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FineLine 200PC High Density Plasma Cutting System

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1. 5 1 1 1 Mle ces et o Figure 3 3 Power Supply Output Connections 3 7 Installation FineLine 200PC 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 measure for zero ohms between the braided shield and the ground stud located on the outside of the RHF console
2. 8 28 Appendix A Propylene Glycol MSDS 22 1 Appendix B Electromagnetic Compatibility 1 Background eseeton nooner ie B 1 SACCO a ae B 1 ASSESSMENT OF ATCA a B 2 Methods of Reducing Emissions re ANNA E Oeo B 2 Appendix C Hydrogen Manifold 1 DESCHDUOB 1 SPCCINCAM odd 1 WMS tA AMON eda eie aes ue fad C 2 Op ration C 4 wi arp C C 5 Hydrogen Manifold Microprocessor P C Board C 6 fou 7 Illustrations Figure 2 1 Power Supply Dimensions 2 3 Figure 2 2 Remote High Frequency Console Mounting Dimensions 2 5 Figure 2 3 Figure 3 1 Figure 3 2 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 Figure 5 10 Figure 5 11 Figure 5 12 Figure 5 13 Figure 5 14 Figure 5 15 F
3. 6 1 Transmitting Parameters to the FineLine System eeeseeeeeeeeeenenenenenn 6 1 Communication Error Checking eg eoe er dt GN ENSE tak ae Res ege aua 6 2 D fault C tt ne Parameters oou modena tas d eunt ahi UE 6 2 Troubleshooting Serial Communication esses enne 6 3 RS 172 Serial CODnimands ui d otn cadi aitas 6 4 Section 7 Maintenance and Troubleshooting 7 1 Routine Maaimlenalnce 7 1 Replacing the Torch Coolant 7 3 230 460 60 Hz Transformer Configurations essere nennen nennen 7 4 MicroprocessorStatus LED Poi le vene edi vec 7 6 Microprocessor Sequence Of Operation 7 7 Troubleshooting Using the Control Panel Status LED S esse 7 8 Troubleshooting Using the Automatic Gas Console Messages Screen 7 9 General Troubleshooting restent o Rua en Ra nn UNUS STR LUE Pa Ree 7 10 FineLine 200PC User s Manual Choppet 7 12 Section Parts List oerte E 8 1 PO W
4. PNG ji d ii Figure 8 2 Power Supply Rear View 8 4 Parts List FineLine 200PC User s Manual o 9lo o glo Li 7 Figure 8 3 Power Supply Left Side View 8 5 Parts List FineLine 200PC User s Manual Figure 8 4 Power Supply Right Side View 8 6 Parts List Fine
5. 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 in psi psi psi psi volts pm in Gn msec Gn 080 130 250 050 1100 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 30 115 200 400 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 mm msec mm 2 129 6400 12 2 5 100 2 0 3 134 4420 1 7 5 145 1920 2 3 3 2 25 80 25 2 200 2 2 6 148 1440 1 7 3 6 10 156 975 2 0 4 5 400 2 3 12 160 820 2 6 4 9 1 Revised on 7 2 07 4 32 Operation FineLine 200PC User s Manual Aluminum Cutting 100 Amps Air Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277286 277284 277282 gt lt D 22 Retaining Cap Swirl Ring Torch Main Body 217154 217151 217283 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 pm in
6. 3 3 Primary Power 3 3 3 5 Console Ground Connection 3 6 Torch Leads to RHF Console Connections m eene 3 8 Torch Connections sacs oe op dV Ver Eu eae ed 3 10 Automatic Gas Console Input Connections 22 222 707004 4 3 13 Automatic Gas Console Output Connections 2 2 2 3 14 CNC Machine Interface Connections 3 15 Torch Coolant Requirements basen sus EN REO 3 15 Filling the Lorch Coolant Reservoir acess aged 3 17 Section 4 Operation 4 4 1 Power Supply Front Panel Controls oe der tro sien ERE PARA EE 4 Automatic Gas Console Keypad 4 3 Automatic Gas Console Help Prompt 2 4 4 Automatic Gas Console Status Screen 2 4 4 4 5 FineLine 200PC User s Manual 4 5 Waking Dre 4 11 Cut Quality 4 11 Consumable 4 12 Sri NE 4 13 Section 5 Automatic Gas Console Advanced Functions
7. Edge start or moving pierce recommended 1 Revised on 7 2 07 4 18 Operation FineLine 200PC User s Manual Mild Steel Cutting 200 Amps Oxygen Plasma Air Shield Shield Cap Nozzle Electrode 277274 277289 277291 59 Retaining Cap Swirl Ring Torch Main Body 271154 271266 271143 2771000 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 pm in Gn msec Gn 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 50 175 1000 155 1 25 155 25 240 350 1400 1 5 165 17 300 158 115 175 12 350 300 400 2 0 185 7 500 160 Edge start or 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 6 124 6100 8 5 0 300 10 130 3480 2 3 5 8 3 8 500 12 132 3160 2 7 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 6
