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Automatic Gas Console

1. 48 1 219 3 3 e 59 9911 32 5 826 43 1 092 Figure 2 1 Power Supply Dimensions Specifications FineLine 260PC User s Manual Automatic Gas Console Specifications 260000 9 in 229 mm 25 in 635 mm 23 8 in 605 mm 80 Ib 36 2 kg Gas Supply Requirements Plasma gas types Mild Steel Stainless Steel Aluminum Shield gas types Mild Steel Oxygen or Air Stainless Steel Air or Nitrogen Oxygen or Air Air or H17 optional Air Aluminum Air or Nitrogen Preflow gas type or Nitrogen Plasma gas flow rate maximum Oxygen oec ee tete 67 scfh 1896 liters hour ETE Ioue sede A 40 scfh 1132 liters hour Shield gas flow rate maximum ij m 19 scfh 538 liters hour 160 scfh 4528 liters hour Air or Nitrogen 30 scfh 850 liters hour Preflow gas flow rate maximum Inlet gas pressures Oxygen 120 psi 8 3 bar Nitrogen
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3. ca 1 1 General Precautions ss ioco ette iple rtr Sates RENDER MAIN 1 Ultraviolet Radiation Protection 1 Noise Protection Toxic Fume Prevention siiras toner ettet etri rr E nates unas SERE ee DE entes 1 Electric Shock Prevention trente 2 Fire Prevention 1 3 Explosion Prevention 21 3 Health Support Equipment 1 4 Safety Standards Booklet Index e 4 Section 2 Specifications 2 22 2 0 2 2 1 System Description 2 1 System Components Pe Moon IE Geter 2 2 Power Supply Specifications is csse ree PERI ELE RS EE 2 2 Automatic Gas Console Specifications 2 4 Remote High Frequency Console Specifications 2 5 Torch Specifications ecce erroe er 2 6 Airborne Noise Efnissions votes eme EIER ere RR ERR 2 7 Section 3 Installation 2 22 22 22 11 Initial eek aS System IntercohheCtoh nein FOR ENTRE ba Power Supply Iristallation x Remote High Frequency Installation Torch con m
4. Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277152 277139 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 4 145 145 130 225 400 125 3 8 155 115 185 500 1 2 25 75 50 1 165 90 230 275 600 130 5 8 65 800 135 170 250 3 4 45 325 1000 140 Metric Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 6 143 3770 3 1 55 400 32 10 156 2825 48 600 12 25 75 50 1 162 2430 55 7 0 33 16 170 1630 34 6 4 1000 20 170 990 8 6 3 6 1 7 2 07 4 37 Operation FineLine 260PC User s Manual Aluminum Cutting 200 Amps Air Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277274 277289 277291 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277266 277143 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 4 150 190
5. Shield Cap Nozzle Electrode 277263 271269 277270 LD 92 E 6 Retaining Swirl Ring Torch Main Body 277154 277266 277258 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 2 125 140 300 139 275 165 5 8 105 135 500 3 4 138 90 120 700 170 300 1 144 65 160 900 20 93 70 0 185 1 25 150 45 475 1200 Tet 163 25 235 350 175 170 20 290 400 190 20 180 15 350 Edge start moving pierce recommended Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 12 139 3290 3 6 300 7 0 4 2 16 2650 3 3 700 138 20 2190 3d 4 8 7 6 900 25 143 1690 4 0 20 93 70 0 47 32 150 1120 44 1200 38 162 645 5 9 89 45 170 495 7 5 4 400 48 50 178 395 87 Edge start or moving pierce recommended 1 Revised on 7 2 07 4 20 Operation FineLine 260PC User s Manual Stainless Steel Cutting 30 Amps Air Plasma Air Shield Shield Cap Nozzle Electrode 277144
6. 1 Revised on 7 2 07 4 40 Operation FineLine 260PC User s Manual Stainless Steel Marking 8 Amps Nitrogen Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277145 277120 277190 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277152 277140 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Delay in psi psi psi psi volts ipm in in msec All Thicknesses 25 25 20 2 125 150 050 050 0 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Delay mm psi psi psi psi volts mm m mm mm msec AII Thicknesses 25 25 20 2 125 3810 13 13 0 1 Revised on 7 2 07 4 41 Operation FineLine 260PC User s Manual Aluminum Marking 10 Amps Nitrogen Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277145 277120 277190 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277152 277140 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Delay in psi psi psi psi volts ipm in in
7. Primary Power Connection eee Cute E ek QUI Ex ER ER nete i yas ruta wea PAN ERE E mas os Power Supply Output Connections RHF Console Ground Connection Torch Leads to RHF Console Connections Torch Connections Ree E ICI SIRE ORTU ee e be eus iere ds 3 10 Automatic Gas Console Input Connections eee e 3 13 Automatic Gas Console Output Connections 3 14 CNC Machine Interface Connections 3 15 Torch Coolant Requirements 3 15 Filling the Torch Coolant Reservoir ERR citing den ste vies eben 3 17 Section 4 Operation 2 2 0 0000 4 1 Power Supply Front Panel Controls 4 1 Automatic Gas Console Keypad EEEE EE exa ce DOE E 4 3 Automatic Gas Console Help Prof ipl i iore ee ern ree e rennen ve ebat au 4 4 Automatic Gas Console Status Screen 2 2 2 4 5 FineLine 260PC User s Manual POULIN miae ccc ics EAE aed E RATER E 4 5 Making a Cut Quality Cons mable Life pet un io ue vb e P pa elites 4 12 EDDA REM EM 4 13 Section 5 Automatic Gas Console Advanced Functions Altering the Current Set Point Setting the Pierce Delay Time Altering Gas Types Altering Gas Pressures
8. H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen 1 Revised on 7 2 07 4 23 Operation FineLine 260PC User s Manual Stainless Steel Cutting 70 Amps Air Plasma Nitrogen Shield This gas combination gives medium cut quality and minimum dross levels Shield Cap 277150 Nozzle 277125 Electrode 277131 6 Retaining Cap Swirl Ring Torch Main Body 277154 277153 277142 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width ga in psi psi psi psi volts ipm in in msec in 10 1135 132 120 060 1150 200 085 3 16 134 100 070 175 25 80 25 2 1 4 140 75 090 200 300 090 3 8 148 50 1120 225 450 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 3 131 3210 14 3 6 200 22 5 25 80 25 2 134 2445 1 8 4 5 300 6 138 2050 2 49 23 1 Revised on 7 2 07 4 24 Operation FineLine 260PC User s Manual Stainless Steel Cutting 100 Amps H17 Plasma Nitrogen Shield This gas combination gives the best cut quality and minimum dross levels Shield Cap
9. Shield Cap Nozzle Electrode 277145 277120 277130 ZN LD a y 227 Retaining Swirl Ring Torch Main Body 277154 277153 277140 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Oxygen Air Voltage Speed Height Height Delay Width ga in psi psi psi psi volts ipm in in msec in 20 036 120 105 080 062 18 048 121 97 090 16 060 125 78 110 065 14 075 35 85 6 2 126 65 105 100 12 105 127 55 11 1120 129 50 070 1120 1125 10 2135 131 40 Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Oxygen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 1 120 2615 2 0 1 6 15 124 2020 2 6 28 1 7 2 35 85 6 2 1615 100 126 27 2 5 1455 m 3 128 1285 29 34 1 Revised on 7 2 07 Operation FineLine 260PC User s Manual Mild Steel Cutting 50 Amps Oxygen Plasma Oxygen or Air Shield Shield Cap Nozzle Electrode 277115 277122 277131 92 oP Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277153 277140 277000 277142 Imperial Cold Rolled Steel Oxygen Shield Swirl Ring 277140 Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Oxyge
10. i w P id 1 2r OD 614 614 233 914 613 14 EN 233 14 181 8009091 Figure 8 22 Automatic Gas Console I O Board 2 4 gp Mersper irrarrr hrissrr Gessner mi Ox o E i i O Parts List FineLine 260PC User s Manual Automatic Gas Console Interface P C Board Assembly 505600 H 1 1 move 2O R4 d H mova 5 4 1 11 111 11111 LLII 1111 1 u In m ag 8 fg L w gt 88 H ns R35 az 8387 ERE Ba R34 P 5 5 C4 5 C6 Movs Rao 5 R37 u2 R43 1 50 Move ad D z R41 1 R42 us 1 7 R44 C7 U6 R F MONITOR R48 R
11. 180 60 240 170 1225 185 45 260 350 400 kats 190 25 270 180 Edge start or moving pierce recommended Metric Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 10 160 3930 41 6 4 500 4 1 12 163 3375 44 6 8 16 168 2645 48 7 6 800 4 2 20 20 93 65 0 173 2055 53 83 25 4 179 1565 6 0 8 8 43 32 185 1120 6 6 89 400 y 3g 189 645 68 4 6 Edge start or moving pierce recommended 1 Revised on 7 2 07 4 39 Operation FineLine 260PC User s Manual Outer Cap Mild Steel Marking 10 Amps Nitrogen Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277145 277120 277190 Retaining Cap Swirl Ring Torch Main Body 277154 277152 277140 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Delay in psi psi psi psi volts ipm in n msec AII Thicknesses 25 25 20 2 120 150 050 050 0 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Delay mm psi psi psi psi volts mm m mm mm msec AII Thicknesses 25 25 20 2 120 3810 13 13 0
12. Altering Arc Voltage Control and X Y Machine Parameters Saving a User Created Cutting Condition Gas Purge Maintenance Screen Viewing Messages Viewing Cut Errors Pressure Diagnostics Setting the Default Delay Parameter Restoring Factory Default Cutting Conditions Measurement System Communication Node Inova Parameter Transmit Viewing Serial Communication Configuring the Optional Hydrogen Manifold Setting an Arc Off Delay Software Updates ES E E e REPRE 5 22 Section 6 Serial Communication Initializing the FineLine System Transmitting Parameters to the FineLine System Communication Error Checking Default Cutting Parameters Troubleshooting Serial Communication RS 422 Serial Commands Section 7 Maintenance and Troubleshooting 7 1 Routine Maintenance Replacing the Torch Coolant Microprocessor Status LED S Microprocessor Sequence of Operation Troubleshooting Using the Control Panel Status LED s Troubleshooting Using the Automatic Gas Console Messages Screen General Troubleshooting Chopper Test Procedure FineLine 260PC User s Manual Section 8 Parts List Power Supply Remote High Frequency Console Torch and Torch Valve Assembly Shielded Torch Leads Gas Hose Package Coolant and Power Leads Work Ground Cable Torch Consuma
13. 120 psi 8 3 bar Air 120 psi 8 3 bar H17 120 psi 8 3 bar Oxygen and nitrogen should be supplied with a purity of at least 99 5 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 Compressed air must be clean dry and oil free and may be supplied from compressed cylinders or from an air compressor Be aware that shop air systems are prone to oil and moisture contamination If shop air is used it must be cleaned to ISO 8573 1 Class 1 4 1 Specify dry air when using compressed cylinders Breathing quality air contains moisture and must not be used 1 4 inside diameter hoses are required for all inlet gas connections Mating connectors are supplied with the unit Quick connect fittings must not be used Specifications FineLine 260PC User s Manual Remote High Frequency Console Specifications Stock Number Height Width Depth Weight 12 75 324 j__ Te eJ 025 in 635 mm 5 00 203 9 P c 4 312 8 mm H 12 00 13 50 305 343 le 10 00 254 235 136 GROUND Innerlogic Inc Figure 2 2 Remote High Frequency Console Mounting Dimensions 2 5 Specifications FineLine 260PC User s Manual Torch Specification
14. 4 8 Operation FineLine 260PC User s Manual Viewing the Torch Parts Required to Make the Cut Once the material substance thickness and process have been chosen the default cutting parameters are selected and adjusted accordingly To display a pictorial view of the torch parts required to make the cut scroll down to Torch Parts and press enter The torch parts screen should be displayed as shown in Figure 4 8 TORCH PARTS SHIELD CAP NOZZE ELECTRODE 277145 277120 277130 OUTER CAP RETAINING CAP SWIRL RING TORCH MAIN BODY 277000 277154 277153 277140 PRESS ANY KEY TO RETURN TO THE STATUS SCREEN CURRENT MODE TORCH PARTS InnerLogic Inc Figure 4 8 Torch Parts Installing the Torch Parts 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 To install the torch parts perform the following steps 1 Insert the electrode into the swirl ring then insert the electrode swirl ring assembly into the nozzle 2 Apply a small amount of o ring lubricant to the electrode o ring and the two o rings on the nozzle 3 Push the electrode swirl ring nozzle assembly into the torch until it is seated properly 4 Inspect the threads on the torch body copper retaining cap and brass outer 4 9 Operation FineLine 260PC User
15. 275A Stainless Air 275A Aluminum Swirl Ring 30A Stainless Air Swirl Ring 30 50A Mild Steel 70A Stainless H17 30A Aluminum Swirl Ring 50 70A Mild Steel 50 70A Stainless Air 50 70A Aluminum Swirl Ring 100A Mild Steel 100A Stainless Air 100A Aluminum Swirl Ring 100A Stainless H17 8 29 Parts List Part Number 277139 277143 277259 277258 277110 277153 277151 277152 277113 277266 277280 716012 500024 500018 820209 277056 277086 277087 260105 277154 Quantity 1 FineLine 260PC User s Manual Description Swirl Ring 150A Mild Steel 150A Stainless 150A Aluminum 260A Stainless H17 Swirl Ring 200A Mild Steel 200A Stainless Air 200A Aluminum Swirl Ring 200A Stainless H17 Swirl Ring 275A Mild Steel 275A Stainless Air 275A 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 200 275A Mild Steel 200A Stainless 200 275A Aluminum 275A Stainless Air Inner Retaining Cap 260A Stainless H17 O ring Lubricant T
16. Altering Gas Pressures Normally the preflow gas and plasma gas pressures should not be changed The shield gas is normally adjusted in small increments to fine tune a cut To alter the gas pressures use the arrow keys to scroll to the appropriate pressure setting The pressure setting should be highlighted as shown in Figure 5 4 and the editing cursor should be blinking Use the numerical keypad to enter the desired operating pressure Use the CLR key to backspace if an error is made Press ENT when the correct value has been entered Note that all of the gases have minimum and maximum limits and cannot be programmed beyond these limits PREFLOW SUBSTANCE MILD STEEL HOT GAS AIR THICKNESS 0 125 inches psi 025 0 PROCESS CUTTING GAS OXYGEN 5 psi 080 0 N CURRENT SET POINT 50 AMPS 5 DELAY GAS OXYGEN ii PIERCE DELAY TIME 0000 ms 05 0550 USE THE NUMERICAL KEYPAD ENTER PLASMA GAS PRESSURE CURRENT MODE PLASMA InnerLogic Inc Figure 5 4 Altering Gas Pressures 5 4 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Altering Arc Voltage Control and X Y Machine Parameters If the pierce height cutting height arc voltage or x y machine speed must be altered to achieve the desired cut quality switch to the voltage screen use the arrow keys to scroll to the desired parameter and edit the parameter using the keypad OUTPUT VOLTAGE VOLTS PHASE VOLTS OUTPUT CURRENT
17. Menu Preflow Gas Menu Plasma Gas Menu Shield Gas Menu Pierce Delay Menu Maint Menu Gas Purge Menu Status Enters the material editing mode Enters the current editing mode Displays the voltage screen Enters the preflow gas editing mode Enters the plasma gas editing mode Enters the shield gas editing mode Enters the pierce delay editing mode Enters the maintenance mode Purges the cutting gases Displays the main status screen Operation FineLine 260PC User s Manual Arrow Keys The Arrow keys are used to scroll up and down in order to edit or select a particular item Function Keys The Function keys are used for various purposes in the editing and maintenance modes The help prompt instructs the user on the use of the Function keys Numerical Keys The Numerical keys are used for entering and editing parameters Automatic Gas Console Help Prompt Help prompts are displayed on the automatic gas console screen to assist the user Different screens may have more than one help prompt but the help prompts will always appear near the bottom of the screen PREFLOW SUBSTANCE MILD STEEL HOT GAS AIR THICKNESS 0 125 inches psi 025 0 PROCESS CUTTING j T TORCH PARTS GAS OXYGEN 5 psi 080 0 CURRENT SET POINT 50 AMPS S DELAY GAS OXYGEN y 055 0 PIERCE DELAY TIME 0000 ns 05 PRESS F3 TD SAVE SETTING FOR 0 125 in MILD STEEL HOT CURRENT MODE STATUS InnerLogic
18. mm msec mm 2 129 6400 1 2 25 100 2 0 134 4420 12 5 145 1920 23 32 25 80 25 2 200 2 2 6 148 1440 17 3 6 10 156 975 2 0 4 5 400 23 12 160 820 2 6 49 1 Revised on 7 2 07 4 35 Operation FineLine 260PC User s Manual Aluminum Cutting 100 Amps Air Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277286 277284 277282 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277151 277283 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 4 145 105 155 200 200 095 3 8 25 94 26 0 156 90 180 250 300 098 12 157 70 195 275 400 100 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 6 143 2710 3 8 4 9 200 2 4 10 25 94 26 0 156 2210 4 6 6 4 12 156 1890 49 6 8 49 gt 1 Revised on 7 2 07 4 36 Operation FineLine 260PC User s Manual Aluminum Cutting 150 Amps Air Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277117 277293 277292
19. s Manual cap and clean as necessary 5 Install a small amount of o ring lubricant to the three o rings on the torch body 6 Apply a small amount of o ring lubricant to the retaining cap o ring and install the retaining cap onto the torch body Tighten the cap firmly but do not over tighten 7 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 8 Install the outer cap onto the torch body and tighten firmly Do not over tighten Viewing Recommended Height Control and X Y Machine Settings Prior to making a cut with the system the torch height control and the x y cutting machine must be configured properly To view the recommended cutting data press the Menu key then Voltage The voltage screen will be displayed as shown in Figure 4 9 The x y machine speed should be set to the value shown Also the height control should be set to the proper pierce height cutting height and arc voltage If a KALIBURN Inova height control is being used simply press the F3 key to automatically transmit the parameters to the Inova E S OUTPUT c VOLTAGE OUTPUT VOLTAGE VOLTS PHASE 1 VOLTS OUTPUT CURRENT AMPS PHASE 2 VOLTS PARAMETER TX STATUS READY PHASE 3 VOLTS C VOLTAGE 110 0 VOLTS TRAVEL SPEED 180 IPN TTING HEIGHT 0 100 INCHES USE THE SCROLL KEYS 0 ERCE HEIGHT 0 135 INCHE
20. 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 Installation FineLine 260PC User s Manual Figure 3 3 Power Supply Output Connections 3 7 Installation FineLine 260PC User s Manual 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 9 1 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 2 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 mea
21. 22 Send nozzle part number msw 23 Send nozzle part number lsw 24 Send retaining cap part number msw 25 Send retaining cap part number Isw 26 Send shield cap part number msw 27 Send shield cap part number lsw 28 Send outer cap part number msw 29 Send outer part number lsw 32 Send process select 33 Send software version 34 Sen 35 Sen 36 Sen cutting chart version number of pierces number of pierce errors Serial Communication Command Continued from previous page Set Process Software Version Cutting Chart Version Number of Pierces Number of Pierce Errors Reset Pierce Counter Power On Power Off Request System Status Purge Gases Set Arc Voltage 32 33 34 35 36 37 38 39 40 41 42 Hex String AA nn FA 20 00 0D AA FA 21 00 AA nn FA 22 00 0D AA nn FA 23 00 0D AA nn FA 24 00 0D AA nn FA 25 00 01 0D AA nn FA 26 00 01 0D AA nn FA 27 00 01 0D AA nn FA 28 0001 0D AA nn FA 29 00 01 0D AA nn FA 2A 0D 6 7 FineLine 260PC User s Manual Additional Information 48 Send cutting condition type 51 Send arc off delay time 52 Send machine type 00 Cutting 01 Marking If re wil uested in command 30 the AGC transmit the software version x 10 If re wil 10 uested in command 30 the AGC transmit the cutting chart version x If requested in command 30 the AG
22. 4 Sisisisisisisisisisis S LL o o 9 Figure 8 16 Gas Console Exterior 8 20 Parts List FineLine 260PC User s Manual 1 9 Lyf og 2 Le l gt 49 o a7 on EN OH Tip o ao 495 1 ae NI Y J PREFLOW 4 N 0 150 PSI SHIELD i T 1 1 4 10 150 Psi 6 9 6 6 6 6 6 6 6 6 61 6 6 610 ig 19 CRD e eo is 9 12345678 91011121314 0 150 PSI 18 o er 2 9 s 3 49 P o Figure 8 17 Gas Console Interior 8 21 Parts List F
23. 575V 60Hz 53 75 Use a Type SO power cable to connect the primary power to the FineLine 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 5 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 Disconnect Box Connections L1 Uy 12 L3 W Ground Strain Relief Figure 3 2 Primary Power Connections Installation FineLine 260PC User s Manual 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 gt 1 Route o
