommended pierce height given in the
129. xygen as a cutting gas Explosion Prevention The ProLine 2150 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 e Never operate the ProLine system in the presence of explosive gases or other explosive materials e Never cut pressurized cylinders or any closed container e 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 e 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 e Compressed gas cylinders should be maintained properly Never attempt to use a cylinder that is leaking cracked or has other signs of physical damage e 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
130. y location outside the United States contrary to the requirements of the EAR 6 30 Parts List ProLine 2150 User s Manual REV M Hydrogen Manifold Interface Cable Optional Part Number Length 277089 1 5 ft 0 5 m Figure 6 26 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 31 Parts List ProLine 2150 User s Manual REV M Consumable Spare Parts Kit Part Number 281267 Part Number Quantity Description 277130 3 Electrode 30A Mild Steel 30A Aluminum 277137 2 Electrode 30 50A Stainless Air 277131 6 Electrode 50 70A Mild Steel 70A Stainless Air 50 70A Aluminum 277132 2 Electrode 70A Stainless H17 277282 3 Electrode 100A Mild Steel 100A Stainless Air 100A Aluminum 277133 2 Electrode 100A Stainless H17 277292 3 Electrode 150A Mild Steel 150A Stainless Air 150A Aluminum 277135 2 Electrode 150A Stainless H17 277120 5 Nozzle 30A Mild Steel 30A Aluminum 277121 3 Nozzle 30A Stainless Air 277122 5 Nozzle 50A Mild Steel 50A Aluminum 277123 3 Nozzle 50A Stainless Air 277125 5 Nozzle 70A Mild Steel 70A Stainless Air 70A Aluminum 277124 3 Nozzle 70A Stainless H17 277284 5 Nozzle 100A Mil

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