8. Shield Cap Nozzle Electrode 277149 277123 277137 1 9 S f 9 c 67 22 Retaining Cap Swirl Ring Torch Main Body 217154 217110 217142 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 Gn 14 075 87 105 12 105 88 75 105 035 060 100 11 120 89 65 30 70 40 4 10 435 90 55 110 3 16 94 50 040 075 200 4 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 2 5 2080 9 1 5 100 2 7 3 30 70 40 4 88 1685 5 94 1235 1 0 1 9 2 8 300 6 98 1075 1 3 2 1 2 9 1 Revised on 7 2 07 4 2 Operation FineLine 200PC 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 Nozzle Electrode Outer Cap Retaining Cap Swirl Ring Torch Main Body 217154 217113 217140 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen 17 Nitrogen Nitrogen Voltage Speed Height Heigh
9. 1 US ino Ore UE D m 16 inp 10 5 2 5 BLANK PCB P N 500809 REV 0 ASSEMBLY P N 500810 Figure 8 19 A C Detect P C Board 8 23 FineLine 200PC User s Manual Parts List Relay P C Board Assembly 500348 c R6 R8 KS ILK1 K7 LEVEL PRESSURE Ke K6 TEMPERATURE 1 1 O R4 TP2 1 R9 TP1 VR1 896006 N d 559 0 AAJ 00 N d 82d JANYA Figure 8 20 Relay P C Board 8 24 Parts List FineLine 200PC User s Manual Power Supply I O P C Board Assembly 277452 8 WE 4054 R9 ELECTRODE NOZZLE SHUNT POS WORK GROUND SHUNT NEG O e gt INNERLLDGIC INC BLANK PCB P N 200351 REV 0 ASSEMBLY P N 200352 Figure 8 21 Power Supply I O P C Board FineLine 200PC User s Manual Parts List Automatic Gas Console I O P C Board Assembly 201080 CECE ve Ud 31 588 g 5 5 EADW 080106 N d ATAWISSY 610106 N d 834 O 19 5 2 55 210180 10140 010140 60190 80140 40180 9110 o ele le le le loe loe o om ome 90190 50180 0190 50190 10190 gt llo 5
10. Command Hex String Additional Information Set Material Type 1 AA mn FA 01 00 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 transmitted to switch the material type to stainless steel for a FineLine system on node 1 AA 01 FA 01 00 0100 6 1 Serial Communication FineLine 200PC 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 AA nn FA 04 0D Time in mS seconds 1000 Valid range 0 to 5000 Once agai
11. Hydrogen Manifold Optional FineLine 200PC 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 connected 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 St ck N MDeT 200535 a a 5 3 in 135 mm bor MM 10 1 in 257 mm Depth p 9 5 in 241 mm aR 12 15 5 4 kg 9 5 241 2 1 4 20 PRESS NUTS amp 5 3 135 Figure C 1 Hydrogen Manifold Mounting Dimensions C 1 Hydrogen Manifold Optional FineLine 200PC User s Manual Gas Supply Requirements Inlet uds Yes benc T Mu H17 Inlet gas flow rate maximum 57 scfh 1614 liters hour Inlet gas Pressures 150 psi 10 3 bar H17 consists of 17 5 hydrogen 32 5 argon and 50 nitrogen 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 disconne
12. Torch Electrode Coolant Supply Lead 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 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 200PC User s Manual 10 11 13 Figure 3 4 Torch Leads to RHF Console Connections 3 9 Installation FineLine 200PC 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 the Torch Solenoid Control Cable from the power supply to the torch station Note that the Shield Gas Hose extends down inside the torch handle so it should be
13. 505599 RO ASSEMBLY PN 505600 P4 KEYPAD B z a B32 A32 Figure 8 23 Automatic Gas Console Interface P C Board 8 27 Parts List FineLine 200PC User s Manual Consumable Spare Parts Kit Part Number 282267 Part Number Quantity Description 271130 3 Electrode 30A Mild Steel Aluminum 211137 2 Electrode 30 504 Stainless Air 277131 6 Electrode 50 70A Mild Steel 70A Stainless Air 50 704 Aluminum 271132 2 Electrode 70A Stainless H17 271282 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 271135 2 Electrode 150 200 Stainless H17 277120 5 Nozzle 30A Mild Steel 30A Aluminum 277121 3 Nozzle 30A Stainless Air 277122 5 Nozzle 50A Mild Steel 50 Aluminum 277123 3 Nozzle 50A Stainless Air 277125 5 Nozzle 70A Mild Steel 70A Stainless Air 70A Aluminum 277124 3 Nozzle 70A Stainless H17 271284 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 277289 5 Nozzle 200A Mild Steel 200A Stainless Air 200A Aluminum 8 28 Parts List Part Number 271287 277145 277144 277149 277115 277150 2