24. AMPS PHASE 2 VOLTS PARAMETER TX STATUS READY PHASE 3 VOLTS C VOLTAGE 110 0 VOLTS TRAVEL SPEED 180 IPM CUTTING HEIGHT 0 100 INCHES USE THE SCROLL KEYS TO ERCE HEIGHT 0 135 INCHES EDIT CUT PARAMETERS FINELINE 260PC PRESS F3 TO TRANSMIT CUTTING PARAMETERS TORCH HEIGHT CONTROL PRESS MENU THEN RETURN TO STATUS SCREEN CURRENT MODE VOLTAGE InnerLogic Inc Figure 5 5 Altering Arc Voltage Control and X Y Machine Parameters 5 5 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Saving a User Created Cutting Condition If one of the default cutting parameters must be altered to achieve good cut quality the new cutting condition can be saved for later use To save a user created cutting condition use the arrow keys to scroll off all selections on the status screen When none of the parameters are highlighted the Press F3 to Save Settings message will be displayed as shown in Figure 5 6 Pressing F3 will cause the save confirmation window to pop up When this occurs press ENT to save the condition or press CLR to cancel the procedure Pressing ENT will save the settings for the particular material being cut and a User icon will appear in the upper right hand corner of the screen The User icon indicates that the parameters for the particular material being cut are not factory defaults but are user created The factory default condition can be restored as described l
25. 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 1 Route the torch leads through the torch handle Note that the threaded end of the torch handle mates with the torch 2 Route the Shield Gas Hose through the torch handle 3 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 Torch Electrode Coolant Supply Lead e Connect the Torch Electrode Coolant Supply Lead to the torch as shown Torch Coolant Return Lead D e Connect the Torch Coolant Return Lead to the torch as shown Note that the Torch Coolant Return Lead fitting has left hand threads Torch Nozzle Lead 3 e Connect the Torch Nozzle Lead to the torch as shown Torch CTP Sensor Lead 3 Connect the Torch Sensor Lead to the torch as shown Shield Gas Hose Connect the Shield Gas Hose to the torch as shown Torch Plasma Gas Hose 3 Connect the Torch Plasma Gas Hose to the torch as shown Installation FineLine 260PC User s Manual Torch to Torch Handle Installation 1 Thread the torch handle onto the torch body 2 Attach the solenoid valve assembly to the torch handle The top of the aluminum solenoid bracket should be flush with the top of
26. Once the error set is selected and the ENT key is pressed on the error selection screen the actual cut errors will be displayed as shown in Figure 5 11 ACTUAL ERRORS TRANSFERRED ARC NOT ESTABLISHED TRANSFERRED ARC LOST BEFORE UPSLOPE TRANSFERRED ARC LOST DURING UPSLOPE TRANSFERRED ARC LOST DURING CUT TRANSFERRED ARC LOST DURING DOWNSLOPE a a lt ME FINELINE 260PC PRESS ANY KEY TO RETURN TO THE ERROR MENU CURRENT MODE CUT ERRORS InnerLogic Inc Figure 5 11 Actual Cut Errors Screen When any of the errors listed on the actual cut errors screen occur measures should be taken to avoid further errors The following is a description of the errors and possible causes Transferred arc not established This error occurs when the cutting arc fails to transfer to the workpiece It primarily causes nozzle damage and is typically due to a pierce height that is too high Transferred arc lost before upslope This error occurs when the cutting arc transfers to the workpiece but is lost immediately It primarily causes nozzle damage and is typically due to a pierce height that is too high Transferred arc lost during upslope This error occurs when the arc transfers to the workpiece but is lost before steady state operation lt primarily causes electrode damage and is typically due to a pierce time that is too long or when cutting a given thickness with excessive current e Transferred arc lost during cut
27. Software Updates The Automatic Gas Console has a floppy disk drive that is used to update the software as new revisions are released To access the floppy disk drive remove the floppy disk drive cover on the rear panel of the console The software update may either be installed on one floppy disk or two floppy disks Follow the instructions below for the appropriate update One Disk Update 1 2 Remove primary power from the FineLine system Insert the floppy disk containing the software update into the floppy disk drive Apply primary power to the system and wait until the AGC Updated Successfully message appears Remove the floppy disk from the floppy disk drive Remove primary power from the system Reinstall the floppy disk drive cover Apply primary power to the system Two Disk Update 2 3 e 11 12 14 Remove primary power from the FineLine system Insert the first floppy disk containing the software update into the floppy disk drive Apply primary power to the system and wait until the AGC Updated Successfully message appears Remove the floppy disk from the floppy disk drive Remove primary power from the system wait five seconds then reapply primary power to the system Wait for the Please Insert Update Disk 2 message to appear Install the second floppy disk containing the software update into the floppy disk drive Press any key on the keyp
28. Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 10 1845 3 8 3 4 7 0 600 12 155 1610 41 25 81 75 13 3 6 16 1260 47 76 1000 20 167 940 6 9 3 7 H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen 1 Revised on 7 2 07 4 27 Operation FineLine 260PC User s Manual Stainless Steel Cutting 150 Amps Air Plasma Nitrogen Shield This gas combination gives medium cut quality and minimum dross levels Shield Cap 277117 Nozzle 277293 Electrode 277292 Outer Cap Retaining Cap Swirl Ring 277154 277152 277139 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 4 145 150 160 225 400 125 3 8 150 115 180 2s 500 1 2 25 75 70 0 155 85 210 600 130 5 8 160 60 220 300 800 i 3 4 168 45 240 1000 135 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 6 144 3910 4 0 5 5 400 32 10 150 2805 47 70 600 12 25 75 70 0
29. This error occurs when the arc is lost during steady state operation It substantially shortens the electrode life and is typically due to a torch standoff distance that is too high or a travel speed that is to slow Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Transferred arc lost during downslope This error occurs when the arc is lost after a stop signal is received but before the current downslope completes It substantially shortens the electrode life and is typically due to an incorrect lead out or when cutting a given material thickness with excessive current When cutting small pieces that tend to drop into the table after being cut there should be a very short lead out or none at all On thicker materials the arc is sometimes lost when crossing the kerf during the lead out It is critical that the lead outs be fine tuned so the arc is not lost before downslope is complete 5 12 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Pressure Diagnostics To enter the pressure diagnostics mode scroll down to the Pressure Diagnostics selection on the maintenance screen and press ENT The pressure diagnostics screen will be displayed as shown in Figure 5 12 Pressing the Preflow Gas Plasma Gas and Shielding Gas buttons will toggle the corresponding valves between the off and on states Note that the preflow valve and the plasma valve cannot be on at the same time Also if
30. 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 8 for details Power Supply Specifications Stock Number 208 VAC 30 60Hz 230 VAC 30 60Hz 380 VAC 30 50Hz 415 VAC 3 50Hz 460 30 60Hz 575 VAG 30 60Hz ere tento Input Current at Maximum Output 208 30 60Hz 230 VAC 3 60Hz 380 VAC 3 50Hz 415 VAC 30 50Hz 460 30 60Hz 575 VAC 3 60Hz 325 VDC 8 275 amps 180 VDC 100 39 kW 104 F 40 C Open Circuit Voltage Output Current Maximum Output Voltage Duty Cycle Maximum Ambient Temperature 2 2 Specifications FineLine 260PC User s Manual Dimensions 32 5 in 826 mm Height including AGC 48 in 1219 mm Depth 43 in 1092 mm Weight including AGC eee 900 Ib 408 kg Torch Cooling System Discharge pressure 150 psi 10 2 bar Flow rate 1 gal min 3 8 liters min Coolant fluid Coolant tank capacity Propylene glycol deionized water 3 2 gal 12 liters
31. 116 2075 40 1 Revised on 7 2 07 Operation FineLine 260PC User s Manual Mild Steel Cutting 70 Amps Oxygen Plasma Air Shield Shield Cap Nozzle Electrode 277150 277125 277131 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277153 277142 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 8 35 110 190 100 100 100 080 3 16 113 130 25 80 2 1 4 25 116 120 110 125 200 085 3 8 122 75 1140 150 250 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 3 35 109 4995 25 100 2 5 2 0 5 25 80 2 113 3265 2 6 25 200 6 115 3105 27 3 0 2 2 1 Revised on 7 2 07 Operation FineLine 260PC User s Manual Mild Steel Cutting 100 Amps Oxygen Plasma Air Shield Shield Cap Nozzle Electrode 277286 277284 277282 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277151 277283 277000 Imperial Material Preflow Plasma Shield Postflow Are
32. 3 5 5 o EST 2008500 0 0 0 C36 hd 6 LEDIO LED LEDI2 LEDI3 LEDI4 LEDIS LEDIG Sw3 P7 Figure C 3 Hydrogen Manifold Microprocessor P C Board C 6 Hydrogen Manifold Optional FineLine 260PC User s Manual Dip Switch Settings Dip Switch 1 SW1 RS 422 Node Termination SW1 1 and SW1 2 should be switched on if the manifold is the last on a string of nodes SW1 1 and SW1 2 should be switched off in all other manifolds on the network Dip Switch 3 SW3 Pressure Diagnostics SW3 1 energizes the pressure control valve and sets the output pressure to 65 psi This is a diagnostic mode only SW3 2 energizes the pressure control valve and sets the output pressure to 115 psi This is a diagnostic mode only
33. 7 Maintenance Screen 5 7 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Viewing Messages To view status messages from the FineLine power supply and automatic gas console scroll down to the View Messages selection on the maintenance screen and press ENT The message screen will be displayed as shown in Figure 5 8 The message screen displays all power supply and gas console messages sequencing and errors The message screen should be the initial starting point when troubleshooting the system MESSAGES Waiting For Start Signal PRESS ENT TO EXIT FINELINE 260PC CURRENT MODE MESSAGES InnerLogic Inc Figure 5 8 Message Screen 5 8 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Viewing Cut Errors The FineLine has an error tracking system that keeps a record of certain cutting faults that occur during operation These faults affect the consumable parts life and measures should be taken to prevent them from occurring To view the cut errors scroll down to the View Cut Errors selection on the maintenance screen and press ENT The cut errors screen will be displayed as shown in Figure 5 9 The error tracking system keeps a record of the total number of pierces the number of errors and the error percentage Any time the consumables are changed the pierce counter should be reset to zero by pressing CLR When this occurs the data from the present count will move in
34. De icing fluid This particular grade of propylene glycol is not recommended for use in pharmaceutical food including animal feed or cosmetic type applications For those applications which involve human and animal exposure consumption Propylene Glycol USP EP should be used Revision Identification Number 40808 1001 Issue Date 03 02 2006 Version 2 0 Most recent revision s are noted by the bold double bars in left hand margin throughout this document Legend N A Not available WW Weight Weight OEL Occupational Exposure Limit STEL Short Term Exposure Limit TWA Time Weighted Average _ _ _ ACGIH American Conference of Governmental Industrial Hygienists Inc DOW IHG Dow Industrial Hygiene Guideline WEEL Workplace Environmental Exposure Level HAZ_DES Hazard Designation Page 7 of 8 Propylene Glycol MSDS FineLine 260PC User s Manual Product Name Propylene Glycol Industrial Grade Issue Date 03 02 2006 The Dow Chemical Company urges each customer or recipient of this M SDS to study it carefully and consult appropriate expertise as necessary or appropriate to become aware of and understand the data contained in this M SDS and any hazards associated with the product The information herein is provided in good faith and believed to be accurate as of the effective date shown above However no warranty express or implied is given Regulatory requirements are subject to ch
35. FA 2E 00 01 0D AA nn FA 2F 00 01 0D AA nn FA 30 00 0D AA nn FA 31 00 0D AA nn FA 32 00 01 0D AA nn FA 33 AA nn FA 34 0D 6 8 FineLine 260PC User s Manual Additional Information Cutting height in mils inches 1000 Valid Range 0 to 999 Also updates the Inova height control if used Pierce height in mils inches 1000 Valid Range 0 to 999 Also updates the Inova height control if used Sets travel speed inches min displayed on the voltage screen in the Cut Parameters window Valid Range 0 to 999 Saves the present cutting conditions as a user file Restores the factory cutting condition for the present material type and thickness If requested in command 30 the will transmit whether the present cutting condition is a factory default setting or a custom user setting Note This is only valid when initially loading material type thickness and process 0 factory 1 custom 0 Disable Hydrogen manifold 1 Enable Hydrogen manifold Reloads the cutting conditions for the present material type and thickness Sets the delay time in mS between the reception of a stop signal and the extinction of the arc Valid Range 0 to 2000 mS If requested in command 30 the AGC will transmit the machine type and torch body being used 101 FineLine 100PC Torch 500715 102 FineLine 100PC Torch 277000 151 FineLine 150PC Torch 200000 152 FineLine 150PC
36. HIGH FREQ LED 4 PREFLOW LED 1 PAR LED 10 PAT When the start signal is removed LED 23 GSV4 will illuminate briefly and then go out with the rest of the cut cycle LED s Maintenance and Troubleshooting FineLine 260PC User s Manual Troubleshooting Using the Control Panel Status LED s If the FineLine system develops a problem first check the control panel status LED s If one or more of the LED s does not illuminate after the ON button is depressed use the status LED s to pinpoint the problem RHF Door LED Extinguishes when the RHF door switch opens Check the RHF door switch and associated wiring Gas Console LED Extinguishes when there is a problem with the gas console or when the unit is adjusting gas pressures Switch to the messages screen on the gas console to pinpoint the problem 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 operation Coolant Flow LED Extinguishes when there is a problem with the torch coolant system Check the coolant pump fuse F2 and verify that 230VAC is present between TB3 13 and TB3 14 Also check for clogs in the coolant leads and coolant filter deionization cartridge Coolant Level LED Extinguishes when the coolant level in the tank has dropped below
37. Hazard No Fire Hazard No Reactive Hazard No Sudden Release of Pressure Hazard No Superfund Amendments and Reauthorization Act of 1986 Title Ill Emergency Planning and Community Right to Know Act of 1986 Section 313 To the best of our knowledge this product does not contain chemicals at levels which require reporting under this statute Pennsylvania Worker and Community Right To Know Act Pennsylvania Hazardous Substances List and or Pennsylvania Environmental Hazardous Substance List The following product components are cited in the Pennsylvania Hazardous Substance List and or the Pennsylvania Environmental Substance List and are present at levels which require reporting Component CAS Amount Propylene glycol 57 55 6 gt 99 5 96 Pennsylvania Worker and Community Right To Know Act Pennsylvania Special Hazardous Substances List To the best of our knowledge this product does not contain chemicals at levels which require reporting under this statute Page 6 of 8 Propylene Glycol MSDS FineLine 260PC User s Manual Product Name Propylene Glycol Industrial Grade Issue Date 03 02 2006 Comprehensive Environmental Response Compensation and Liability Act of 1980 CERCLA Section 103 To the best of our knowledge this product does not contain chemicals at levels which require reporting under this statute US EPA Emergency Planning and Community Right To Know Act EPCRA SARA Title III Section 302 Extremely Ha
38. Inc Help Prompt Figure 4 3 Help Prompt 4 4 Operation FineLine 260PC User s Manual Automatic Gas Console Status Screen When the automatic gas console is in the status mode the status screen is displayed as shown in Figure 4 4 The status screen displays all of the primary cutting parameters To edit a parameter on the status screen the arrow keys can be used to scroll through the different parameters or the Menu key can be used as described previously Note that when the Menu key is pressed the Menu icon appears in the upper right hand corner of the screen as shown To return to the status mode from another mode press the Menu key then the Status key The status screen also displays the Please Wait icon while the gas pressures are being adjusted or when an error occurs with the gas system PREFLOW MENU UBSTANCE MILD STEEL HOT GAS AIR CKNESS 0 125 inches psi 025 0 CESS CUTTING CH PARTS PLEASE c PLASMA GAS OXYGEN psi 080 0 cra RENT SET POINT 50 AMPS 22 DELAY GAS OXYGEN PIERCE DELAY TIME 0000 ms 058 095 0 PRESS F3 SAVE SETTING FOR 0 125 in MILD STEEL HOT CURRENT MODE STATUS InnerLogic Inc FINELINE 260PC Figure 4 4 Status Screen Setting up a Cut The automatic gas console makes it very simple to set up the machine to make a cut Selecting a material type material thickness and process cutting or
39. Nozzle Electrode 277146 277126 277133 Body Outer Cap Retaining Cap Swirl Ring Torch Main 277154 277113 277141 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 3 16 138 115 105 200 200 100 14 28 67 46 13 140 100 125 225 300 105 3 8 152 65 180 250 400 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 3 138 2865 27 5 1 2 5 28 67 46 13 300 6 139 2625 3 0 5 5 27 H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen 1 Revised on 7 2 07 4 25 Operation FineLine 260PC User s Manual Stainless Steel Cutting 100 Amps Air Plasma Nitrogen Shield This gas combination gives medium cut quality and minimum dross levels Outer Cap Shield Cap 277286 Nozzle 277284 Electrode 277282 Torch Main Retaining Cap Swirl Ring 277154 277151 277283 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Air Nitr
40. a particular regulator is adjusting the corresponding valve status will display N A PREFLOM 123 psi ALVE STATUS OFF PLASMA 123 psi ALVE STATUS OFF SHIELD 123 psi ALVE STATUS OFF POSTFLOH 15 4 psi ALVE STATUS ON PRESS TO TOGGLE PREFLOW VALVE ON OFF PRESS em TO TOGGLE PLASMA VALVE ON OFF PRESS TO TOGGLE SHIELD VALVE ON OFF BAS PRESS ENT TO RETURN TO THE MAINTENANCE MENU CURRENT MODE PRESSURE DIAGNOSTICS InnerLogic Inc FINELINE 260PC Figure 5 12 Pressure Diagnostics Screen Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Setting the Default Delay Parameter As previously mentioned the pierce delay time is usually adjusted such that the cutting arc fully penetrates the workpiece before the motion output signal is generated If the pierce delay time is set via the x y machine controller the Default Delay parameter on the FineLine must be disabled When the Default Delay parameter is enabled a pierce delay time is automatically retrieved after a material type and thickness are entered Note that when the Default Delay parameter is disabled the present Pierce Delay Time will be used for all cutting conditions Make sure the Pierce Delay Value is set to zero or another chosen value after the Default Delay parameter is disabled To view the status of the Default Delay parameter scroll down to the Default Delay selection on the maint
41. and can be ordered in one gallon containers PN 500695 Installation FineLine 260PC User s Manual This solution provides freezing protection down to 13 C 9 F For operating temperatures below 13 C the concentration of propylene glycol in the coolant solution must be increased See Figure 3 8 to determine the percentage of propylene glycol required for the application 100 propylene glycol can be ordered in one gallon containers PN 500720 Failure to use the proper propylene glycol deionized water solution may result in cooling system and or torch damage The torch coolant should be flushed out of the FineLine system every six months and replaced with new coolant The water filter deionization cartridge should also be changed at the same time See Section 7 for details Temperature C Temperature F Propylene Glycol Percent by Weight in Water Figure 3 8 Freezing Points of Aqueous Propylene Glycol Solutions Installation FineLine 260PC User s Manual Filling the Torch Coolant Reservoir Note Never turn on the power supply before filling the torch coolant reservoir with the proper coolant solution 1 Remove the coolant reservoir cap and fill the reservoir with 2 gallons of coolant solution 2 Apply main power to the FineLine unit 3 Depress and hold the green ON button on the FineLine control panel 4 The coolant pump will begin pumping coolant fluid through the system The Co