14. Board Lies EH RUE RES 8 25 Automatic Gas Console P C Board 2 8 26 Automatic Gas Console Interface P C Board 8 27 Hydrogen Manifold Mounting Dimensions eere C 1 Hydrogen Manifold Mounting Location eere C 3 Hydrogen Manifold Microprocessor P C Board C 6 This page intentionally left blank Safety FineLine 200PC 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 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 200PC 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 protecte
15. Optional FineLine 200PC 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
16. CNC Machine Travel Speed Torch Body Part Number msw Torch Body Part Number 15 Torch Electrode Part Number msw Torch Electrode Part Number 15 Torch Swirl Ring Part Number msw Torch Swirl Ring Part Number Isw Torch Nozzle Part Number msw Torch Nozzle Part Number 15 Torch Retaining Cap Part Number msw Torch Retaining Cap Part Number Isw 13 15 16 17 18 19 20 21 22 23 24 25 Hex String nn FA OC OD nn FA OD 0D nn FA OF 0D AA nn FA 10 0D nn FA 11 00 AA nn FA 12 0D AA nn FA 13 0D AA nn FA 14 0D AA nn FA 15 0D AA nn FA 16 0D AA nn FA 17 0D AA nn FA 18 0D AA nn FA 19 0D 6 5 FineLine 200PC User s Manual Additional Information If requested in command 30 the will transmit the recommended pierce height in mils inches x 1000 Range 0 to 999 If requested in command 30 the will transmit the recommended cutting height in mils inches x 1000 Range 0 to 999 If requested in command 30 the will transmit the recommended travel speed in inches per minute Range 0 to 999 If requested in command 30 the will transmit the most significant word of the torch body part number If requested in command 30 the will transmit the least significant word of the torch body part number If r
17. 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 reinstall the plug 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 Maintenance and Troubleshooting FineLine 200PC 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 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 bee
18. Oxygen Oxygen Air Voltage Speed Height Height Delay Width ga in psi psi psi psi volts pm in in msec Gn 12 105 123 70 120 075 11 120 25 74 12 1 126 60 125 135 100 078 10 135 128 50 135 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 Gn msec Gn 14 075 200 075 12 1105 106 190 4100 1135 100 1125 180 25 74 19 1 080 10 1135 110 170 4110 3 16 113 105 145 200 085 1 4 117 75 165 250 087 Metric Cold Rolled Steel Oxygen Shield Swirl Ring 277140 Material Preflow Plasma Shield Postflow 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 2 5 121 1895 2 9 1 9 25 74 12 1 3 4 100 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 m
19. 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 200PC PRESS F3 TO CHANGE SYSTEM DF MEASUREMENT PRESS ENT TO RETURN TO THE MAINTENANCE MENU CURRENT MODE MEASUREMENT SYSTEM InnerLogic Inc Figure 5 15 Measurement System Selection Screen 5 16 Automatic Gas Console Advanced Functions FineLine 200PC 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 displayed as shown in Figure 5 16 Press 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 200PC PRESS F3 SELECT THE PROPER NODE NUMBER PRESS ENT TO RETURN TO THE MAINTENANCE MENU CURRENT MODE COMMUNICATION NODE InnerLogic Inc Figure 5 16 Communication Node
20. or has other signs of physical damage gas cylinders should be secured to a wall or rack to prevent accidental knock over e If a compressed gas cylinder is not being used replace the protective valve cover Never attempt to repair compressed gas cylinders Keep compressed gas cylinders away from intense heat sparks or flames 1 3 Safety FineLine 200PC User s Manual Clear the compressed gas cylinder connection point by opening the valve momentarily prior to installing a regulator Never lubricate compressed gas cylinder valves or pressure regulators with any type of oil or grease e Never use a compressed gas cylinder or pressure regulator for any purpose other than which it is intended e Never use a pressure regulator for any gas other than which it is intended e Never use a pressure regulator that is leaking or has other signs of physical damage e Never use oxygen hoses and pressure regulators for any gas other than oxygen e Never use any gas hose that is leaking or has other signs of physical damage Health Support Equipment The FineLine 200PC 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 ma
21. psi psi psi volts ipm in in msec in 1 4 145 150 160 225 400 125 3 8 150 115 180 538 500 1 2 25 75 70 0 155 85 210 600 130 5 8 160 60 220 500 800 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 7 0 600 12 25 75 70 0 153 2330 5 1 33 16 160 1510 5 6 7 6 1000 20 170 1030 6 2 3 4 H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen 1 Revised on 7 2 07 4 27 Operation FineLine 200PC 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 9 5 5 0 0 Outer Cap Retaining Cap Swirl Ring Torch Main Body 271154 271266 271259 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen H17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width Gn psi psi psi psi volts in Gn msec Gn 3 8 156 80 195 250 300 150 1 2 148 75 130 T 500 5 8 37 68 85 13 155 60 190 700 155 3 4 160 50 200 300 9
22. psi volts mm m mm mm msec mm 1 135 3885 1 6 1 7 30 92 20 2 0 8 100 1 5 135 2520 2 1 1 8 1 Revised on 7 2 07 4 30 Operation FineLine 200PC User s Manual Aluminum Cutting 50 Amps Air Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277150 277122 277131 Retaining Cap Swirl Ring Torch Main Body Outer Cap 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 in psi psi psi psi volts pm in Gn msec Gn 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 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 5 137 3870 t5 2 1 25 74 19 1 2 5 100 2 0 142 2360 1 8 2 2 1 Revised on 7 2 07 4 31 Operation FineLine 200PC User s Manual Aluminum Cutting 70 Amps Air Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277150 277125 277131 Outer Cap Retaining Cap Swirl Ring Torch Main Body
23. returned goods shall be at the buyer s risk and expense Beyond this remedy KALIBURN will not be responsible for any special incidental or consequential damages or injury to the person or property of anyone by reason of any defect in any equipment sold hereunder This warranty will be considered void if torches or torch consumables manufactured by anyone other than KALIBURN are incorporated into this product Returned Goods Procedure KALIBURN utilizes a returned goods procedure that must be followed before returning any items for repair replacement or restocking This means that a returned goods authorization number must be obtained prior to shipment to KALIBURN It will be necessary for the customer to provide a description along with the stock number and serial number if applicable of the item to be returned In no case will KALIBURN accept a returned shipment without the proper returned goods authorization number FineLine 200PC User s Manual Electromagnetic Compatibility EMC The 380V 50Hz and 415V 50Hz FineLine 200PC plasma cutting systems are manufactured to comply with the European standards EN 60974 Arc welding equipment Part 1 Welding power sources and EN 50199 Electromagnetic compatibility EMC Product standard for arc welding equipment Information about the EMC standard EN 50199 can be found in Appendix B FineLine 200PC User s Manual TABLE OF CONTENTS Section 1 Safety D E EC S es 1 1 Gener
24. 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 Connect the Torch Electrode Coolant Supply Lead to the torch as shown Torch Coolant Return Lead 9 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 2 e Connect the Torch Nozzle Lead to the torch as shown Torch CTP Sensor Lead 3 e Connect the Torch CTP Sensor Lead to the torch shown Shield Gas Hose e Connect the Shield Gas Hose to the torch as shown Torch Plasma Gas Hose 15 e Connect the Torch Plasma Gas Hose to the torch as shown 3 10 Installation FineLine 200PC 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 the torch handle Torch Plasma Gas Hose Connect the Torch Plasma Gas Hose to the soleno