42. be given to shielding the supply cable of permanently installed plasma cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the plasma power source so that good electrical contact is maintained between the conduit and the plasma power source enclosure Maintenance of the Plasma Cutting Equipment The plasma cutting equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the plasma cutting equipment is in operation The plasma cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations B 2 Electromagnetic Compatibility EMC FL 260PC User s Manual 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 compo
43. illuminates Automatic Gas Console Display Shows all of the power supply and gas console settings errors and sequencing Automatic Gas Console Keypad 7 Operator interface to automatic gas console QUICK DATA INNERLOGIC FINELINE 260PC rower O cooranr row Q cooranr rever INNERLOGI Figure 4 1 Front Panel Controls 4 2 Operation FineLine 260PC User s Manual Automatic Gas Console Keypad All cutting information is entered on the keypad of the automatic gas console as shown in Figure 4 2 This section provides a description of each key and its function MENU F1 F2 F3 7 8 9 MATERIAL CURRENT VOLTAGE 4 5 6 PREFLOW PLASMA SHIELDING GAS GAS GAS PIERCE GAS DELAY MANT PURGE CLR per ENT STATUS Figure 4 2 Automatic Gas Console Keypad Menu Key The Menu key is used to select the bottom portion of a split level key When the Menu key is pressed a menu icon will appear in the upper right hand corner of the screen Pressing the Menu key again will clear the icon and return to the previous mode Pressing a split level key while the menu icon is visible will enter the specified mode The following is a list and description of menu key functions Menu Material Menu Current Menu Voltage
44. marking are the only parameters that must be entered All other parameters are adjusted automatically Perform the following steps to enter the cutting data See Section 5 for advanced functions of the automatic gas console 45 Operation FineLine 260PC User s Manual Selecting Material Type From the status mode press the down arrow once to scroll down to substance or press Menu then Material The substance area should be highlighted as shown in Figure 4 5 and the substance type should be blinking To change the substance type press F3 as indicated by the help prompt Pressing F3 repeatedly will scroll through the list of possible substance choices The available substance types are as follows Mild Steel Cold Rolled Mild Steel Hot Rolled Stainless Steel e Aluminum e Other PREFLOW SUBSTANCE MILD STEEL HOT GAS ALR THICKNESS 0 125 inches psi 029 0 PROCESS CUTTING T TORCH PARTS GAS OXYGEN amp psi 080 0 M CURRENT SET POINT 50 5 lt DELAY GAS OXYGEN PIERCE DELAY TIME 0000 ns PSE 095 0 DRESS TO CHANGE CURRENT MODE MATERIAL InnerLogic Inc Figure 4 5 Selecting Material Substance 4 6 Operation FineLine 260PC User s Manual Setting Material Thickness To set the material thickness use the down arrow to scroll down to Thickness The material thickness should be highlighted as shown in Figure 4 6 and the editing cursor should be blinking Use the numerical keypa
45. signal applied check for 325 VDC at the FineLine output terminal block between Electrode and Work If 325 V is present the 7 10 Maintenance and Troubleshooting FineLine 260PC User s Manual chopper is working properly 8 If 325 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 9 b LED s 1 through 5 on LED 6 off go to step 10 LED s 1 through 5 on LED 6 on LED 7 off go to step 11 d Only some of LED s through 5 on replace chopper 9 Check the 120 VAC supply to the chopper between 1 1 and 1 2 on the chopper p c board If 120 V is present replace the chopper If 120 V is not present check fuse F2 and associated wiring 10 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 11 Turn off primary power to the power supp
46. 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 rear of the torch are tightened securely Only tighten the fittings enough to make a water or gas seal The fittings are subject to damage if over tightened Also make sure the torch lead insulating sleeves are positioned to properly cover the brass torch fittings at the rear of the torch 4 Remove the torch consumables from the torch and inspect the o rings on the torch body 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 5 Wipe any excess o ring lubricant off of the torch body 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 025 64 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
47. toxic to aquatic organisms on an acute basis LC50 EC50 gt 100 mg L in the most sensitive species tested Fish Acute amp Prolonged Toxicity 11 050 rainbow trout Oncorhynchus mykiss 96 h 44 000 51 600 mg l Aquatic Invertebrate Acute Toxicity 50 water flea Daphnia magna 48 h immobilization 4 850 34 000 mg l 1050 saltwater mysid Mysidopsis bahia static 96 h 18 800 mg l Aquatic Plant Toxicity 50 green alga Selenastrum capricornutum biomass growth inhibition 19 000 mg l Toxicity to Micro organisms 50 OECD 209 Test activated sludge respiration inhibition 3 h gt 1 000 mg l 13 Disposal Considerations DO NOT DUMP INTO ANY SEWERS ON THE GROUND OR INTO ANY BODY OF WATER disposal praclices must be in compliance with all Federal State Provincial and local laws and regulations Regulations may vary in different locations Waste characterizations and compliance with applicable laws are the responsibility solely of the waste generator DOW HAS NO CONTROL OVER THE MANAGEMENT PRACTICES OR MANUFACTURING PROCESSES OF PARTIES HANDLING OR USING THIS MATERIAL THE INFORMATION PRESENTED HERE PERTAINS ONLY TO THE PRODUCT AS SHIPPED IN ITS INTENDED CONDITION AS DESCRIBED IN MSDS SECTION Composition Information FOR UNUSED amp UNCONTAMINATED PRODUCT the preferred options Page 5 of 8 A 5 Propylene Glycol MSDS FineLine 260PC User s Manual Product Name Propylene Glycol Industrial
48. 07 4 30 Operation FineLine 260PC User s Manual Stainless Steel Cutting 260 Amps H17 Plasma Nitrogen Shield This gas combination gives the best cut quality and minimum dross levels Outer Cap Shield Cap 277211 Nozzle 277118 Electrode 277135 Retaining Cap Swirl Ring 277154 277280 277139 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 3 8 145 85 160 500 190 2 142 80 140 275 5 8 145 65 185 600 40 63 70 14 195 3 4 150 55 225 300 800 1 0 160 33 250 325 1000 200 1 25 170 26 280 300 500 205 Edge start or moving pierce recommended Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 10 144 2140 4 0 500 4 8 12 142 2060 34 7 0 16 145 1640 47 800 40 63 70 14 5 0 20 151 1315 5 8 EN 1000 25 159 875 6 3 8 2 5 1 32 170 650 74 7 9 500 5 2 H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen Edge start required some dross evident 1 Re
49. 10 Amps Marking 0A 260 Amps Cutting 275 Amps Cutting Pierce Delay Time in ms Valid Range 0 to 5000 Preflow psi x 10 Valid Range 0 to 1200 00 Oxygen 01 2 Nitrogen 02 Air 04 17 Plasma psi x 10 Valid Range 0 to 1200 00 Oxygen 01 Nitrogen 02 Air 03 Alternate Shield psi x 10 Valid Range 0 to 1200 Serial Communication FineLine 260PC User s Manual Command Hex String Additional Information Torch Height 1 AA nn FA OB 0D If requested in command 30 the AGC Control Voltage Set will transmit the recommended arc Point voltage x 100 Range 0 to 20000 Torch Height 2 nn FA 0 00 If requested in command 30 AGC Control Pierce will transmit the recommended pierce Height height in mils inches x 1000 Range 0 to 999 Torch Height 3 nmn FA If requested in command 30 the AGC Control Cutting will transmit the recommended cutting Height height in mils inches x 1000 Range 0 to 999 CNC Machine 5 AA nmn FAF 0D If requested in command 30 the AGC Travel Speed will transmit the recommended travel speed in inches per minute Range 0 to 999 Torch Body Part 6 AAnnFA 10 0D If requested in command 30 the AGC Number msw will transmit the most significant word the torch body part number Torch Body Part 7 AAnnFA 11 0D If requested in command 30 the AGC Number 15 will transmit the least significant word o the torc
50. 1120 89 65 30 70 40 4 10 1135 90 55 110 3 16 94 50 040 075 200 1 4 100 40 060 085 300 115 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 2 2565 87 25 2080 9 L5 100 27 3 30 70 40 4 88 1685 5 94 1235 1 0 19 2 8 300 6 98 1075 13 2 1 2 9 1 Revised on 7 2 07 4 22 Operation FineLine 260PC User s Manual Stainless Steel Cutting 70 Amps H17 Plasma Nitrogen Shield This gas combination gives the best cut quality and minimum dross levels Shield Cap 277150 Nozzle 277124 Electrode 277132 Torch Main Body Outer Cap Retaining Cap Swirl Ring 277154 277113 277140 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 316 35 60 36 13 135 80 100 200 200 090 Metric Material Preflow Plasma Shield Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 5 35 60 36 13 135 2030 2 5 51 200 2 3
51. 135 200 200 150 3 8 155 145 140 250 300 1 2 110 400 20 82 58 0 135 300 155 5 8 95 500 160 3 4 65 150 350 600 160 Dose 175 35 200 j 400 170 Edge start or moving pierce recommended Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 6 149 4955 3 3 49 200 38 10 3545 35 65 155 400 12 2995 73 20 82 58 0 34 3 9 16 160 2380 7 6 600 20 162 1575 3 9 89 41 25 4 174 940 5 0 400 4 3 Edge start moving pierce recommended 1 Revised on 7 2 07 4 38 Operation FineLine 260PC User s Manual Aluminum Cutting 275 Amps Air Plasma Nitrogen Shield Shi ield Cap 277263 Nozzle 277276 Electrode 277270 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277266 277258 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 3 8 160 160 160 250 400 160 1 2 165 125 180 275 500 i 5 8 168 105 190 300 600 165 3 4 20 93 65 0 172 85 200 325 800
52. 153 2330 51 33 16 160 1510 5 6 i 7 6 1000 20 170 1030 6 2 3 4 1 Revised on 7 2 07 4 28 Operation FineLine 260PC User s Manual Stainless Steel Cutting 200 Amps H17 Plasma Nitrogen Shield This gas combination gives the good cut quality and minimum dross levels Shield Cap Nozzle Electrode 277274 277287 277135 Outer Cap Retaining Cap Swirl Ring 277154 277266 277259 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 3 8 156 80 195 250 300 150 12 148 75 130 335 500 5 8 37 68 85 13 155 60 190 700 155 3 4 160 50 200 300 900 1 0 170 35 240 325 1300 160 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 10 154 2010 47 6 4 500 38 12 149 1935 3 6 6 8 16 37 68 85 13 155 1515 48 7 0 900 39 20 161 1215 5 2 77 1300 25 169 915 6 0 8 2 41 H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen 1 Revised on 7 2 07 4 29 Operation FineLine 260P
53. 2 709179 1 Terminal block 10 position 13 709192 1 Terminal block marker strip 10 position 14 505039 1 Floppy disk drive 15 500021 1 Floppy disk drive cover Not shown 505047 1 Floppy disk drive cable 16 501145 8 Manifold 17 708097 4 Pressure switch 80 200 psi 18 715097 4 Transducer isolator 19 708095 3 Solenoid valve 20 500867 3 Motorized regulator assembly 0 125 psi 22 500060 Motorized regulator assembly 0 15 psi 23 709007 Terminal block 14 position 24 709009 1 Terminal block marker strip 14 position 25 200082 Solenoid valve assembly 3 gang 26 500907 Solenoid valve bracket 27 200083 Solenoid valve assembly 4 gang 28 501170 Power supply 29 505041 Video card upper p c board 30 260049 CPU middle p c board 31 505600 Interface p c board assembly lower p c board Not shown 260110 1 Video card CPU Interface p c board assembly 33 201080 1 0 p c board assembly 34 708078 3 Transducer 0 150 psi 35 708109 Transducer 0 15 psi Parts List FineLine 260PC User s Manual QUICK DATA 4 n mm y 4 SEE DETAIL BELOW 4 4 y 4 4 4 4 y o o o o DISPLAY DETAIL 9 Y PREFLOW AUXILIARY NITROGEN OXYGEN AR AY p E E Er M 4 4 M d tb oe 4 NEZ 4 1123456782910 N 4 Fars IN
54. 277121 277137 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277110 277138 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Air Air Voltage Speed Height Height Delay Width ga in psi psi psi psi volts ipm in in msec in 20 036 200 020 71 065 18 048 165 30 80 30 14 035 050 100 16 060 74 125 068 14 075 75 90 025 070 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Air Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 1 71 4855 0 6 30 80 30 14 13 100 1 7 1 5 73 3260 0 9 1 Revised on 7 2 07 4 21 Operation FineLine 260PC User s Manual Stainless Steel Cutting 50 Amps Air Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277149 277123 277137 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277110 277142 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width ga in psi psi psi psi volts ipm in in msec in 14 075 87 105 12 105 88 75 105 035 060 100 11
55. 46 4 us L R50 Co RSL L Mavel uio R54 2 OO R53 1 8 cie movof RSS R56 8080 Movio oP R57 PS 1 R58 0 5 o 5 LED C33 g 07 UE O 5 P C20 Cae 5 R60 KEYPAD C32 T R61 RE ov ios c31 ee so LED3 cea 5 pee TP4 TPS C c24 P 27 2 1 Of DCUM lev US 4 M a Cu os gt Bi 58558585 1 1 Co 19 D0 Figure 8 23 Automatic Gas Console Interface P C Board 8 27 Parts List FineLine 260PC User s Manual Consumable Spare Parts Kit Part Number 280267 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 277291 3 Electrode 200A Mild Steel 200A Stainless Air 200A Aluminum 277135 2 Electrode 150 200 260A Stainless H17 277270 3 Electrode 275A Mild Steel 275A Stainless Air 275A Aluminum 277120 5 Nozzle 30A Mild Steel 30A Aluminum 277121 3 Nozzle 30A Stainless Air 277122 5 Nozzle 50A Mild Steel 50A Aluminum 271123 3
56. 5 35 ft 10 7 m 200306 40 40 ft 12 2 m 200306 45 45 ft 13 7 m 200306 50 50 ft 15 2 m 200306 55 55 ft 16 8 m 200306 60 60 ft 18 3 m 200306 65 65 ft 19 8 m 200306 70 70 ft 21 3 m 200306 75 75 ft 22 9 m 200306 80 80 ft 24 4 m 200306 85 85 ft 25 9 m 200306 90 90 ft 27 4 m 200306 95 95 ft 29 0 m 200306 100 100 ft 30 5 m RHF CONSOLE CONTROL CABLE POWER SUPPLY ELECTRODE LEAD LIC O POWER SUPPLY NOZZLE LEAD o 9 POWER SUPPLY CTP SENSOR LEAD og Ei RAND POWER SUPPLY COOLANT RETURN HOSE LERI t Ar HAND powER SUPPLY COOLANT SUPPLY HOSE RIGHT HAND Figure 8 9 Coolant and Power Leads Parts List FineLine 260PC User s Manual Work Ground Cable Part Number Length 2003 18 10 10 ft 3 0 m 200318 15 15 ft 4 6 m 2003 18 20 20 ft 6 1 m 2003 18 25 25 ft 7 6 m 2003 18 30 30 ft 9 1 m 200318 35 35 ft 10 7 m 2003 18 40 40 ft 12 2 m 200318 45 45 ft 13 7 m 2003 18 50 50 ft 15 2 m 2003 18 55 55 ft 16 8 m 2003 18 60 60 ft 18 3 m 2003 18 65 65 ft 19 8 m 2003 18 70 70 ft 21 3 m 2003 18 75 75 ft 22 9 m 2003 18 80 80 ft 24 4 m 200318 85 85 ft 25 9 m 2003 18 90 90 ft 27 4 m 200318 95 95 ft 29 0 m 200318 100 100 ft 30 5 m Figure 8 10 Work Ground Cable Parts List FineLine 260PC User
57. 5 709001 6 707001 7 706019 8 702069 9 708057 10 500014 11 740039 12 505043 13 740072 14 800041 15 500505 16 715021 17 500503 18 205010 19 200287 22 500098 Coolant return fitting left hand Coolant supply fitting right hand Strain relief Lock nut 4 pin receptacle Line filter Transformer 5000V 20 mA Capacitor 15 kV Door interlock switch Spark gap assembly Spark gap electrode High frequency inductor Standoff Busbar RHF console p c board assembly Coolant supply fitting right hand Cathode manifold CTP sensor lead filter assembly Transformer insulating plate Ground cable 8 7 Parts List FineLine 260PC User s Manual 15 13 12 16 1 11 10 17 9 8 18 7 19 6 Figure 8 5 Remote High Frequency Console 8 8 Parts List FineLine 260PC User s Manual Torch and Torch Valve Assembly Item Number Part Number Quantity Description 8 Not shown Not shown Not shown Not shown 277475 Torch valve assembly includes bracket 500549 Torch valve bracket 820134 Torch handle 277000 Torch main body 500740 Torch solenoid plasma hose 820209 O ring 500024 O ring 500018 O ring 716008 O ring lubricant 277056 1 Consumable removal tool 277086 Electrode removal tool driver 277087 Electrode removal tool socket MAC 8 Figure 8 6 Torch and Torch Valve Assembly 8 9 Parts List FineLine 260PC User s Manual Shielded Tor
58. C will transmit the number of pierces Range 0 to 9999 If requested in command 30 the AGC will transmit the number of pierce errors Range 0 to 9999 Resets number of pierces and errors to 0 Energizes power supply torch coolant pump and cooling fans If torch coolant flow switch not satisfied within 8 seconds unit will power down Deenergizes power supply torch coolant pump and cooling fans System status can only be requested after a Power On command 38 is transmitted The status is returned in the ollowing form All bits 0 fault 1 ok LSB Bit 0 RHF Door LSB Bit 1 AC Power LSB Bit 2 Coolant Flow LSB Bit 3 Coolant Level LSB Bit 4 Coolant Temp LSB Bit 5 AGC status LSB Bit 6 Inlet Gas Pressures LSB Bit 7 Gas Hose Change Required MSB Bit 0 Hydrogen Manifold Installed MSB Bit 1 Hydrogen Manifold Enabled Purges gas lines Arc Voltage in Volts x 100 Valid Range 5000 to 20000 Also updates the Inova height control if used Serial Communication Command Set Cutting Height Set Pierce Height Set Travel Speed Save as User File Restore Factory Condition Cutting Condition Type Configure Hydrogen Manifold Reload Cutting Condition Set Arc Off Delay Time Machine Type Node Focus 44 45 46 47 48 49 50 51 52 254 AA C8 FA FE 00 nn 0D Hex String AA nn FA 2B AA nn FA 2C 0D AA nn FA 2D 0D AA nn
59. C User s Manual Stainless Steel Cutting 200 Amps Air Plasma Nitrogen Shield This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277274 277289 277291 9 QO D Retaining Cap Swirl Ring Body 277154 277266 277143 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 4 130 200 200 200 1070 150 3 8 133 150 225 300 1 2 140 110 115 250 152 5 8 146 75 150 600 20 82 58 0 300 155 3 4 153 60 190 800 1 0 158 40 210 1200 160 Tare 170 20 250 325 165 300 180 10 275 175 Edge start or moving pierce recommended Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 6 129 5220 1 8 5 0 200 38 10 134 3655 1 9 5 8 300 12 138 3020 2 6 6 2 16 146 1890 3 8 7 6 800 3 9 20 82 58 0 20 153 1450 4 8 T 1200 25 157 1050 2 2 82 32 170 495 64 4 2 83 300 3g 179 260 6 9 44 Edge start or moving pierce recommended 1 Revised on 7 2
60. 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 Work Ground Lead 1 Route one end of the 1 0AWG Work Ground Lead through the middle strain relief on the rear of the power supply and connect it to the Work terminal 2 Connect the other end of the Work Ground Lead to the star ground point on the cutting table The star ground point is generally referred to as the common ground point on the cutting table where all subsystems of the machine are grounded This point is then connected to a driven earth ground rod that should be as close as possible to the star ground The ground rod should have no other wires connected to it The ground rod should be at least 3 4 inches in diameter and should be driven into the earth s permanent moisture layer The length of the ground rod varies from installation to installation and should be installed according to local and national codes Refer to the National Electrical Code Article 250 Section H Ground Electrode System for additional information RHF Console Ground Connection Perform the following steps to connect the chassis of the RHF Console to the cutting table See Figure 3 3 for additional information
61. Dynamic Viscosity 48 6 mPs 25 Literature Pour point lt 57 lt 71 F Literature Stability and Reactivity Stability Instability Stable under recommended storage conditions See Storage Section 7 Hygroscopic Conditions to Avoid Exposure to elevated temperatures can cause product to decompose Generation of gas during decomposition can cause pressure in closed systems Avoid direct sunlight or ultraviolet sources Incompatible Materials Avoid contact with Strong acids Strong bases Strong oxidizers Hazardous Polymerization Will not occur Thermal Decomposition Decomposition products depend upon temperature air supply and the presence of other materials Decomposition products can include and are not limited to Aldehydes Alcohols Ethers Organic acids Toxicological Information Acute Toxicity Ingestion 1 050 Rat 20 000 34 000 mg kg Skin Absorption 11 250 Rabbit gt 20 000 mg kg Repeated Dose Toxicity In rare cases repeated excessive exposure to propylene glycol may cause central nervous system effects Chronic Toxicity and Carcinogenicity Did not cause cancer in laboratory animals Developmental Toxicity Did not cause birth defects or any other fetal effects in laboratory animals Reproductive Toxicity animal studies did not interfere with reproduction Genetic Toxicology vitro genetic toxicity studies were negative Animal genetic toxicity studie
62. FineLine 260PC User s Manual FineLine 260PC High Density Plasma Cutting System With Automatic Gas Console Revision H 7 12 07 Manual Part Number 718079 KALIBURN 455 Fleming Road Charleston SC 29412 USA 800 252 2850 Toll Free 843 795 4286 Phone 843 795 8931 Fax www kaliburn net This page intentionally left blank FineLine 260PC User s Manual Limited Warranty KALIBURN expressly warrants that this product shall be free from defects in materials and workmanship under proper and normal use for the intended function of such equipment for a period of one 1 year for the FineLine 260PC torch and leads and three 3 years for the FineLine 260PC power supply and automatic gas console This product is intended for commercial use and is not intended for personal family or household purposes There are no warranties that extend beyond the description on the face hereof All other warranties either expressed or implied including any implied warranty of merchantability or fitness for any particular purpose are expressly excluded If this product or any component thereof is determined to be defective in manufacture KALIBURN will repair or replace the defective component or product The buyer s remedies are limited to the return of the product for repair or replacement of any non conforming product or part at the sole discretion of KALIBURN No freight charges of any kind are covered under this warranty All
63. Grade Issue Date 03 02 2006 include sending to a licensed permitted Recycler Reclaimer Incinerator or other thermal destruction device As a service to its customers Dow can provide names of information resources to help identify waste management companies and other facilities which recycle reprocess or manage chemicals or plastics and that manage used drums Telephone Dow s Customer Information Group at 1 800 258 2436 or 1 989 832 1556 U S or 1 800 331 6451 Canada for further details Transport Information DOT Non Bulk NOT REGULATED DOT Bulk NOT REGULATED NOT REGULATED NOT REGULATED This information is not intended to convey all specific regulatory or operational requirements information relating to this product Additional transportation system information can be obtained through an authorized sales or customer service representative It is the responsibility of the transporting organization to follow all applicable laws regulations and rules relating to the transportation of the material 1 Regulatory Information OSHA Hazard Communication Standard This product is not a Hazardous Chemical as defined by the OSHA Hazard Communication Standard 29 CFR 1910 1200 Superfund Amendments and Reauthorization Act of 1986 Title Emergency Planning and Community Right to Know Act of 1986 Sections 311 and 312 Immediate Acute Health Hazard No Delayed Chronic Health
64. H c EEI gt Fur d 8 129 C frus 2 80 ves zem 4 ri frat 00 Qu OO 1 18 0 i E c nel D Ra Ew s i8 c FET Tr TM 18 5 R73 tnt 5 3 i 8 ere ME 1 1 lo wot 20 16 C84 DUTY CYCLE RIT u33 ues hg 1 4 UTY CYCLE SHIELD Em TE Leng Oo OREO am Se R 2 NA 2 Ra LT OR 5 T 7 SQ 7 s CON B 6 2268 T 018 ar T Ree Pwr m bar 23 5 OFF BO fer g 8 H Le T Q ear T dL 58 4 Eso 818 LED24 ces worn LEDs Ores UT o8 PLASMA E con T7 8 WE m ors Oie IO Lp um a 9 ines iens 5 BG ame 5 g LATCH El Ts B Lenee LEDIA 8 t pume Qr ue IF T Ge Peay Res ms ux mur K Lens Ore ma es s Fi SERO um d Bom sme 3 B H NE ux J 3 PHASE 3 Pte ye INNERLDGIC INC 3 ras 159 BLANK PCB P N 200349 REV 8 LED ASSEMBLY P N 200350 LED Bom 3 Mn Pee OL a 8 o o R Figure 8 18 Power Supply Microprocessor P C Boa
65. JANVYE Parts List FineLine 260PC User s Manual Power Supply I O P C Board Assembly 277452 R3 LN DH Ri TAGE eo o 0 P 9 M 1 10 ks gt a amp 1 5 EN fi EEE gt O 4 pw s 4015 d O 1 10 10 2 d 1 MEN i E A S I ELECTRODE NOZZLE SHUNT POS WORK GROUND SHUNT NEG C_D C D C C 2 C 2 INNERLOGIC INC BLANK PCB P N 200351 REV 0 ASSEMBLY P N 200352 Figure 8 21 Power Supply I O P C Board 8 25 FineLine 260PC User s Manual Automatic Gas Console I O P C Board Assembly 201080 Parts List wa T sol o ss s a EL BL HL SL EL SL BL BL RL 5 52 um Goat arx ex sum pg HO S Qi 5 6 00 00 Q 00 99
66. LE INOVA PARAMETER TRANSMIT PRESS ENT TO RETURN TO THE MAINTENANCE MENU CURRENT MODE PARAMETER TRANSMIT InnerLogic Inc Figure 5 17 Inova Parameter Transmit Screen Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Viewing Serial Communications To view the serial communication between the FineLine and an external device scroll down to the View Serial Communication selection on the Maintenance screen and press enter The Serial Communication screen will be displayed as shown in Figure 5 18 incoming and outgoing data is displayed in decimal base 10 format Note that incoming data is appended to show an R before the data and outgoing transmissions are appended to show a T before the data Pressing F3 will toggle the display on and off and pressing CLR will clear the screen PRESS F3 TO TOGGLE ON OFF R170 R1 R260 R38 ROO R01 R13 PRESS CLR T0 CLEAR SCREEN PRESS ENT TO EXIT SERIAL COMM ON FINELINE 260PC CURRENT MODE SERIAL COMMUNICATION InnerLogic Inc Figure 5 18 View Serial Communication Screen Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Configuring the Optional Hydrogen Manifold When a hydrogen manifold is installed on the system the hydrogen mixture will automatically be selected as the plasma gas for certain material types and thicknesses To prevent the use of hydrogen the hydrogen manifold must be disabled To disable the hydrogen mani
67. Line convert the following hex strings to 8 bit binary arrays AA 10101010 and transmit them using a 9600 baud RS 422 serial communication port The port settings should have a start bit one stop bit and no parity A table can be found in this section that lists the RS 422 commands and their descriptions This table contains the necessary hex strings for sending different commands and parameters to the system For example to switch the material type from mild steel to stainless steel look up the command for setting material type in the table You will see the following table entry Command Hex String Additional Information Set Material Type 1 AAnnFAO100 0D 00 Mild Steel Hot Rolled 01 Stainless Steel 02 Aluminum 03 Other 04 Mild Steel Cold Rolled Note that spaces in the command string are shown for clarity only and should not be sent as part of the command A command string always begins with the value AA hex The nn is the net node communication node of the FineLine system that is to receive the command The net node value of a system is set via the Set Communication Node selection on the maintenance screen See Section 5 for detailed information on setting the net node The value FA hex is the FineLine identifier The value 01 hex is the value that signifies the Set Material Type command The value hex is the end of command character In the above example the following hex string would need to be transm
68. NY 10036 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 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 Standard 70 National Electrical Code obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 15 CGA booklet P 1 Safe Handling of Compressed Gases in Containers obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 Safety FineLine 260PC User s Manual 6 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 7 CGA booklet TB 3 Hose Line Flashback Arrestors obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 8 CSA Standard W117 2 Safety in Welding Cutting and Allied Processes
69. Nozzle 50A Stainless Air 271125 5 Nozzle 70A Mild Steel 70A Stainless Air 70A Aluminum 277124 3 Nozzle 70A Stainless H17 277284 5 Nozzle 100A Mild Steel 100A Stainless Air 100A Aluminum 277126 3 Nozzle 100A Stainless H17 277293 5 Nozzle 150A Mild Steel 150A Stainless Air 150A Aluminum 277297 3 Nozzle 150A Stainless H17 8 28 Parts List Part Number 271289 277287 277118 277269 277276 277 277 277 277 277 45 44 49 15 50 277286 277 277 46 17 277298 277274 277211 277263 277 277 277 38 40 42 277283 277 41 Quantity 5 FineLine 260PC User s Manual Description Nozzle 200A Mild Steel 200A Stainless Air 200A Aluminum Nozzle 200A Stainless H17 Nozzle 260A Stainless H17 Nozzle 275A Mild Steel Nozzle 275A Stainless Air 275A Aluminum Shield Cap 30A Mild Steel 30A Aluminum Shield Cap 30A Stainless Air Shield Cap 50A Stainless Air Shield Cap 50A Mild Steel Shield Cap 70A Mild Steel 70A Stainless 50 70A Aluminum Shield Cap 100A Mild Steel 100A Stainless Air 100A Aluminum Shield Cap 100A Stainless H17 Shield Cap 150A Mild Steel 150A Stainless Air 150A Aluminum Shield Cap 150A Stainless H17 Shield Cap 200A Mild Steel 200A Stainless 200A Aluminum Shield Cap 260A Stainless H17 Shield Cap 275A Mild Steel
70. Operation FineLine 260PC User s Manual Aluminum Cutting 30 Amps Air Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277145 277120 277130 9 Retaining Cap Swirl Ring Torch Main Body 277154 277153 277140 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 040 150 065 065 050 30 92 20 2 135 120 030 075 100 063 90 085 070 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 1 135 3885 1 6 17 30 92 20 2 0 8 100 15 135 2520 2 1 8 1 Revised on 7 2 07 4 33 Operation FineLine 260PC User s Manual Aluminum Cutting 50 Amps Air Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277150 277122 277131 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277153 277142 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width in psi psi p
71. Rear View Power Supply Left Side View Power Supply Right Side View Remote High Frequency Console Torch and Torch Valve Assembly Shielded Torch Leads Gas Hose Package Coolant and Power Leads ertet eet teet 8 12 Figure 8 10 Figure 8 11 Figure 8 12 Figure 8 13 Figure 8 14 Figure 8 15 Figure 8 16 Figure 8 17 Figure 8 18 Figure 8 19 Figure 8 20 Figure 8 21 Figure 8 22 Figure 8 23 Figure C 1 Figure C 2 Figure C 3 FineLine 260PC User s Manual Work Ground Cable ideni e yan etes Torch Consumables Mild Steel Cutting Torch Consumables Stainless Steel Cutting Air Plasma Torch Consumables Stainless Steel Cutting H17 Plasma Torch Consumables Aluminum Cutting Torch Consumables Marking Gas Console Exterior Gas Console Interior Power Supply Microprocessor P C Board A C Detect P C Board Relay P C Board Power Supply I O P C Board Automatic Gas Console I O P C Board Automatic Gas Console Interface P C Board Hydrogen Manifold Mounting Dimensions Hydrogen Manifold Mounting Location Hydrogen Manifold Microprocessor P C Board This page intentionally left blank Safety FineLine 260PC User s Manual Section 1 Safety General Precautions Whereas plasma cutting has been used safely for years it does require certain precautions to ensure the safety of
72. S EDIT CUT PARAMETERS FINELINE 260PC PRESS F3 TRANSHIT CUTTING PARAMETERS TO TORCH HEIGHT CONTROL PRESS MENU THEN crane RETURN TO STATUS SCREEN CURRENT MODE VOLTAGE InnerLogic Inc Figure 4 9 Voltage Screen Operation FineLine 260PC User s Manual Making a Cut Once the material type thickness and process have been entered the correct torch parts are installed and the x y machine and height control systems have been properly configured perform the following steps to cut with the system 1 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 solutions 2 The automatic gas console will purge the gas hoses and set the correct gas pressures automatically After the pressures have been set correctly the Gas Console status LED will illuminate 3 Once the Gas Console LED illuminates the unit is ready for cutting Upon the reception of a cycle start signal the following sequence will take place Two second gas preflow High frequency starting circuit energized Pilot arc initiation Transferred arc cutting arc established Motion output relay energized after Pierce Delay timer complete 4 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 Cut Quality Before t
73. THE ABOVE SETTING PRESS THEN THEN ove TO RESTORE ALL DEFAULT SETTINGS PRESS THEN comer THEN TO RESTORE CORRUPTED USER DATA PRESS F3 TD CHANGE SUBSTANCE TYPE CURRENT MODE RESTORE DEFAULTS InnerLogic Inc FINELINE 260PC Figure 5 14 Restore Factory Defaults Screen Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Measurement System The FineLine system will operate using Imperial units or Metric units To change the units of operation scroll down to the Measurement System selection on the maintenance screen and press ENT The measurement system screen will be displayed as shown in Figure 5 15 Press F3 to toggle the measurement system between Imperial and Metric SYSTEM IMPERIAL FINELINE 260PC PRESS F3 TO CHANGE SYSTEM OF MEASUREMENT PRESS ENT TO RETURN TO THE MAINTENANCE MENU CURRENT MODE MEASUREMENT SYSTEM InnerLogic Inc Figure 5 15 Measurement System Selection Screen Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Communication Node When multiple FineLine systems are being used together on an RS 422 serial communication link each system must have a unique identification number node number to identify itself to the network To set the communication node number for the FineLine system scroll down to the Set Communication Node selection on the maintenance screen and press ENT The communication node selection screen will be
74. Torch 277000 201 FineLine 200PC Torch 200000 202 FineLine 200PC Torch 277000 261 FineLine 260PC Torch 200000 262 FineLine 260PC Torch 277000 Sends a global command to all systems and sets the node focus to system nn Maintenance and Troubleshooting FineLine 260PC User s Manual Section 7 Maintenance and Troubleshooting Warning Only qualified maintenance personnel should perform maintenance on the FineLine system The system utilizes potentially fatal A C and D C voltages All maintenance should be performed with safety in mind Be aware that the large blue electrolytic capacitors inside the power supply store large amounts of energy even after power has been removed from the system Wait at least five minutes after turning off power before touching any of the internal components Routine Maintenance Note At minimum these checks should be performed on a monthly basis In excessively dirty environments or in heavy usage situations the checks should be performed more frequently Power Supply 1 Remove the left right front and rear panels of the power supply 2 Using clean dry compressed air blow out all accumulated dust inside the power supply including dust on p c boards and fans Be sure to blow out the fan and heat exchanger at the rear of the unit In an excessively dirty environment blow out the unit on a weekly basis 3 Verify that all torch lead and work ground connections are secure and free
75. Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 4 125 150 090 125 150 3 8 130 100 130 4175 200 090 1 2 25 94 26 0 65 1155 400 5 8 143 47 200 600 1185 095 3 4 145 35 900 Metric Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 6 124 3950 21 3 0 150 10 2405 3 3 45 2 3 130 400 12 25 94 26 0 1850 3 7 49 16 143 1180 47 5 1 900 2 4 20 145 800 1 Revised on 7 2 07 Operation FineLine 260PC User s Manual Mild Steel Cutting 150 Amps Oxygen Plasma Air Shield Shield Cap Nozzle Electrode 277117 277293 277292 Zw Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277151 277152 277139 277000 Imperial Retaining Cap 277151 Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 4 118 165 105 200 300 125 3 8 20 74 30 0 123 125 135 225 400 1 2 125 90 140 250 130 Retaining Cap 277152 Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierc
76. YGEN 5 CURRENT SET POINT 50 AMPS 5 DELAY GAS OXYGEN ii 055 0 PIERCE DELAY TIME 0000 ns PS USE THE NUMERICAL KEYPAD ENTER DELAY TIME CURRENT MODE DELAY InnerLogic Inc Figure 5 2 Setting the Pierce Delay Time 5 2 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Altering Gas Types Although the gas types should not normally be changed the procedure is given here anyway Note that the preflow gas cannot be changed To alter the gas types used for a particular cut use the arrows to scroll to the appropriate gas or press the Menu key then the Plasma Gas or Shielding Gas key The appropriate gas selection should be highlighted as shown in Figure 5 3 and the present gas choice should be blinking Press F3 to scroll through the gas choices When the desired gas type is blinking press ENT to accept the gas type The plasma gas can be changed to air oxygen or nitrogen and the shield gas can be changed to air oxygen nitrogen or alternate PREFLOW SUBSTANCE MILD STEEL HOT GAS AIR THICKNESS 0 125 inches psi 025 0 PROCESS CUTTING TORCH PARTS e psi 080 0 S CURRENT SET POINT 50 AMPS 5 DELAY GAS OXYGEN ERCE DELAY TINE 0000 ns 005 0 iE PRESS TO CHANGE CURRENT MODE PLASMA InnerLogic Inc Figure 5 3 Altering Gas Types 5 3 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual
77. a outlet has right hand threads Postflow Outlet e Connect the Postflow Hose to the postflow outlet as shown Note that the postflow outlet has right hand threads FineLine 260PC User s Manual NENNEN POSTFLOW sm PREHLOW AUXILIARY NITROGEN OXYGEN or or AR 9 0 o Figure 3 7 Automatic Gas Console Output Connections 3 14 Installation FineLine 260PC User s Manual CNC Machine Interface Connections Perform the following steps to properly interface the FineLine 260PC system with a CNC cutting machine See the system schematic for additional information Plasma Start Signal e The FineLine 260PC requires a contact closure between P8 pins 3 and 4 to commence the cutting sequence The cutting sequence is terminated when the contacts are opened The contacts should be rated for 12VDC 10mA Arc Hold IHS Complete Signal e The FineLine 260PC 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 s
78. ad Wait for the Updated Successfully message to appear Leave the second update disk in the floppy disk drive remove primary power from the system wait five seconds then reapply primary power Wait for the AGC Updated Successfully message to appear Remove the floppy disk from the floppy disk drive Remove primary power from the system Reinstall the floppy disk drive cover 15 Apply primary power to the system 5 22 FineLine 260PC User s Manual Serial Communication FineLine 260PC User s Manual Section 6 Serial Communication Initializing the FineLine System The FineLine system uses an RS 422 serial communication port located on the rear of the automatic gas console to receive and respond to commands that are transmitted from an x y controller The system communicates at 9600 baud with RS 422 levels generally between 0 and 5 volts although the system is rated for the full protocol range of 7 to 12 volts The communications ground is isolated to prevent ground loops System initialization is simple Apply power wait until the automatic gas console AGC has finished booting then transmit the desired material type material thickness and process cutting or marking and the system will be ready for operation All other parameters will be set to their default values and may be changed at any time Transmitting Parameters to the FineLine System To transmit parameters to the Fine
79. agnetic Compatibility EMC FL 260PC User s Manual Assessment of Area Before installing plasma cutting equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the plasma cutting equipment b radio and television transmitters and receivers c computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may require additional protection measures h the time of day that plasma cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Plasma cutting equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should