25. 14 socket receptacle P7 4 pin receptacle P16 9 socket receptacle F1A F1B fuse holder FIA FIB fuse FNM 6 25A Strain relief A C detect p c board assembly Coolant reservoir without fittings or cap Coolant reservoir assembly with fittings and cap Coolant reservoir cap level gauge LS1 coolant level switch TS1 Coolant temperature switch Pump motor 1 3hp 230V 50 60 Hz V band clamp 8 1 Parts List FineLine 200PC User s Manual Item Number Part Number Quantity Description 37 38 39 40 4l 42 43 44 45 46 47 48 49 50 5 52 53 54 55 56 57 58 39 61 62 63 64 65 66 67 68 69 12 73 74 75 76 77 78 79 80 81 82 83 500511 708061 715084 708068 708059 500516 5005 14 200103 500509 500510 708110 500348 702048 708011 701165 500536 705011 709 167 702054 217452 Contact factory 200361 709117 708106 706036 706041 706042 706043 280003 708103 708104 708105 709190 709191 740106 704050 200204 715052 500526 709228 709227 709231 500525 701141 1 e e e e e a a NOR Ne ND RB DO amp eme ik NR NR Coolant pump 70 gph Solenoid valve 220 240VAC Check valve coolant return CONG coolant pump relay FS1 coolant flow switch Fan heat exchanger front panel Heat exchanger Shunt Coolant filter housing Coolant filter deionization cartridge CON main contactor Relay p c board assembly EMI filter 380 415 V
26. 25th 174 940 5 0 400 4 3 Edge start or moving pierce recommended 1 Revised on 7 2 07 4 35 Operation FineLine 200PC User s Manual Mild Steel Marking 10 Amps Nitrogen Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277145 277120 277190 91 Retaining Cap Swirl Ring Torch Main Body 217154 217152 217140 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 Gpm in in msec All Thicknesses 25 25 20 2 120 150 050 050 0 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 Thicknesses 25 25 20 2 120 3810 1 3 1 3 0 1 Revised on 7 2 07 4 36 Operation FineLine 200PC User s Manual Stainless Steel Marking 8 Amps Nitrogen Plasma Nitrogen Shield Shield Cap 277145 Nozzle 271120 Electrode 271190 a D lt Retaining Cap 97 Torch Body Swirl Ring 217154 217152 217140 277000 Imperial Material
27. 8 FineLine 200PC User s Manual Description 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 200A Mild Steel 200A Stainless 200A Aluminum O ring Lubricant Torch 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 8 30 Glycol MSDS FineLine 200PC User s Manual Appendix A Propylene Glycol MSDS 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 TEL
28. Altering Arc Voltage Control and X Y Machine Parameters 5 5 Automatic Gas Console Advanced Functions FineLine 200PC 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 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 later in this section PREFLOW SUBSTANCE MILD STEEL HOT GAS AIR 2 THICKNESS 0 125 inches pst 025 0 PROCESS CUTTING 7 TORCH PARTS E CURRENT SET POINT 50 5 DELAS GAS OXYGEN y PIERCE DELAY TIME 0000 ms PSE 005 0 PRESS F3 SAVE SETTING FOR 0 125 in MILD STEEL HOT CURRENT MODE STATUS InnerLogic Inc Figure 5 6 User Created Cutting Conditions Gas Purge The gas lines can be pur
29. 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 1 5 Safety FineLine 200PC User s Manual 16 CGA booklet P 14 Accident Prevention in Oxygen Rich and Oxygen Deficient Atmospheres obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 17 CGA booklet TB 3 Hose Line Flashback Arrestors obtainable from the Compressed Gas Association 1725 Jefferson Davis Highway Suite 1004 Arlington VA 22202 18 CSA Standard W117 2 Safety in Welding Cutting and Allied Processes obtainable from Canadian Standards Association 178 Rexdale Boulevard Toronto Ontario MOW IR3 Canada 19 Canadian Electrical Code Part 1 Safety Standard for Electrical Installations obtainable from the Canadian Standards Association 178 Rexdale Boulevard Toronto Ontario 1R3 Canada 1 6 Specifications FineLine 200PC User s Manual Section 2 Specifications System Description The FineLine 200PC is a microprocessor controlled 200 amp 10096 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 200PC is equipped with a computer controlled automatic gas console with VGA display All cutting parameters are contro
30. Gas 5 3 Altering Gas Pressures 25 ts dre Iu S eas 5 4 Altering Arc Voltage Control and X Y Machine Parameters 5 5 User Created Curing eset om b Pee P eid eg 5 6 Maintenance ee 5 7 Message 5 8 Cut Errors SCRE CD ee pi odi Edi ome qn UE 5 9 Error Selection 5 10 75151111 Cut Errors 5 11 Pressure Diagnostics Screen 5 13 Default Pierce Delay SCree ml qu nere p rt 5 14 Restore Factory Defaults Screen 5 15 Measurement System Selection Screen 5 16 Communication Node Selection Screen essere 5 17 Parameter Transmit Screen aise oceso tenebo eate 5 18 View Serial Communication Screen 5 19 Configure Hydrogen Manifold Screen sese 5 20 Set Arc Off Delay Screen i uiscera e UR DES 5 21 230V 60 Hz Transformer Configuration esee 7 5 460V 60 Hz Transformer Configuration 12 004 7 5 Chopper Diagnostics Part 1 7 14 Chopper Diagnostics Patt 7 15 POWER Supply Front 8 3 Power Supply Rear View c 8 4 Power Supply