80. al Item Number Part Number Quantity Description 1 3 ON tA gt N 708088 708111 708090 708089 501163 501164 501162 501161 707260 500557 706205 500559 706261 706262 706263 706260 706264 709086 709007 709058 709012 709011 709076 709033 261450 709002 709001 709124 709061 709128 709060 500810 200092 200292 500518 708062 505024 500052 500513 DASA N Off switch red Off actuator red On switch green On actuator green illuminated Light housing Bulb White lens Red lens L1 inductor TR2 control transformer 208 230 460 V 60 Hz TR2 control transformer 575 V 60 Hz TR2 control transformer 380 415 V 50 Hz TR1 main transformer 230 V 60 Hz 30 TR1 main transformer 380 V 50 Hz 38 TR1 main transformer 415 V 50 Hz 30 TRI main transformer 460 V 60 Hz 30 TRI main transformer 575 V 60 Hz 30 terminal block marker strip 14 position TB4 terminal block 14 position F2 F11 fuse holder F10 fuse AGC 3A fuse F3 F4 fuse AGC 5A F6 F7 F9 F11 fuse AGC 2 F5 F8 fuse AGC 1A Microprocessor p c board assembly P8 P12 P13 14 socket receptacle P7 4 pin receptacle P16 9 socket receptacle FIA FIB fuse holder FIA FIB fuse FNM 6 25 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 leve
81. ange and may differ between various locations It is the buyer s user s responsibility to ensure that his activities comply with all federal state provincial or local laws The information presented here pertains only to the product as shipped Since conditions for use of the product are not under the control of the manufacturer it is the buyer s user s duty to determine the conditions necessary for the safe use of this product Due to the proliferation of sources for information such as manufacturer specific M SDSs we are not and cannot be responsible for M SDSs obtained from any source other than ourselves If you have obtained an M SDS from another source or if you are not sure that the M SDS you have is current please contact us for the most current version Page 8 of 8 Electromagnetic Compatibility EMC FL 260PC User s Manual Appendix B Electromagnetic Compatibility EMC Background The 380V 50Hz and 415V 50Hz FineLine 260PC plasma cutting systems are manufactured to comply with the European standard EN 50199 Electromagnetic compatibility EMC Product standard for arc welding equipment The limits used in this standard are based on practical experience However the ability of plasma cutting equipment to work in a compatible manner with other radio and electronic systems is greatly influenced by the manner in which it is installed and used For this reason it is important that the plasma cutting equipment be ins
82. as solenoid power satisfactory LED 21 OVER CURRENT Current output exceeded 200 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 28 COMM PWR LED 29 15V LED 30 XMIT LED 31 RECV 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 TR5 energized 5V communication power supply satisfactory 15V analog power satisfactory Blinks to show serial transmission to automatic gas console Blinks to show serial transmission from automatic gas console Maintenance and Troubleshooting FineLine 260PC User s Manual Microprocessor Sequence of Operation The following LED s should illuminate after primary power is applied LED 16 5V uP PWR LED 17 12V uP PWR LED 18 ILK PWR LED 19 ANALOG PWR LED 20 GAS PWR LED 28 COMM PWR LED 29 15V The following LED s should illuminate when the ON button is depressed LED 263 PHASE LED 7 PUMP LEDSLATCH The following LED s should illuminate in sequence after a start signal is received LED8START LED4PREFLOW e LED 14 HOLD OUT LED 2 CON LED 9 CHOPPER LED 1 PAR LED 10 PAT LED 27 HIGH FREQ e LEDII TAC LED24 PLASMA LED 12 MOTION After a transferred cutting arc is established the following LED s will go out LED 14 HOLD OUT LED 27
83. ater in this section MATERIAL PREF LOW UBSTANCE MILD STEEL HOT GAS AIR THICKNESS 0 125 inches psi 022 0 PROCESS CUTTING TORCH PARTS cr PLASMA GAS OXYGEN psi 080 0 CURRENT SET POINT 50 AMPS DELAY GAS OXYGEN PIERCE DELAY TIME 0000 ns PSE 095 0 PRESS F3 TO SAVE SETTING FOR 0 125 in MILD STEEL HOT CURRENT MODE STATUS InnerLogic Inc FINELINE 260PC Figure 5 6 User Created Cutting Conditions Gas Purge The gas lines can be purged at any time by pressing the Menu key then the Gas Purge key Also the gas pressures are readjusted at this time 5 6 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Maintenance Screen To display the maintenance screen press the Menu key then the Maint key The maintenance screen will be displayed as shown in Figure 5 7 From the maintenance screen use the arrow keys to scroll up or down to highlight a selection and press the Ent key to enter the desired maintenance mode The different maintenance modes are described below MAINTENANCE AGES SET COMMUNICATION NODE ERRORS INOVA PARAMETER TRANSMIT CTORY DEFAULTS VIEN SERIAL COMMUNICATION DIAGNOSTICS CONFIGURE HYDROGEN MANIFOLD ERCE DELAY SET ARC OFF DELAY SYSTEM FINELINE 260PC PRESS MENU THEN crams RETURN STATUS SCREEN PRESS ENT TO SELECT AN OPTION FROM THE MENU CURRENT MODE MAINTENANCE InnerLogic Inc Figure 5
84. ay be damaged Next the RS 422 communication cable must be installed between one of the communication ports on the rear of the automatic gas console and the plug labeled AGC Console on the hydrogen manifold Finally the power cable must be installed between the plug labeled P13 on the rear of the FineLine 260PC power supply and the input power adaptor on the hydrogen manifold The power switch on the hydrogen manifold must be placed in the on position Note that the hydrogen manifold communication cable should be the only serial communication cable connected to the automatic gas console When using another serial communication device such as an x y controller or Inova torch height control connect the communication cable from the external device to the RS 422 In plug on the hydrogen manifold If multiple FineLine systems are being used in a network configuration connect an RS 422 serial communication cable from the RS 422 Out plug on the hydrogen manifold to the RS 422 In plug on the additional FineLine system C2 Hydrogen Manifold Optional FineLine 260PC User s Manual Figure C 2 Hydrogen Manifold Mounting Location 3 Hydrogen Manifold Optional FineLine 260PC User s Manual Operation The hydrogen manifold is fully integrated with the operating software of the FineLin
85. back transmitted in exactly the same form for error checking With a multiple torch system global commands will not be back transmitted Only the system with node focus will back transmit the commands The purpose of the node focus command 254 is to allow one FineLine system to use the transmission lines at a time If no node focus is set on initialization the first system to receive a command will receive node focus automatically Commands may be transmitted to systems without node focus but there will be no back transmission from those systems Also all parameters can be read at any time by transmitting a Send Parameter command 30 to the FineLine followed by the appropriate parameter to be read Default Cutting Parameters When communicating with the FineLine system material type material thickness and process cutting or marking are the only parameters that must be transmitted in order to initialize the unit All other parameters will be set to their default value Whenever the material type material thickness process or cutting current is changed new default values will be retrieved for all other parameters To use non standard parameters first set the material type material thickness process and cutting current then set the remaining parameters to their desired values Serial Communication FineLine 260PC User s Manual Troubleshooting Serial Communication When troubleshooting serial communication with the FineLine sys
86. bles Mild Steel Cutting Torch Consumables Stainless Steel Cutting Air Plasma Torch Consumables Stainless Steel Cutting H17 Plasma Torch Consumables Aluminum Cutting Torch Consumables Marking Automatic Gas Console Power Supply Microprocessor P C Board 8 22 A C Detect Board Relay P C Board Power Supply I O P C Board Automatic Gas Console I O P C Board Automatic Gas Console Interface P C Board Consumable Spare Parts Kit Appendix Propylene Glycol MSDS Appendix B Electromagnetic Compatibility Background Installation and Use Assessment of Area Methods of Reducing Emissions Appendix C Hydrogen Manifold Optional C 1 Description Specifications Installation Operation Parts List Hydrogen Manifold Microprocessor P C Board Dip Switch Settings eee Illustrations Figure 2 1 Power Supply Dimensions Figure 2 2 Remote High Frequency Console Mounting Dimensions Figure 2 3 Torch Dimensions Figure 3 1 System Interconnection Diagram Figure 3 2 Primary Power Connections Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 5 6 Figure 5 7 Figure 5 8 Figure 5 9 Figu
87. ch Leads Part Number Length 261150 10 10 ft 3 0 m 261150 15 15 ft 4 6 m 261150 20 20 ft 6 1 m 261150 25 25 ft 7 6 m 261150 30 30 ft 9 1 m 261150 35 35 ft 10 7 m 261150 40 40 ft 12 2 m 261150 45 45 ft 13 7 m 261150 50 50 ft 15 2 m Figure 8 7 Shielded Torch Leads Parts List FineLine 260PC User s Manual Gas Hose Package Part Number Length 200317 20 20 ft 6 1 m 200317 25 25 ft 7 6 m 2003 17 30 30 ft 9 1 m 200317 35 35 ft 10 7 m 200317 40 40 ft 12 2 m 200317 45 45 ft 13 7 m 200317 50 50 ft 15 2 m 200317 55 55 ft 16 8 m 2003 17 60 60 ft 18 3 m 200317 65 65 ft 19 8 m 200317 70 70 ft 21 3 m 200317 75 75 ft 22 9 m 2003 17 80 80 ft 24 4 m 200317 85 85 ft 25 9 m 2003 17 90 90 ft 27 4 m 2003 17 95 95 ft 29 0 m 200317 100 100 ft 30 5 m PLASMA GAS HOSE ID 181 PREFLOW GAS HOSE SHIELD GAS HOSE D POSTFLOW GAS HOSE 0 t TORCH SOLENOID CONTROL CABLE i Figure 8 8 Gas Hose Package Parts List FineLine 260PC User s Manual Coolant and Power Leads Part Number Length 200306 5 5 ft 1 5 m 200306 10 10 ft 3 0 m 200306 15 15 ft 4 6 m 200306 20 20 ft 6 1 m 200306 25 25 ft 7 6 m 200306 30 30 ft 9 1 m 200306 3
88. d to enter the material thickness Use the CLR key to backspace if an error is made Press the enter key when the correct value has been entered SUBSTANCE MILD STEEL HOT GAS AIR THICKNESS 0 125 inches psi 025 0 PROCESS CUTTING 7 TORCH PARTS psi 080 0 CURRENT SET POINT 50 AMPS 5 DELAY GAS OXYGEN y PIERCE DELAY TIME 0000 ns PSE 05 0 USE THE NUMERICAL KEYPAD TO ENTER THICKNESS CURRENT MODE MATERIAL InnerLogic Inc Figure 4 6 Setting Material Thickness 4 7 Operation FineLine 260PC User s Manual Selecting Process To set the operating process use the down arrow to scroll down to Process The process area should be highlighted as shown in Figure 4 7 and the process should be blinking To change the process press F3 as indicated by the help prompt Repeatedly pressing F3 will alternate between cutting and marking Press the enter key when the desired process has been selected At this point the default cutting parameters are selected and adjusted automatically for the material type material thickness and process selected PREFLOW SUBSTANCE MILO STEEL HOT 00 AIR THICKNESS 0 125 inches psi 025 0 PROCESS CUTTING 2 TORCH PARTS GAS OXYGEN amp psi 080 0 CURRENT SET POINT 5D ANPS lt DELAY GA OXYGEN PIERCE DELAY TINE 0000 ms 050 PRESS F3 CHANGE CURRENT MODE MATERIAL InnerLogic Inc Figure 4 7 Selecting Process
89. displayed as shown in Figure 5 16 Press F3 to scroll through the available node numbers When using an Inova torch height control system with the FineLine the communication node feature must be disabled To disable the communication node press F3 until disabled is displayed in the node number selection box RS 422 SERIAL COMMUNICATION NODE NUMBER 1 FINELINE 260PC PRESS F3 TO SELECT THE PROPER NODE NUMBER PRESS ENT TO RETURN TO THE MAINTENANCE MENU CURRENT MODE COMMUNICATION NODE InnerLogic Inc Figure 5 16 Communication Node Selection Screen Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Inova Parameter Transmit If an Inova arc voltage control system is not being used with the FineLine system the Inova Parameter Transmit feature must be disabled With the Inova Parameter Transmit feature enabled pressing F3 while the voltage screen is being displayed will automatically transmit the pierce height cutting height and arc voltage set points to the Inova arc voltage control To view the status of the Inova Parameter Transmit setting scroll down to the Inova Parameter Transmit selection on the maintenance screen and press ENT The Inova parameter transmit screen will be displayed as shown in Figure 5 17 Pressing F3 will toggle the Inova Parameter Transmit setting between enabled and disabled INOVA PARAMETER TRANSMIT STATUS DISABLED FINELINE 260PC PRESS F3 TO ENABLE DISAB
90. e cutting machine or on the cutting table See Figure 2 2 for RHF console mounting dimensions Torch Installation The FineLine 260PC torch must be installed on the positioner of an arc voltage control capable of maintaining the cutting arc voltage within 1 arc volt The arc voltage must be adjustable in 1 arc volt increments The positioner must be rigid to ensure cut quality and a torch collision sensor is highly recommended See Figure 2 3 for torch mounting dimensions Primary Power Connection Before connecting primary power check the data plate to verify the voltage required by the FineLine power supply A primary disconnect switch should be provided for each FineLine power supply The disconnect switch should be located as close as possible to the power supply so it can be turned off quickly in case of an emergency The disconnect switch should be equipped with time delay fuses only The magnetic inrush current of the power supply will cause fast acting fuses to blow The disconnect switch should be sized according to local and national codes The rating must meet or exceed the continuous rating of the fuses used See the following chart for recommended fuse sizes 3 3 Installation FineLine 260PC User s Manual 3 Phase Input Current Recommended Input Voltage at Maximum Output Time Delay Fuse Size VAC amps amps 208V 60Hz 147 200 230V 60Hz 133 190 380V 50Hz 81 125 415V 50Hz 74 100 460V 60Hz 67 95
91. e Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 5 8 127 70 140 275 600 130 3 4 130 55 900 135 1 20 74 45 0 134 40 150 300 1200 1 25 145 25 200 140 500 LSet 155 15 225 Edge start or moving pierce recommended Metric Retaining Cap 277151 Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 6 117 4305 2 6 5 0 300 32 10 20 74 30 0 123 3040 34 5 8 400 12 124 2485 3 5 62 3 3 Retaining Cap 277152 Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 16 127 1760 36 7 0 900 3 3 20 130 1340 3 4 1200 25 20 74 45 0 133 1040 3 16 6 320 145 625 E 3 6 500 38 154 385 5 6 Edge start moving pierce recommended 1 Revised on 7 2 07 4 18 Operation FineLine 260PC User s Manual Mild Steel Cutting 200 Amps Oxygen Plasma Air Shield Shield Cap Nozzle Electrode 277274 277289 277291 Outer Cap Retaining Cap Swirl Ring Torc
92. e automatic gas console When an appropriate thickness stainless steel is selected H17 will be selected for the plasma gas and nitrogen will be selected for the shield gas A message will alert the operator to move the plasma outlet hose from the rear of the automatic gas console to the outlet port of the hydrogen manifold Simply move the hose then press enter on the automatic gas console keypad to clear the alert As with other operating conditions ensure that the correct torch parts are installed before continuing with the cut During normal operation the power error LED on the front panel of the hydrogen manifold is constantly illuminated When an error occurs the LED flashes on and off to indicate an error The number of flashes can be counted to determine what error has been encountered The following chart shows the number of flashes and the corresponding errors Power Error LED Number of Flashes Error 1 AGC not found 2 Low 17 inlet pressure 3 Incorrect H17 outlet pressure 4 Lost communication with AGC Hydrogen Manifold Optional Parts List Item Number Part Number 1 709003 2 709207 3 706041 4 704009 3 707006 6 709033 7 708076 8 200503 9 501147 10 200502 11 200501 Not Shown 708097 Not Shown 200285 Not Shown 200505 Not Shown 200504 FineLine 260PC User s Manual duantity Description Receptacle 9 position Receptacle 7 position Transformer 12V LED panel mount Input
93. e 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 Health Support Equipment The FineLine 260PC 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 FineLine system Observe the following guidelines to minimize exposure to these electric and magnetic fields e Stay as far away from the FineLine power supply torch torch leads and remote high frequency console as possible e Route the torch 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 ob
94. eatment necessary Notes to Physician No specific antidote Treatment of exposure should be directed at the control of symptoms and the clinical condition of the patient 5 Fire Fighting Measures Extinguishing Media Water fog or fine spray Dry chemical fire extinguishers Carbon dioxide fire extinguishers Foam Do not use direct water stream May spread fire Alcohol resistant foams ATC type are preferred General purpose synthetic foams including AFFF or protein foams may function but will be less effective Fire Fighting Procedures Keep people away Isolate fire and deny unnecessary entry Use water spray to cool fire exposed containers and fire affected zone until fire is out and danger of reignition has passed Fight fire from protected location or safe distance Consider the use of unmanned hose holders or monitor nozzles Immediately withdraw all personnel from the area in case of rising sound from venting safety device or discoloration of the container Burning liquids may be extinguished by dilution with water Do not use direct water stream May spread fire Move container from fire area if this is possible without hazard Burning liquids may be moved by flushing with water to protect personnel and minimize property damage Special Protective Equipment for Firefighters Wear positive pressure self contained breathing apparatus SCBA and protective fire fighting clothing includes fire fighting helmet coat trousers boots and
95. ected to the inlet port and the plasma outlet hose must be connected to the outlet port The manifold is fully integrated with the operating software of the automatic gas console Specifications 260535 5 3 in 135 mm 10 1 in 257 mm 9 5 in 241 mm 12 Ib 5 4 kg e 31 9 5 241 8 7 221 4 1 4 20 PRESS NUTS 4 L 4 10 BE Et 9 2 233 20 4 10 10 1 257 5 3 135 Figure C 1 Hydrogen Manifold Mounting Dimensions Hydrogen Manifold Optional FineLine 260PC User s Manual Gas Supply Requirements Inlet gas type Inlet gas flow rate maximum 57 scfh 1614 liters hour Inlet gas pressure 150 psi 10 3 H17 consists of 17 5 hydrogen 32 5 argon and 50 nitrogen HI7 A 1 4 inside diameter hose is required for the inlet gas connection A mating connector is supplied with the unit A quick connect fitting must not be used for the inlet gas supply Using a quick connect fitting to connect and disconnect a pressurized hose may cause damage to the system Installation The hydrogen manifold must be installed on the cooling system shelf of the FineLine 260PC power supply The cooling system shelf is located at the rear of the unit as shown in Figure C 2 Use 1 4 20 bolts and 1 4 lock washers to secure the hydrogen manifold to the shelf Note that the bolts must not be longer than 1 2 or the manifold m
96. eel Cutting 100 Amps Oxygen Air 4 17 Mild Steel Cutting 150 Amps Oxygen Air 4 18 Mild Steel Cutting 200 Amps Oxygen Air 4 19 Mild Steel Cutting 275 Amps Oxygen Air 4 20 Stainless Stee Cutting 30 Amps Air Air 4 21 Stainless Stee Cutting 50 Amps Air Nitrogen 4 22 Stainless Stee Cutting 70 Amps 17 Nitrogen 4 23 Stainless Stee Cutting 70 Amps Air Nitrogen 4 24 Stainless Stee Cutting 100 Amps 17 Nitrogen 4 25 Stainless Stee Cutting 100 Amps Air Nitrogen 4 26 Stainless Stee Cutting 150 Amps 17 Nitrogen 4 27 Stainless Stee Cutting 150 Amps Air Nitrogen 4 28 Stainless Stee Cutting 200 Amps 17 Nitrogen 4 29 Stainless Stee Cutting 200 Amps Air Nitrogen 4 30 Stainless Stee Cutting 260 Amps 17 Nitrogen 4 31 Stainless Stee Cutting 275 Amps Air Nitrogen 4 32 Aluminum Cutting 30 Amps Air Nitrogen 4 33 Aluminum Cutting 50 Amps Air Nitrogen 4 34 Aluminum Cutting 70 Amps Air Nitrogen 4 35 Aluminum Cutting 100 Amps Air Nitrogen 4 36 Aluminum Cutting 150 Amps Air Nitrogen 4 37 Aluminum Cutting 200 Amps Air Nitrogen 4 38 Aluminum Cutting 275 Amps Air Nitrogen 4 39 Mild Steel Marking 10 Amps Nitrogen Nitrogen 4 40 Stainless Steel Marking 8 Amps Nitrogen Nitrogen 4 41 Aluminum Marking 10 Amps Nitrogen Nitrogen 4 42 4 13 Operation FineLine 260PC User s Manual Mild Steel Cutting 30 Amps Oxygen Plasma Oxygen Shield
97. enance screen and press ENT The default delay screen will be displayed as shown in Figure 5 13 Pressing F3 will toggle the Default Delay parameter between enabled and disabled STATUS DISABLED FINELINE 260PC PRESS F3 TO ENABLE DISABLE DEFAULT PIERCE DELAY PRESS ENT TO RETURN TO THE MAINTENANCE MENU CURRENT MODE DEFAULT PIERCE DELAY InnerLogic Inc Figure 5 13 Default Pierce Delay Screen Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Restoring Factory Default Cutting Conditions To restore a factory default cutting condition scroll down to the Restore Factory Defaults selection on the maintenance screen and press ENT The restore screen will be displayed as shown in Figure 5 14 Note that the present material type and thickness selected on the status screen will be automatically displayed on the restore screen Press ENT to restore the factory default setting for the material type and thickness displayed To change the material type press the F3 key To edit the material thickness use the arrow keys to scroll to Thickness and use the numerical keypad to enter the thickness To restore the factory default cutting condition for all user saved files press 1 then 2 then 3 as shown on the screen below To restore corrupted cutting conditions press 7 then 8 then 9 as shown on the screen below SUBSTANCE MILD STEEL HOT THICKNESS 0 125 inches PROCESS CUTTING PRESS ENT TO RESTORE DEFAULTS FOR
98. fold scroll down to the Configure Hydrogen Manifold selection on the Maintenance Screen and press enter The Configure Hydrogen Manifold screen will be displayed as shown in Figure 5 19 Pressing F3 will toggle the Hydrogen Manifold setting between enabled and disabled HYDROGEN MANIFOLD STATUS ENABLED FINELINE 260PC PRESS F3 TO ENABLE DISABLE HYDROGEN MANIFOLD PRESS ENT TO RETURN TO THE MAINTENANCE MENU CURRENT MODE CONFIGURE MANIFOLD InnerLogic Inc Figure 5 19 Configure Hydrogen Manifold Screen 5 20 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Setting an Arc Off Delay In some instances such as when cutting thicker stainless steel materials it may be desirable to delay the extinction of the cutting arc after a stop signal is received To program an arc off delay scroll down to the Set Arc Off Delay selection on the Maintenance Screen and press enter The Set Arc Off Delay screen will be displayed as shown in Figure 5 20 Use the keypad to enter the desired delay time in milliseconds The delay can be set from 0 to 2000 mS ARC OFF DELAY DELAY 0250 USE THE NUMERICAL KEYPAD ENTER THE TIME DELAY BETWEEN THE RECEPTION OF A STOP SIGNAL AND THE EXTINCTION OF THE ARC FINELINE 260PC PRESS ENT TO RETURN TO THE MAINTENANCE MENU CURRENT MODE ARC OFF DELAY InnerLogic Inc Figure 5 20 Set Arc Off Delay Screen 5 21 Automatic Gas Console Advanced Functions
99. from corrosion 4 Verify that the primary three phase A C voltage connections are tight 5 Verify that all p c board connectors are installed securely 6 Verify that the rear panel cable connectors are installed securely 7 Verify that the automatic gas console connector is installed securely to the plug 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 Automatic Gas Console 1 Remove the cover of the automatic 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 d 7 1 Maintenance and Troubleshooting FineLine 260PC User s Manual 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
100. from corrosion Use a wire brush to clean the connection point if necessary Maintenance and Troubleshooting 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 1 2 Remove primary power to the system Remove the rear cover of the power supply to expose the cooling system Remove the coolant reservoir cap level gauge Make sure that consumables are properly installed in the torch 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 Remove the torch coolant supply hose from the rear of the power supply Note that the coolant supply hose has right hand threads 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 Unscrew the lower portion of the coolant filter housing and remove the coolant filter deionization cartridge Reconnect the coolant hoses and replace the coolant and coolant filter deionization cartridge Only use the recommended FineLine torch coolant solution Commercially available antifreeze contains corrosion inhibitors that will damage the coolin
101. g system See Section 3 for more information on torch coolant requirements FineLine 260PC User s Manual Maintenance and Troubleshooting FineLine 260PC User s Manual Microprocessor Status LED s The microprocessor p c board controls all of the functions of the FineLine 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 SHIELD 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 16 5V 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 Not used Coolant pump relay CR5 energized Plasma start signal applied to FineLine 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 Not used 5V microprocessor power supply satisfactory 12V microprocessor power supply satisfactory 12V interlock power supply satisfactory 15V analog power satisfactory 24V g
102. gloves If protective equipment is not available or not used fight fire from a protected location or safe distance Unusual Fire and Explosion Hazards Container may rupture from gas generation in a fire situation Violent steam generation or eruption may occur upon application of direct water stream to hot liquids Hazardous Combustion Products During a fire smoke may contain the original material in addition to combustion products of varying composition which may be toxic and or irritating Combustion products may include and are not limited to Carbon monoxide Carbon dioxide 6 Accidental Release Measures Steps to be Taken if Material is Released or Spilled Contain spilled material if possible Small spills Any absorbent material Collect in suitable and properly labeled open containers Wash the spill site with large quantities of water Large spills Dike area to contain spill Pump into suitable and properly labeled containers See Section 13 Disposal Considerations for additional information Page 2 of 8 Propylene Glycol MSDS FineLine 260PC User s Manual Product Name Propylene Glycol Industrial Grade Issue Date 03 02 2006 Personal Precautions Use appropriate safety equipment For additional information refer to Section 8 Exposure Controls and Personal Protection Keep unnecessary and unprotected personnel from entering the area Spilled material may cause a slipping hazard Environmental Preca
103. h Main Body 277154 277266 277143 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 4 125 230 040 200 300 3 8 130 140 090 225 150 1 2 133 120 115 250 500 5 8 137 100 130 152 3 4 140 75 150 700 153 20 82 58 0 300 1 147 50 75 1000 155 1 25 155 25 240 350 1400 165 17 300 158 1 75 175 12 350 300 400 20 185 7 500 160 Edge start or moving pierce recommended Metric Material Preflow Plasma Shield Arc Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 6 124 6100 8 5 0 300 10 130 3480 2 3 5 8 3 8 500 12 132 3160 27 6 2 16 137 2515 3 3 6 4 700 20 141 1810 3 8 20 82 58 0 7 6 1000 3 9 25 146 1310 43 32 155 610 61 8 9 1400 38 164 435 7 5 40 45 175 295 9 2 7 6 400 50 183 195 12 2 4 1 Edge start or moving pierce recommended 1 Revised on 7 2 07 4 19 Operation FineLine 260PC User s Manual Mild Steel Cutting 275 Amps Oxygen Plasma Air Shield
104. h body part number Torch Electrode Part 8 AAnnFA 12 If requested in command 30 the AGC Number msw will transmit the most significant word the electrode part number Torch Electrode Part 9 AAnnFA 13 0D If requested in command 30 the Number 15 will transmit the least significant word o the electrode part number Torch Swirl Ring 20 AAnnFA 14 If requested in command 30 the Part Number msw will transmit the most significant word o the swirl ring part number Torch Swirl Ring 21 AAnnFA 15 If requested in command 30 the AGC Part Number Isw will transmit the least significant word o the swirl ring part number Torch Nozzle Part 22 AAnnFA 16 0D If requested in command 30 the Number msw will transmit the most significant word o the nozzle part number Torch Nozzle Part 23 nn FA 17 0D If requested in command 30 the Number 15 will transmit the least significant word o the nozzle part number Torch Retaining Cap 24 AA nn FA 18 If requested in command 30 the Part Number msw will transmit the most significant word o the retaining cap part number 6 5 Serial Communication Command Torch Retaining Cap Part Number Isw Torch Shield Cap Part Number msw Torch Shield Cap Part Number Isw Torch Outer Cap Part Number msw Torch Outer Cap Part Number Isw Send Paramete
105. he current path back to the power supply e Never bypass the safety interlock devices e Before removing any of the FineLine covers switch the system off at the wall disconnect Wait at least five 5 minutes before removing any cover This Safety FineLine 260PC User s Manual will give the capacitors inside the unit time to discharge e Never operate the FineLine system without all of the covers in place e Preventive maintenance should be performed daily to avoid possible safety hazards Fire Prevention When using the FineLine 260PC system it is necessary to exercise good judgment While cutting the arc produces sparks that could cause a fire should they fall on flammable material Make sure that all flammable material such as paper cloth etc is a suitable distance away from the cutting area All flammable liquids should be at least 40 feet away from the cutting area preferably stored in a metal cabinet Plasma cutting should never be attempted on containers that contain flammable materials Make sure that fire extinguishers are readily accessible in the cutting area Make sure that the cutting area is properly ventilated when using oxygen as a cutting gas Explosion Prevention The FineLine 260PC 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 FineLine sy
106. he 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 FineLine system When the cut quality is not satisfactory the cutting speed torch height or gas pressures may need to be adjusted in small increments until the proper cutting condition is obtained The following guidelines should be useful in determining which cutting parameter to adjust Note Before making any parameter changes verify that the torch is square to the workpiece Also it is essential to have the correct torch parts in place and to ensure that they are in good condition Check the electrode for excessive wear and the nozzle and shield cap orifices for roundness Also check the parts for any dents or distortions Irregularities in the torch parts can cause cut quality problems 1 A positive cut angle top dimension of piece smaller than the bottom dimension usually occurs when the torch standoff distance is too high when cutting too fast or when excessive power is used to cut a given plate thickness 2 A negative cut angle top dimension of piece larger than the bottom dimension usually occurs when the torch standoff distance is too low or when 4 11 Operation FineLine 260PC User s Manual the cutting speed is too slow Top dross usually occurs when the torch standoff distance is too high 4 Bottom dross usually occurs when
107. he power supply so it can be turned off in case of an emergency 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 FineLine 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 FineLine power supply Make sure the connection is securely tightened e Make sure the positive output work ground of the FineLine 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 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 Make sure the FineLine system is switched off at the wall disconnect before servicing the power supply or torch e Never change torch consumable parts unless the FineLine 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 t
108. hould be rated for 12VDC 10mA Motion Output Signal e The FineLine 260PC provides a maintained contact closure output between P8 pins 12 and 14 as long as a cutting arc is maintained between the torch and the workpiece The motion contacts are rated for 6A 125VAC 6A 110VDC 24 30VDC RS 422 Serial Communication Link An RS 422 serial communication link can be connected between the plug on the rear of the automatic gas console and a CNC machine or automatic height control system All cutting parameters can be controlled via the RS 422 communication link Also cutting information such as pierce height cutting height recommended arc voltage and recommended cutting speed can be transmitted from the automatic gas console to the CNC machine or height control See Section 6 for additional information Torch Coolant Requirements Note Refer to the Material Safety Data Sheet in Appendix A for information regarding safety handling and storage of propylene glycol The FineLine 260PC system is shipped without torch coolant in the reservoir Coolant must be added before applying power to the system Only use the recommended FineLine torch coolant solution Commercially available antifreeze contains corrosion inhibitors that will damage the cooling system The FineLine torch coolant solution will maintain optimal system performance The standard coolant solution consists of 25 industrial grade propylene glycol and 75 deionized water
109. id 1 50 31 318 2 lOMINOO GIONSIOS HOYOL YANOLLISOd VAONI 3SOH SVD 29 AlddNS S3MOd ANITANIS Figure 3 1 System Interconnection Diagram 3 2 Installation FineLine 260PC User s Manual Power Supply Installation The FineLine 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 power supply must be cleaned as often as necessary to prevent the accumulation of metallic dust inside the unit See Figure 2 1 for power supply dimensions Remote High Frequency Console Installation The Remote High Frequency RHF Console should be mounted in a convenient location that is away from other electronic control devices The high voltage high frequency signal generated inside the unit can interfere with the operation of certain control systems The RHF console is usually mounted on the gantry of th
110. inal block 4 position Bulb power on switch LED lens green Fan 120V Drain petcock Fan guard large outside Fan guard small inside terminal block large Strain relief F2 fuse MDL 5A Fan heat exchanger front panel 8 2 Parts List FineLine 260PC User s Manual Item Number Part Number Quantity Description 83 701141 1 R9 2 ohm pilot arc resistor INNERLOGIG N o OS mm SS oa vVvvvvvvvvvvvvvvvvvvv 299 Fi 4 Tam FS 123456789 EN 292 1 5 5 9 99 9 9 6 619 66 6 1 6 do petras 9 6 Ee E OO s E P ea Sh E OOpa Linie esee F2 s Ojo dd jog o 9 i 9 Front panel fans not shown item numbers 42 and 82 Figure 8 1 Power Supply Front View 8 3 Parts L
111. ineLine 260PC User s Manual Power Supply Microprocessor P C Board Assembly 260450 1 LED30 COA ru No I CDU ev 1 Ost m es 4 ae Q 2 Jo amp pus ls lt c75 LI g SO 20 sr A ud Ley res n H we jaer sxe a Ld wR sc e 08 FLOW E Ge 30 sLJo 33 op AE 5 PRES 8 M ha 8 M PONE hs 9 n 1662 ves Pas 12 g LED29 ir isv Ld le cse 1 ow mm n ROW H E a Lal 5 B
112. ist FineLine 260PC User s Manual ARR SIS Se Figure 8 2 Power Supply Rear View 8 4 Parts List FineLine 260PC User s Manual Figure 8 3 Power Supply Left Side View 8 5 Parts List FineLine 260PC User s Manual Figure 8 4 Power Supply Right Side View Parts List FineLine 260PC User s Manual Remote High Frequency Console Note See Figure 8 5 Item Number Part Number Quantity Description 1 715051 2 715050 3 709227 4 710147
113. itted to switch the material type to stainless steel for a FineLine system on node 1 AA 01 FA 01 00 01 0D Serial Communication FineLine 260PC User s Manual To send a parameter the parameter value needs to be sent as part of the command For example to send a desired pierce delay time of 1000 milliseconds to the system look up the Set Pierce Delay command in the command table You will see the following table entry Command Hex String Additional Information Set Pierce Delay 4 nn FA 04 0D Time in mS seconds 1000 Valid range 0 to 5000 Once again AA hex signifies the start of the command is the net node of the power supply and FA hex is the FineLine identifier The value 04 hex signifies the Set Pierce Delay command and OD hex signifies the end of the command The in the hex string is the MSB followed by the LSB of a type int The integer is the value used in the additional information column Thus the is sometimes referred to as the additional information value In the example we wanted to transmit a pierce delay time of 1000 mS 1 second This value in hexadecimal would be 03E8 msb 03 Isb E8 In this example the following string would be transmitted in order to set the pierce delay time to 1000mS for a power supply on net node 1 AA 01 FA 04 03 E8 0D Communication Error Checking With a single torch system all commands and parameters transmitted to the FineLine will be
114. l gauge LS1 coolant level switch TS1 Coolant temperature switch Pump motor 1 3hp 230V 50 60 Hz V band clamp 8 1 Parts List FineLine 260PC User s Manual Item Number Part Number Quantity Description 500511 708061 715084 708068 708059 500516 260250 260012 500509 500510 708110 500348 702076 708011 701165 500536 705011 709167 702054 277452 Contact factory 260008 709117 708106 706036 706041 706042 706043 280003 708103 708104 708105 709190 709191 740106 704050 200204 715052 500526 500574 709228 709227 709231 500525 amp _ Coolant pump 70 gph Solenoid valve 220 240VAC Check valve coolant return CONG coolant pump relay FSI coolant flow switch Fan 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 PAR CR2 relay R7 R8 3 ohm pilot arc resistor PAT IGBT drive p c board assembly PATIGBT 5 30 power terminal block PAT IGBT filter capacitor I O p c board assembly Height control voltage divider p c board assembly Chopper assembly terminal block small Relay DPDT TR8 transformer 241 4 36 TR4 TR7 transformer 241 3 12 TRS transformer 241 4 12 TR3 transformer 241 6 12 Power supply 24VDC CRI relay CRI relay socket CRI hold down clip TB6 terminal block marker strip 4 position TB6 term
115. losing 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 Damaged or loose torch lead connections 8 Shorted torch or torch leads Check the continuity between the Electrode lead and the Nozzle lead to make sure they are not shorted 9 Open torch or torch leads Check the continuity from the Electrode lead to the torch electrode and the Nozzle lead to the large brass body of the torch No spark between the spark gap 1 Improper spark gap Set gap to 025 635 electrodes mm 2 Worn spark gap electrodes Clean electrodes with fine 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 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 2 Pierce height too high 3 Incorrect damaged or worn consumables Blown gas console fuse F10 Loose cables inside the gas console Remove and reinstall all plugs on the interface p c board computer video board and display 3 Bad power supply inside gas console Check for all voltage LED s on the interface board and computer 4 Loose plug P17 on the bottom of the gas console Remove and rei
116. ly Disconnect P2 from the chopper p c board and P26 from the microprocessor p c board Check continuity between P26 8 and P2 1 and between P26 7 and P2 2 Also check that these wires are not shorted to each other If the cable is OK connect P26 to the microprocessor p c board but leave P2 disconnected from the chopper With power applied give the power supply a start signal and check for approximately 10 VDC between P26 7 ground and P26 8 signal when the main contactor is energized If 10 VDC is not present replace the microprocessor p c board If 10 VDC is present turn all power off reconnect P2 to the chopper p c board and repeat the test for 10 VDC between P2 2 ground and P2 1 signal If 10 VDC is present and LED 7 is not illuminated replace the chopper Maintenance and Troubleshooting FineLine 260PC User s Manual FUSES CORRECT AS NECESSARY CHECK CON1 AND WIRING CHOPPER OK SEE NEXT PAGE Figure 7 1 Chopper Diagnostics Part 1 Maintenance and Troubleshooting FineLine 260PC User s Manual FROM PREVIOUS PAGE CHECK F2 AND WIRING REPAIR ON OFF CABLE REPLACE REPAIR DUTY MICROPROCESSOR CABLE BOARD REPLACE CHOPPER ASSEMBLY Figure 7 2 Chopper Diagnostics Part 2 This page intentionally left blank Parts List Section 8 Parts List Power Supply Note See Figures 8 1 to 8 4 FineLine 260PC User s Manu