31. Gn msec Gn 1 4 145 105 155 200 200 095 3 8 25 94 26 0 156 90 180 250 300 098 1 2 157 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 4 400 2 5 12 156 1890 4 9 6 8 1 Revised on 7 2 07 4 33 Operation FineLine 200PC User s Manual Aluminum Cutting 150 Amps Air Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277293 277292 1 4 S f 9 c 6 7 SL 4 e 226 Retaining Cap Swirl Ring Torch Main Body 217154 217152 217139 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 pm in in msec Gn 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 Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Height Delay Width mm psi psi psi psi
32. Left Side VIEW 8 5 Power Supply Right Side View sscsicisccosdaavacsivasezsseseasscetaesedeusteavecadcessetevancis 8 6 Figure 8 5 Figure 8 6 Figure 8 7 Figure 8 8 Figure 8 9 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 200PC User s Manual Remote High Frequency Consoles s coop et 8 8 Torch and Torch Valve Assembly stetit qe 8 0 Shielded Torch Leads Me RR 8 10 8 11 Coolant and Power 8 12 Work Ground Cable estia I ie te Re EROR AA 8 13 Torch Consumables Mild Steel Cutting see 8 14 Torch Consumables Stainless Steel Cutting Air Plasma 8 15 Torch Consumables Stainless Steel Cutting H17 Plasma 8 16 Torch Consumables Aluminum Cutting eene 8 17 Torch Consumables Marking 8 18 Consoles Exterior 8 20 Gas C ns le e 8 21 Power Supply Microprocessor P C Board sese 8 22 AC Detect P C Board 8 23 Relay P C 5152105 adsessor 8 24 Power Supply IO
33. Main Body Outer Cap 217154 217151 277283 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 pm in Gn msec Gn 1 4 125 150 090 4125 150 3 8 130 100 4130 175 200 090 1 2 25 94 26 0 65 155 400 5 8 143 47 200 600 185 095 3 4 145 35 900 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 6 124 3950 2 1 3 0 150 10 2405 3 3 4 5 2 3 130 400 12 25 94 26 0 1850 37 4 9 16 143 1180 4 7 5 1 900 24 20 145 800 1 Revised on 7 2 07 4 17 Operation FineLine 200PC User s Manual Mild Steel Cutting 150 Amps Oxygen Plasma Air Shield Shield Cap 277117 Nozzle 277293 Electrode 277292 Torch Retaining Swirl Ring 271154 277151 277152 277139 277000 Imperial Retaining Cap 277
34. Parts List FineLine 200PC User s Manual 81 0 1504 PREFLOW 0 150 PSI m m Ec coy cl ro p V 955 9 lt S 0 150 2 65 POSTFLow 0 15 PSI oo BERE Ol Figure 8 17 Gas Console Interior 8 21 Parts List FineLine 200PC User s Manual Power Supply Microprocessor P C Board Assembly 200450 p30 iL r lc U2 m lg BE GOB RESET m ftor 4n _ ETN 682 3 OS om E ee3CO RD wl 181 ke 882 eva 055 ka en eva c c c c c c C o fol LEDI6 7 ens SV uP LEDI PVR START PAR LEDI7 LEDS Or uP cree R67 R69 LK NC PWR LEDe3 1523 PWR TAC G R61 7 es PLASMA PREFLOW LED24 MOTION TO SIAUM OW LEDI LEDI3 HOLD CURRENT IN R34 LED22 nd HDLD ERRUR DUT LEDIS MANUAL CONSOLE INNERLOGIC INC LED BLANK PCB P N 800349 REV2 R65 Osa ASSEMBLY P N 200350 FREQ Figure 8 18 Power Supply Microprocessor P C Board 8 22 Parts List FineLine 200PC User s Manual A C Detect P C Board Assembly 500810
35. 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 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 Thicknesses 25 25 20 2 125 3810 1 3 1 3 0 Revised on 7 2 07 4 37 Operation FineLine 200PC User s Manual Aluminum Marking 10 Amps Nitrogen Plasma Nitrogen Shield Shield Cap 277145 Nozzle 271120 Electrode 277190 a lt Retaining Cap 97 Torch Body Swirl Ring 217154 217152 217140 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 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 Thicknesses 25 25 30 2 12
36. 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 installed and used in accordance with the information below if electromagnetic compatibility is to be achieved Plasma cutting equipment is primarily intended for use in an industrial environment There may be potential difficulties in ensuring electromagnetic compatibility in other environments Installation and Use The user is responsible for installing and using the plasma cutting equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the plasma cutting equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be 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 C
37. User s Manual CNC Machine Interface Connections Perform the following steps to properly interface the FineLine 200PC system with a CNC cutting machine See the system schematic for additional information Plasma Start Signal e FineLine 200PC 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 200PC requires a contact closure between P8 pins 10 and 11 to inhibit arc starting even though a plasma start signal has been applied to the unit When the arc hold IHS complete contacts are opened the cutting arc is initiated This feature is used to decrease cycle time by allowing pre cut gas and contact sequencing to occur simultaneously with initial torch height positioning The contacts should be rated for 12VDC 10mA Motion Output Signal e The FineLine 200PC 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 2A 30VDC RS 422 Serial Communication Link e 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
38. 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 In animal studies did not interfere with reproduction Genetic Toxicology In vitro genetic toxicity studies were negative Animal genetic toxicity studies were negative Page 4 of 8 Propylene Glycol MSDS FineLine 200PC 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 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 Ha
39. 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 e High frequency starting circuit energized e Pilot arc initiation e Transferred arc cutting arc established e 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 the optimum cutting condition can be achieved on a particular material type and thickness the machine operator must have a thorough understanding of the cutting characteristics of the 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 A
40. 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 MILD STEEL HOT GAS AIR THICKNESS 0 125 inches psi 029 0 PROCESS CUTTING TORCH PARTS MEE psi 080 0 CURRENT SET POINT 50 AMPS 5 DELAY GAS OXYGEN 2 PIERCE DELAY TINE 0000 ms Pst 099 0 X PRESS TO CHANGE CURRENT MODE MATERIAL InnerLogic Inc Figure 4 7 Selecting Process 4 8 Operation FineLine 200PC 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 NOZZLE ELECTRODE 277145 277120 277130 OUTER CAP RETAINING CAP SMRL RING TORCH BODY 277194 277193 277140 277000 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 ins
41. lost during current slope down 6 Start signal applied prematurely 7 Start signal removed prematurely 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 7 9 Maintenance and Troubleshooting General Troubleshooting FineLine 200PC 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 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 illumin
42. 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 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 from corrosion Use a wire brush to clean the connection point if necessary 7 2 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 l 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 fro
43. 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 Verify that all torch lead and work ground connections are secure and free from corrosion Verify that the primary three phase A C voltage connections are tight Verify that all p c board connectors are installed securely Verify that the rear panel cable connectors are installed securely Verify that the 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 p ub 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
44. 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 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 W W 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 200PC 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 con
45. replace the microprocessor 11 Turn off primary power to the power supply Disconnect P2 from the chopper p c board and P26 from the microprocessor p c board Check continuity between P26 8 and 2 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 7 13 Maintenance and Troubleshooting FineLine 200PC User s Manual FUSES CORRECT AS NECESSARY YES CHECK CON1 AND WIRING CHOPPER OK SEE NEXT PAGE Figure 7 3 Chopper Diagnostics Part 1 7 14 Maintenance and Troubleshooting FineLine 200PC User s Manual FROM PREVIOUS PAGE 22 CHOPPER AND WIRING REPAIR ON OFF CABLE REPLACE REPAIR TY MICROPROCESSOR CABLE 4 REPLACE 10VDC AT CHOPPER 26 7 8 ASSEMBLY 10VDC AT 2 1 2 Figure 7 4 Chopper Diagnostics Part 2 7 15 This page intentionally left bla