117. m 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 FineLine 260PC 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 FineLine 260PC 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 3 1 FineLine 260PC User s Manual Installation 21875 ouv 8 J 8VO 1oulNOO 75 Javo 3 3igvo ALOW3Y 3105 02 VAONI H3MOd 9 318 2 10MINOO 310SNOO Qv31 ANNOYS AYOM AVIS SQV31 LNV1009 e e cow ta ino 9 9189 dd 8d 218 2 58 310SNOO 50 31 S
118. msec All Thicknesses 25 25 30 2 120 100 050 050 0 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Thickness Air Nitrogen Nitrogen Air Voltage Speed Height Height Delay mm psi psi psi psi volts mm m mm mm msec AII Thicknesses 25 25 30 2 120 2540 13 13 0 1 Revised on 7 2 07 4 42 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Section 5 Automatic Gas Console Advanced Functions This section describes how to operate the FineLine unit when non standard cutting conditions are desired Instructions are also given on how to access the various maintenance modes of the system Altering the Current Set Point To alter the current set point from the default setting use the arrow keys to scroll to Current Set Point or press the Menu key then the Current key The current setting should be highlighted as shown in Figure 5 1 and the set point should be blinking Press F3 to scroll through the available current choices The current can only be set to values of 30 50 70 100 150 200 260 or 275 amps while cutting and 8 9 or 10 amps while marking Once the desired value is blinking press ENT PHEFLOW SUBSTANCE MILD STEEL MDT GAS AIR HICKNESS 0 125 inches psi 029 0 PROCESS CUTTING T ORCH PARTS GAS OXYGEN amp psi 080 0 CURRENT SET POINT 50 ANS gt lt DELAY GAS OXYGEN ii i 055 0 PIERCE DELAY TINE 0000 n
119. n Air Voltage Speed Height Height Delay Width ga in psi psi psi psi volts ipm in in msec in 12 105 123 70 1120 075 11 120 25 74 12 1 126 60 125 135 100 078 10 4135 128 50 1135 Hot Rolled Steel Air Shield Swirl Ring 277142 Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width ga in psi psi psi psi volts ipm in in msec in 14 075 200 075 12 105 106 190 100 135 100 125 180 25 74 19 1 080 10 1135 10 170 110 3 16 113 105 140 145 200 085 14 117 75 165 250 087 Metric Cold Rolled Steel Oxygen Shield Swirl Ring 277140 Material Preflow Plasma Shield Arc Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Oxygen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 25 121 1895 2 9 1 9 25 74 12 1 34 100 3 125 1555 3 1 2 0 Hot Rolled Steel Air Shield Swirl Ring 277142 Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Air Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 259 4885 1 9 106 2 5 3 4 100 3 4660 2 0 25 74 19 1 5 13 2555 3 7 3 6 250 22 6
120. n the front panel ON button is pressed and released No arc at the torch GOO ports Bester gt Ne Possible Cause Primary disconnect fuse blown Fuse F1 or F4 blown White light or associated wiring bad Transformer TR2 or associated wiring bad RHF door open Low coolant level Fuse F4 blown Faulty ON switch or associated wiring The ON switch is normally open Faulty OFF switch or associated wiring The OFF switch is normally closed Relay CRI coil open Check the control panel status LED s and troubleshoot accordingly Check the gas console messages screen and troubleshoot accordingly Faulty latch relay on relay p c board Faulty relay p c board Faulty microprocessor p c board Relay CRI defective Incorrect torch consumables installed Incorrect gas pressure settings Check the control panel status LED s and troubleshoot accordingly 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 Check the automatic gas console messages screen and troubleshoot accordingly If the output voltage low error is present perform the chopper test in this section Pilot arc resistor PAR or pilot arc transistor 7 8 Maintenance and Troubleshooting FineLine 260PC User s Manual PAT is not c
121. n use a voltmeter to verify that the capacitors are fully discharged before touching the chopper Note A chopper troubleshooting flow chart can be found at the end of this section 1 Turn off all power to the FineLine 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 TBS refer to Figure 3 2 6 Depress the ON button to energize the FineLine 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 225 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
122. ne 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 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 P16 on the rear of the power supply 2 Connect the RHF Console Control Cable plug labeled P1 to the connector labeled P1 on the RHF console Power Supply Coolant Supply Hose 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 Installation FineLine 260PC User s Manual Power Supply Coolant Return Hose 6 1
123. nents and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applications B 3 This page intentionally left blank Hydrogen Manifold Optional FineLine 260PC User s Manual Appendix C Hydrogen Manifold Optional Description 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 conn
124. nstall the plug The gas console screen is blank Ne No response from the gas console 1 Loose keypad cable inside the gas console keypad Remove and reinstall the keypad cable Gas pressures will not adjust properly Wrong consumables installed in torch Loose pressure transducer cable Remove and reinstall P7 on the gas console I O p c board 3 Loose motorized regulator plugs Remove and reinstall the motor plugs and P3 P6 on the gas console I O p c board 4 Pressure regulator orifice clogged with dirt or debris Turn off primary power and turn motorized regulator screw all the way in by hand 5 Binding regulator Turn off primary power and turn all motorized regulators to their mid positions by hand Ne 7 9 Maintenance and Troubleshooting FineLine 260PC User s Manual Low pressure error 1 Supply gas pressure s less than 150 psi 2 Faulty pressure switch or associated wiring inside gas console Pressure error during cut 1 Supply gas pressure s fluctuating during cut Chopper Test Procedure Warning Only qualified maintenance personnel should perform the chopper test procedure The system utilizes potentially fatal A C and D C voltages All maintenance should be performed with safety in mind Be aware that the large blue electrolytic capacitors on the chopper assembly store large amounts of energy even after power has been removed from the system Wait at least five minutes after turning off power and the
125. obtainable from Canadian Standards Association 178 Rexdale Boulevard Toronto Ontario M9W IR3 Canada 9 Canadian Electrical Code Part 1 Safety Standard for Electrical Installations obtainable from the Canadian Standards Association 178 Rexdale Boulevard Toronto Ontario M9W 183 Canada Specifications FineLine 260PC User s Manual Section 2 Specifications System Description The FineLine 260PC is a microprocessor controlled 275 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 up to 2 thick and stainless steel up to 1 1 2 thick The FineLine 260PC is equipped with a computer controlled automatic gas console with VGA display All cutting parameters are controlled from the automatic gas console Setting up a cut is as simple as entering the material type material thickness and process cutting or marking All gas types and pressures are set automatically and the cutting parameters are transmitted to the FineLine power supply Switching to a different screen on the gas console gives the operator a pictorial view of the torch parts required to make the cut Another screen shows the recommended cutting speed and torch height for making the cut These parameters can even be transmitted to an x y machine controller or an arc voltage control system via RS 422 serial communication The RS 422 port also allows for full control
126. of the cutting parameters from an x y machine controller The gas console also tracks the number of cuts made with a particular set of consumables and keeps a detailed record of errors that may occur during the cutting sequence To aid in troubleshooting a message screen on the gas console displays all power supply and gas console sequencing All gas inlets and outlets are connected to the rear of the automatic gas console For cutting mild steel the FineLine 260PC uses oxygen for the plasma gas and either oxygen or air for the shielding gas When cutting stainless steel or other non ferrous materials 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 The FineLine 260PC is technologically advanced to produce the highest quality cuts while maximizing consumable life The torch is water cooled and consumables are machined to exacting dimensions and checked with the latest computerized coordinate measuring systems Eight nozzle sizes 30 50 70 100 150 200 260 and 275 amps are available to produce excellent cut quality throughout the cutting range Specifications FineLine 260PC User s Manual System Components The FineLine 260PC consists of the following components Standard Components Power Supply Automatic Gas Console Remote High Frequency RHF Console RHF Console Control Cable
127. ogen Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 4 141 100 135 200 250 092 3 8 25 94 35 0 147 80 170 225 350 1 2 154 35 210 250 450 2098 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 6 140 2595 32 5 0 250 2 3 10 25 94 35 0 148 1935 44 5 8 12 152 1540 5 0 62 m9 54 1 Revised on 7 2 07 4 26 Operation FineLine 260PC User s Manual Stainless Steel Cutting 150 Amps H17 Plasma Nitrogen Shield This gas combination gives the best cut quality and minimum dross levels Shield Cap Nozzle Electrode 277298 277297 277135 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277266 277139 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 4 165 95 250 250 400 1135 3 8 75 150 500 275 1 2 25 81 75 13 155 60 165 600 140 5 8 50 185 800 300 3 4 165 40 250 1000 145 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf
128. olant 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 6 When the Coolant Flow LED illuminates release the green ON switch The FineLine system should remain energized and continue pumping coolant through the system 7 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 8 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 9 Check for coolant leaks at all hose connections inside the power supply RHF console and at the torch This page intentionally left blank Operation FineLine 260PC User s Manual Section 4 Operation Power Supply Front Panel Controls All of the FineLine controls and status indicator lights are located on the front panel of the system This section describes the function of each control and indicator See Figure 4 1 for front panel control and indicator locations Power Off Button O Deenergizes the FineLine system and turns off the cooling fans and coolant pump Power On Button Indicator Energizes the FineLine system and turns on
129. orch and arc current cutting level acceptable noise levels may be exceeded Proper ear protection should be used as defined by local or national codes See Section 2 for noise emission levels Toxic Fume Prevention Care should be taken to ensure adequate ventilation in the cutting area Some materials give off toxic fumes that can be harmful or fatal to people in the vicinity of the cutting area Also some solvents decompose and form harmful gases when exposed to ultraviolet radiation These solvents should be removed from the area prior to cutting 1 1 Safety FineLine 260PC User s Manual 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 Electric Shock Prevention The FineLine 260PC 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 FineLine 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 t
130. orch O ring blue lower Torch O ring red middle Torch O ring black upper Nozzle Removal Tool Electrode Removal Tool Driver Electrode Removal Tool Socket Swirl Ring Removal Tool Outer Retaining Cap Propylene Glycol MSDS FineLine 260PC User s Manual Appendix A Propylene Glycol MSDS ll Material Safety Data Sheet The Dow Chemical Company Product Name Propylene Glycol Industrial Grade Issue Date 03 02 2006 Print Date 24 Jul 2007 The Dow Chemical Company encourages and expects you to read and understand the entire M SDS as there is important information throughout the document We expect you to follow the precautions identified in this document unless your use conditions would necessitate other appropriate methods or actions 1 Product and Company Identification Product Name Propylene Glycol Industrial Grade COMPANY IDENTIFICATION The Dow Chemical Company 2030 Willard H Dow Center Midland MI 48674 USA Customer Information Number 800 258 2436 EMERGENCY TELEPHONE NUMBER 24 Hour Emergency Contact 989 636 4400 Local Emergency Contact 989 636 4400 Emergency Overview Color Colorless Physical State Liquid Odor Odorless Hazards of product No significant immediate hazards for emergency response are known OSHA Hazard Communication Standard This product is not a Hazardous Chemical as defined by the OSHA Hazard Communication Standard 29 CFR 1910 1200 P
131. otential Health Effects Eye Contact May cause slight temporary eye irritation Corneal injury is unlikely Mist may cause eye irritation Skin Contact Prolonged contact is essentially nonirritating to skin Repeated contact may cause flaking and softening of skin Skin Absorption Prolonged skin contact is unlikely to result in absorption of harmful amounts Inhalation At room temperature exposure to vapor is minimal due to low volatility Mist may cause irritation of upper respiratory tract nose and throat Indicates a Trademark Page 1 of 8 Propylene Glycol MSDS FineLine 260PC User s Manual Product Name Propylene Glycol Industrial Grade Issue Date 03 02 2006 Ingestion Very low toxicity if swallowed Harmful effects not anticipated from swallowing small amounts Effects of Repeated Exposure In rare cases repeated excessive exposure to propylene glycol may cause central nervous system effects 3 Composition Information Component CAS Amount Propylene glycol 57 55 6 gt 99 5 Eye Contact Flush eyes thoroughly with water for several minutes Remove contact lenses after the initial 1 2 minutes and continue flushing for several additional minutes If effects occur consult a physician preferably an ophthalmologist Skin Contact Wash skin with plenty of water Inhalation Move person to fresh air if effects occur consult a physician Ingestion No emergency medical tr
132. posure guideline When respiratory protection is required for certain operations use an approved air purifying respirator In misty atmospheres use an approved particulate respirator The following should be effective types of air purifying respirators Organic vapor with acid gas cartridge and particulate pre filter Ingestion Use good personal hygiene Do not consume or store food in the work area Wash hands before smoking or eating Engineering Controls Ventilation Provide general and or local exhaust ventilation to control airborne levels below the exposure guidelines 9 Physical and Chemical Properties Physical State Liquid Color Colorless Odor Odorless Flash Point Closed Cup 103 C 217 F Literature PMCC 3018 A 3 Propylene Glycol MSDS FineLine 260PC User s Manual Product Name Propylene Glycol Industrial Grade Issue Date 03 02 2006 Flammable Limits In Air Lower 2 6 V Estimated Upper 12 5 V Estimated 371 C 700 F Literature 0 3 mbar 25 C Literature 187 4 C 369 3 F Literature Autoignition Temperature Vapor Pressure Boiling Point 760 mmHg Vapor Density air 1 Specific Gravity 20 1 Freezing Point 2 62 Literature 1 04 20 C 20 Literature No test data available Melting Point No test data available Solubility in Water by 100 weight pH Not applicable Evaporation Rate Butyl 0 02 Estimated Acetate 1
133. power module Fuse 1A Pressure gauge 200 psi Fan Fan guard filter Pressure regulator electronic Power supply Pressure switch 80 200 psi Microprocessor p c board Communication Cable Power Cable AGC CONSOLE AGC COMM RS 422 iN 422 COMM RS 422 OUT POWER ERROR PRESSURE P LOO v RA 5 Hydrogen Manifold Optional FineLine 260PC User s Manual Hydrogen Manifold Microprocessor P C Board Assembly 200285 Feb PN 200284 RO a A iO ZB F 5 RI 1 1 n Be 5 Re 2 EH 3 4 ho Y Ole x a pr R3 gt 5 ls x O ai lus Es 8 REL re De o wove R4 14 05 85 16 07 86 De n R7 mo R9 hus 28 RIB RIS RID RED RIS cf R u 115 zu pre pra un en oo m7 ow Yi Aly RT i i FS vi Press TP d PS 1 kd C 2 R35 R lus P Sv Qs m bn E bue nee bns Rag m E Des m gx 124 re R50 Des RSe 127 m Ree b vi PRESSI Ve press u20 c30 Rsel R57 m C33 R59 Ras Ras Ion ZI Press 8 ERROR VIDUT AUX VelUr SV 24V 5 55 8 8 8
134. r DIES 30 Hex String AA nn FA 19 AA nn FA IA AA nn FA IB 0D AA nn FA IC 0D AA nn FA ID 0D AA nn FA IE 6 6 FineLine 260PC User s Manual Additional Information If requested in command 30 the will transmit the least significant word o the retaining cap part number If requested in command 30 the will transmit the most significant word o the shield cap part number If requested in command 30 the AGC will transmit the least significant word o the shield cap part number If requested in command 30 the AGC will transmit the most significant word o the outer cap part number If requested in command 30 the AGC will transmit the least significant word o the outer cap part number 01 Send material type 02 Send material thickness 03 Send current set point 04 Send pierce delay time 05 Send preflow gas type 06 Send preflow pressure 07 Send plasma gas type 08 Send plasma gas pressure 09 Send shield gas type 10 Send shield gas pressure 11 Send recommend arc voltage 12 Send recommended pierce height 13 Send recommended cutting height 15 Send recommended travel speed 16 Send torch body part number msw 17 Send torch body part number Isw 18 Send electrode part number msw 19 Send electrode part number Isw 20 Send swirl ring part number msw 21 Send swirl ring part number Isw
135. rd 8 22 Parts List FineLine 260PC User s Manual Detect P C Board Assembly 500810 3 z 5 TA d g 2 ND 2 3SVHd T 3SVHd 5 o Pl TP6 7 BLANK PCB P N 500809 REV 0 ASSEMBLY P N 500810 Figure 8 19 A C Detect P C Board 8 23 Figure 8 20 Relay P C Board 8 24 S 3 x u ES e e z g 2 2 72 2 Kd RHF Q Y en 9 RHF 9d 5 eye enu o E LEV par 5 ILK1 pnr ILK1 ILK2 8 ILK2 B d a 3 PHASE ox ci PHASE ree TEMP s 8 TEMP x z FLOW FLOW S PRESS PRESS dhal ISVHd ILK2 g ue 4 59 2 ug gt x Xa Nu o8 ot mp N N 55384 2 LEVEL 8 Oo T 55384 LEVEL ie E H21v1 FLOW T T VT oF 3S FLOW zo Po aS TEMP 5 AE TEMP N Ave OQ Z RHF N Av2 ei RHF LATCH ce E amp M 9 5 5 O as D Bn 9 gt ELI a vo 4 25 lt 8PE00G N d ATAWISSY 0 Ad 2 6006 N d 809
136. re 5 10 Figure 5 11 Figure 5 12 Figure 5 13 Figure 5 14 Figure 5 15 Figure 5 16 Figure 5 17 Figure 5 18 Figure 5 19 Figure 5 20 Figure 7 1 Figure 7 2 Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 Figure 8 5 Figure 8 6 Figure 8 7 Figure 8 8 Figure 8 9 FineLine 260PC User s Manual Power Supply Output Connections sse Torch Leads to RHF Console Connections Torch Connections Automatic Gas Console Input Connections Automatic Gas Console Output Connections Freezing Points of Aqueous Propylene Glycol Solution Front Panel Controls Automatic Gas Console Keypad Help Prompt Status Screen Selecting Material Substance Setting Material Thickness Selecting Process Torch Parts Voltage Screen Altering the Current Set Point Setting the Pierce Delay Time Altering Gas Types Altering Gas Pressures Altering Arc Voltage Control and X Y Machine Parameters User Created Cutting Conditions Maintenance Screen Message Screen Cut Errors Screen Error Selection Screen Actual Cut Errors Screen Pressure Diagnostics Screen Default Pierce Delay Screen Restore Factory Defaults Screen Measurement System Selection Screen Communication Node Selection Screen Inova Parameter Transmit Screen View Serial Communication Screen Configure Hydrogen Manifold Screen Set Arc Off Delay Screen Chopper Diagnostics Part 1 Chopper Diagnostics Part 2 Power Supply Front View Power Supply
137. returned goods shall be at the buyer s risk and expense Beyond this remedy KALIBURN will not be responsible for any special incidental or consequential damages or injury to the person or property of anyone by reason of any defect in any equipment sold hereunder This warranty will be considered void if torches or torch consumables manufactured by anyone other than KALIBURN are incorporated into this product Returned Goods Procedure KALIBURN utilizes a returned goods procedure that must be followed before returning any items for repair replacement or restocking This means that a returned goods authorization number must be obtained prior to shipment to KALIBURN It will be necessary for the customer to provide a description along with the stock number and serial number if applicable of the item to be returned In no case will KALIBURN accept a returned shipment without the proper returned goods authorization number FineLine 260PC User s Manual Electromagnetic Compatibility The 380V 50Hz and 415V 50Hz FineLine 260PC plasma cutting systems are manufactured to comply with the European standards EN 60974 Arc welding equipment Part 1 Welding power sources and EN 50199 Electromagnetic compatibility EMC Product standard for arc welding equipment Information about the EMC standard EN 50199 can be found in Appendix B FineLine 260PC User s Manual TABLE OF CONTENTS Section T Savery
138. s Stock Number Torch main body 277000 Torch handle assembly 820134 Diameter 2 in 50 8 mm Length Torch main body 4 65 in 118 mm Torch main body handle assembly 13 85 in 352 mm Weight including handle and valves 4 Ib 1 8 kg 1 le 2 50 8 13 2 335 F 4 65 118 Y Y Figure 2 3 Torch Dimensions 2 6 Specifications FineLine 260PC User s Manual Airborne Noise Emissions The FineLine 260PC 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 FineLine 260PC when operating at 2775 amps 145 arc volts The measurements were made with a sound level meter Distance From Torch A Weighted Sound C Weighted Sound Pressure Level Pressure Level 1 meter horizontal 1 6 meters 110 dB 107 dB above the workpiece The maximum noise level is 127 dB at a distance of 3 inches 76 2 mm from the torch while cutting at 275 amps 145 arc volts This page intentionally left blank Installation FineLine 260PC User s Manual Section 3 Installation Initial Inspection systems undergo full testing before being shipped fro
139. s Manual Torch Consumables Mild Steel Cutting i ap Retaining Cap Nozzle Swirl Ring Electrode Torch body Figure 8 11 Torch Consumables Mild Steel Cutting Parts List FineLine 260PC User s Manual Torch Consumables Stainless Steel Cutting Air Plasma Figure 8 12 Torch Consumables Stainless Steel Cutting Air Plasma Parts List FineLine 260PC User s Manual Torch Consumables Stainless Steel Cutting H17 Plasma Figure 8 13 Torch Consumables Stainless Steel Cutting H17 Plasma Parts List FineLine 260PC User s Manual Torch Consumables Aluminum Cutting zle Swirl Ring Electrode Torch body Figure 8 14 Torch Consumables Aluminum Cutting Parts List FineLine 260PC User s Manual Torch Consumables Marking Outer Cap Shield Cap Retaining Cap Nozzle Swirl Ring Electrode Torch body 277145 277152 277120 277140 277190 277000 Figure 8 15 Torch Consumables Marking Parts List FineLine 260PC User s Manual Automatic Gas Console Assembly 260000 Note See Figures 8 16 and 8 17 Item Number Part Number Quantity Description 1 500032 1 AGC decal membrane switch 2 501146 1 AGC aluminum display panel 3 500860 1 AGC display window 4 710199 4 Aluminum standoff 5 500861 1 AGC EL display 6 706044 1 Transformer 241 7 16 7 500568 1 Fan 8 501147 1 Fan guard filter 9 709003 2 Receptacle 9 position 10 700404 1 Filter bracket 11 702037 5 Filter 1
140. s PS PRESS F3 TO CHANGE CURRENT MODE CURRENT InnerLogic Inc Figure 5 1 Altering the Current Set Point 5 1 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Setting the Pierce Delay Time After the FineLine cutting arc transfers to the workpiece a motion signal ok to move signal is sent to the x y controller or torch height control The time delay between arc transfer and the motion signal output can be adjusted with the Pierce Delay Time parameter The pierce delay is usually adjusted so the arc fully penetrates the plate before the motion output signal is generated Depending on the status of the Default Delay parameter see below a default pierce delay time can be automatically retrieved after a material type and thickness are entered or the delay time can be entered manually To alter the pierce delay time use the arrow keys to scroll to Pierce Delay Time The pierce time should be highlighted as shown in Figure 5 2 and the editing cursor should be blinking Use the numerical keypad to enter the desired pierce delay time Note that the units are in milliseconds 1000 milliseconds 1 second Use the CLR key to backspace if an error is made When the correct value has been entered press ENT Note that the maximum allowable pierce delay time is 5000 milliseconds 5 seconds PREFLOW SUBSTANCE MILD STEEL HOT GAS AIR THICKNESS 0 125 inches psi 022 0 PROCESS CUTTING T TORCH PARTS BAS OX
141. s are subject to damage if over tightened Air Inlet 4 e Air must be supplied to the unit at all times regardless of the cutting current or material type Oxygen Inlet Q2 e Oxygen must be supplied to the unit when mild steel is being cut Nitrogen Inlet 3 Nitrogen must be supplied to the unit when aluminum is being cut or stainless steel is being cut at 50 70 100 150 200 or 260 amps Auxiliary Inlet e The auxiliary inlet is reserved for future use POSTFLOW PLASMA SHIELD PREFLOW AUXILIARY NITROGEN AR o iit i 4 4 A 4 4 4 e q 4 Figure 3 6 Automatic Gas Console Input Connections 3 13 Installation Automatic 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 3 Connect the Preflow Hose to the preflow outlet as shown Note that the preflow outlet has left hand threads Shield Outlet e Connect the Shield Hose to the shield outlet as shown Note that the shield outlet has right hand threads Plasma Outlet e Connect the Plasma Hose to the plasma outlet as shown Note that the plasm
142. s were negative Page 4 of 8 Propylene Glycol MSD FineLine 260PC User s Manual Product Name Propylene Glycol Industrial Grade Issue Date 03 02 2006 12 Ecological Information CHEMICAL FATE Data for Component Propylene glycol Movement amp Partitioning Bioconcentration potential is low BCF less than 100 or log Pow less than 3 Potential for mobility in soil is very high Koc between 0 and 50 Given its very low Henry s constant volatilization from natural bodies of water or moist soil is not expected to be an important fate process Henry s Law Constant H 1 2E 8 atm m3 mole Measured Partition coefficient n octanol water log Pow 0 92 Measured Partition coefficient soil organic carbon water Koc lt 1 Estimated Persistence and Degradability Material is readily biodegradable Passes OECD test s for ready biodegradability Biodegradation may occur under anaerobic conditions in the absence of oxygen Indirect Photodegradation with OH Radicals Rate Constant Atmospheric Half life Method 1 28 11 cm3 s 10h Estimated OECD Biodegradation Tests Biodegradation Exposure Time Method 81 28d OECD 301F Test 95 8 96 64d OECD 306 Test Biological oxygen demand BOD BOD5 BOD 10 BOD 20 BOD 28 69 96 70 96 86 Chemical Oxygen Demand 1 53 mg mg Theoretical Oxygen Demand 1 68 mg mg ECOTOXICITY Data for Component Propylene glycol Material is practically non
143. si psi volts ipm in in msec in 050 135 180 050 080 063 25 74 19 1 138 140 065 100 100 082 080 143 90 075 085 Metric Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 15 137 3870 15 2 1 25 74 19 1 25 100 2 0 142 2360 1 8 22 1 Revised on 7 2 07 4 34 Operation FineLine 260PC User s Manual Aluminum Cutting 70 Amps Air Plasma Nitrogen Shield Outer Cap Shield Cap 277150 Nozzle 277125 a D Electrode 277131 Retaining Cap Swirl Ring Torch Main Body 277154 277153 277142 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 080 130 250 050 100 080 1 8 135 160 070 100 3 16 145 80 100 125 25 80 25 2 085 1 4 150 50 060 150 200 3 8 155 40 075 175 300 090 1 2 162 30 ALS 200 400 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm
144. stem 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 e Never attempt to repair compressed gas cylinders e Keep compressed gas cylinders away from intense heat sparks or flames 1 3 Safety FineLine 260PC User s Manual e Clear the compressed gas cylinder connection point 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 pressur
145. sure for zero ohms between the braided shield and the ground 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 D 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 2 e Connect the 14AWG Torch Nozzle Lead to the angled bracket on the red standoff Torch CTP Sensor Lead 3 e Connect the 18AWG Torch CTP Sensor Lead to the red standoff as shown 3 8 Installation FineLine 260PC User s Manual 0000 Figure 3 4 Torch Leads to RHF Console Connections Installation FineLine 260PC User s Manual Torch Connections Perform the following steps to connect the torch leads and gas hoses to the torch 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
146. tainable 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 Safety FineLine 260PC User s Manual 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 749 1 Safety in Welding Cutting and Allied Processes obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 7 ANSI Standard 741 1 Standard For Men s Safety Toe Footwear obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 8 ANSI Standard 749 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 2 Street New York
147. talled and used in accordance with the information below if electromagnetic compatibility is to be achieved Plasma cutting equipment is primarily intended for use in an industrial environment There may be potential difficulties in ensuring electromagnetic compatibility in other environments Installation and Use The user is responsible for installing and using the plasma cutting equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the plasma cutting equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the plasma cutting circuit see Note In other cases it could involve constructing an electromagnetic screen enclosing the plasma power source and the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer troublesome Note The plasma cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel plasma cutting current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC 974 13 Arc welding equipment Installation and use Electrom
148. tem switch to the View Serial Communication Screen to view incoming and outgoing data See Section 5 for information on the Serial Communication Screen Serial Communication Note RS 422 Serial Commands FineLine 260PC User s Manual In the following commands represents the net node of the power supply that is to receive the command To send a global command to all power supplies in a network configuration nn should be set to C8 hex 200 decimal The in the hex string is the MSB followed by the LSB of a type int The integer is the value found in the additional information column Command Set Material Type Set Thickness Set Operating Current Set Pierce Delay Set Preflow Pressure Set Plasma Gas Type Set Plasma Pressure Set Shield Gas Type Set Shield Pressure 10 Hex String AA nn FA 01 00 0D AA nn FA 02 0D AA nn FA 03 00 0D AA nn FA 04 0D AA nn FA 06 0D AA nn FA 07 00 0D AA nn FA 08 0D AA nn FA 09 00 0D AA nn FA 0D 6 4 Additional Information 00 Mild Steel Hot Rolled 01 Stainless Steel 02 Aluminum 03 Other 04 Mild Steel Cold Rolled Thickness in mils inches x 1000 Valid Range 0 to 2000 012 30 Amps Cutting 02 50 Amps Cutting 032 70 Amps Cutting 04 100 Amps Cutting 05 2 150 Amps Cutting 06 200 Amps Cutting 072 8 Amps Marking 08 9 Amps Marking 09
149. 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 5 Always use the error tracking feature on the automatic gas console to keep track of cut errors See Section 5 for information on the error tracking feature Operation Cutting Charts FineLine 260PC User s Manual 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 vol age 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 Page Mild Steel Cutting 30 Amps Oxygen Oxygen 4 14 Mild Steel Cutting 50 Amps Oxygen Oxygen or Air 4 15 Mild Steel Cutting 70 Amps Oxygen Air 4 16 Mild St
150. 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 FineLine system DC Power Indicator Illuminates when then main contactor has been energized and D C current is flowing through the torch Status Indicators 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 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 Operation FineLine 260PC User s Manual 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
151. 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 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 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 gt Consumable Life Use the following guidelines to maximize consumable parts life 1 Use the recommended pierce height given in the cutting charts A pierce height that is too low will allow molten metal that is ejected during the piercing process to damage the shield cap and nozzle A pierce height that is too high will cause the pilot arc time to be excessively long and will cause nozzle damage 2 Make sure
152. the operator and other people around the equipment It is management s responsibility to see that the following safety information is provided to each person who will operate observe perform maintenance or work in close proximity to this piece of equipment Installation as well as repairs made to the FineLine 260PC system should only be performed by qualified personnel The FineLine 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 FineLine 260PC system generates high noise levels while cutting Depending on the size of the cutting area distance from the cutting t
153. 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 7 6 Maintenance and Troubleshooting FineLine 260PC User s Manual Troubleshooting Using the Automatic Gas Console Messages Screen If all of the status LED s are illuminated but the FineLine system still has a problem switch to the messages screen on the automatic gas console see Section 5 for specific instructions on switching to the messages mode The gas console may display information that is useful in pinpointing the problem While the automatic gas console is displaying an error message the power supply microprocessor 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 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 3 TAC lost during current slope down 6 Start signal applied prematurely 7 Start signal removed prematurel
154. the torch handle 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 left hand threads 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 Q9 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 3 11 Installation FineLine 260PC User s Manual Figure 3 5 Torch Connections Installation FineLine 260PC User s Manual Automatic 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 fitting
155. to the first previous errors position The data that was in the first previous errors position will move to the second previous errors position and so on PIERCES 44 ERRORS 8 PERCENT ERROR 2 1 PIERCES 1216 ERRORS 12 PERC 2 0 0 R FARU ERRORS 0 PER 0 0 R 0 R ES ERCES ES ERRORS 0 PE FINELINE 260PC PRESS F3 TO VIEW ERRORS PRESS CLR RESET COUNT PRESS ANY OTHER KEY TO RETURN TO THE MAINTENANCE MENU CURRENT MODE CUT ERRORS InnerLogic Inc Figure 5 9 Cut Errors Screen 5 9 Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Selecting an Error Set to View When the cut errors screen is being displayed press F3 to view the actual cut errors When F3 is pressed the error selection screen is displayed as shown in Figure 5 10 Use the arrow keys to scroll to the error set that is to be viewed and press ENT ERROR MENU EW PRESENT ERRORS PREVIOUS ERRORS 1 EI PREVIOUS ERRORS PRE Me 2 z PREVIOUS ERRORS 3 9 PREVIOUS ERRORS 4 Ly PREVIOUS ERRORS 5 lt PRESS MENU THEN crows RETURN TO STATUS SCREEN a PRESS ENT TO SELECT AN OPTION FROM THE MENU CURRENT MODE CUT ERRORS InnerLogic Inc Figure 5 10 Error Selection Screen Automatic Gas Console Advanced Functions FineLine 260PC User s Manual Viewing Actual Errors
156. utions Prevent from entering into soil ditches sewers waterways and or groundwater See Section 12 Ecological Information Handling and Storage Handling General Handling Product handled hot may require additional ventilation or local exhaust Other Precautions Spills of these organic materials on hot fibrous insulations may lead to lowering of the autoignition temperatures possibly resulting in spontaneous combustion Storage Store away from direct sunlight or ultraviolet light Keep container tightly closed when not in use Store in a dry place Protect from atmospheric moisture Store in the following material s Stainless steel Aluminum Plasite 3066 lined container 316 stainless steel Opaque HDPE plastic container Shelf life Use within Maximum storage temperature 12 0 Months 40 C Exposure Controls Personal Protection Exposure Limits Component List Type Value oues glycol WEEL TWA 10 mg m3 Aerosol Personal Protection Eye Face Protection Safety glasses should be sufficient for most operations however for misty operations wear chemical goggles Skin Protection No precautions other than clean body covering clothing should be needed Hand protection Chemical protective gloves should not be needed when handling this material Consistent with general hygienic practice for any material skin contact should be minimized Respiratory Protection Atmospheric levels should be maintained below the ex
157. vised on 7 2 07 4 31 Operation FineLine 260PC User s Manual Stainless Steel Cutting 275 Amps Air Plasma Nitrogen Shield This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277263 277276 277270 22 LD 4 D m Q D XZ Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277266 277258 277000 Imperial Material Preflow Plasma Shield Postflow Are Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width in psi psi psi psi volts ipm in in msec in 1 2 143 120 125 250 400 165 5 8 148 90 140 275 600 i 3 4 152 80 180 300 800 20 93 70 0 170 1 0 165 55 210 1000 125 175 35 250 325 400 180 155 185 25 300 Edge start moving pierce recommended Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 12 141 3220 31 6 2 400 42 16 148 2275 3 6 7 0 800 20 153 1940 47 77 20 93 70 0 1000 4 3 25 164 1435 5 2 82 22 175 880 6 4 83 400 4 6 38 184 640 735 Edge start or moving pierce recommended 1 Revised on 7 2 07 4 32
158. y 8 Output voltage below 60V 9 Output voltage above 210V 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 Maintenance and Troubleshooting General Troubleshooting FineLine 260PC User s Manual The following chart lists general troubleshooting guidelines for the FineLine system when the status LED s or the automatic gas console messages screen 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 of the control fuses are located behind the front panel of the unit beside the microprocessor p c board The automatic gas console fuse is located behind the right side panel of the system Also check all of the voltage LED s on the system p c boards before performing any tests Problem Front panel white A C power light will not illuminate Unit will not energize when the ON button is pressed Power supply will not stay on whe
159. zardous Substance 40 CFR 355 Appendix A To the best of our knowledge this product does not contain chemicals at levels which require reporting under this statute California Proposition 65 Safe Drinking Water and Toxic Enforcement Act of 1986 This product contains no listed substances known to the State of California to cause cancer birth defects or other reproductive harm at levels which would require a warning under the statute US Toxic Substances Control Act All components of this product are on the TSCA Inventory or are exempt from TSCA Inventory requirements under 40 CFR 720 30 CEPA Domestic Substances List DSL All substances contained in this product are listed on the Canadian Domestic Substances List DSL or are not required to be listed European Inventory of Existing Commercial Chemical Substances EINECS The components of this product are on the EINECS inventory or are exempt from inventory requirements 16 Other Information Product Literature Additional information on this and other Dow products may be obtained by visiting our web page at www dow com Hazard Rating System NFPA Health Fire Reactivity 0 1 0 Recommended Uses and Restrictions Dow recommends that you use this product in a manner consistent with the listed use If your intended use is not consistent with Dow s stated use please contact Dow s Customer Information Group Chemical intermediate e g for manufacture of polyester resins Solvent

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