46. 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 e 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 e 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 e Transferred arc lost during upslope This error occurs when the arc transfers to the workpiece but is lost before steady state operation It 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 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 5 11 Automatic Gas Console Advanced Functions FineLine 200PC User s Manual e 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 o
47. 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 025 0 PROCESS CUTTING TORCH PARTS S psi 080 0 S CURRENT SET POINT 50 AMPS 5 DELAY GAS OXYGEN zi PIERCE DELAY TINE 0000 PSE 099 0 PRESS F3 SAVE SETTING FOR 0 125 in MILD STEEL HOT CURRENT MODE STATUS InnerLogic Inc Help Prompt Figure 4 3 Help Prompt 4 4 Operation FineLine 200PC 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 sc
48. unit on a weekly basis 3 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 7 1 Maintenance and Troubleshooting FineLine 200PC 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 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 3 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
49. volts mm m mm mm msec mm 6 143 3770 3 1 5 5 400 32 10 156 2825 4 8 600 12 25 75 50 1 162 2430 5 5 7 0 3 3 16 170 1630 3 4 6 4 1000 20 170 990 8 6 3 6 1 Revised on 7 2 07 4 34 Operation FineLine 200PC User s Manual Aluminum Cutting 200 Amps Air Plasma Nitrogen Shield Shield Cap Nozzle Electrode 277289 277291 1 4 S f 9 0 222 4 226 Retaining Cap Swirl Ring Torch Main Body 217154 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 pm in Gn msec Gn 1 4 150 190 135 200 200 150 3 8 145 140 250 300 155 1 2 110 400 20 82 58 0 135 300 155 5 8 95 500 160 3 4 65 150 350 600 160 1 0 175 35 200 400 170 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 4 9 200 38 10 3545 3 5 6 5 155 400 12 2995 7 3 20 82 58 0 3 4 3 9 16 160 2380 7 6 600 20 162 1575 3 9 89 4 1
50. 0 2540 1 3 1 3 0 Revised on 7 2 07 4 38 Automatic Gas Console Advanced Functions FineLine 200PC 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 or 200 amps while cutting and 8 9 or 10 amps while marking Once the desired value 1s blinking press ENT PREFLOW SUBSTANCE MILD STEEL HOT GAS AIR THICKNESS 0 125 inches pst 025 0 PROCESS CUTTING TORCH PARTS psi 080 0 S CURRENT SET POINT 50 AMPS 5 CELAT GAS OXYGEN y PIERCE DELAY TIME 0000 ms PSE 005 0 X PRESS TD CHANGE CURRENT MODE CURRENT InnerLogic Inc Figure 5 1 Altering the Current Set Point 5 1 Automatic Gas Console Advanced Functions FineLine 200PC 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 t
51. 00 1 0 170 35 240 325 1300 160 Metric Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen 17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width mm psi psi psi psi volts mm m mm mm msec mm 10 154 2010 4 7 6 4 500 3 8 12 149 1935 3 6 6 8 16 37 68 85 13 155 1515 4 8 7 0 900 39 20 161 1215 52 73 1300 25 169 915 6 0 8 2 4 1 H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen 1 Revised on 7 2 07 4 28 Operation FineLine 200PC 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 277289 277291 9 5 Outer Cap Retaining Cap Swirl Ring Torch Main Body 271154 271266 271143 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 pm in Gn msec Gn 1 4 130 200 200 200 070 150 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 1 25 170 20 250 325
52. 00306 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 35 35 ft 10 7 m 200306 40 40 ft 12 2 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 NOZZLE LEAD POWER SUPPLY CTP SENSOR LEAD LEFT HAND POWER SUPPLY COOLANT RETURN HOSE LEFT HAND RIGHT HAND powER SUPPLY COOLANT SUPPLY HOSE RIGHT HAND Figure 8 9 Coolant and Power Leads 8 12 Parts List Work Ground Cable Part Number 200318 10 200318 15 200318 20 200318 25 200318 30 200318 35 200318 40 200318 45 200318 50 200318 55 200318 60 200318 65 200318 70 200318 75 200318 80 200318 85 200318 90 200318 95 200318 100 Figure 8 10 Work Ground Cable FineLine 200PC User s Manual Length 10 ft 3 0 m 15 ft 4 6 m 20 ft 6 1 m 25 ft 7 6 m 30 ft 9 1 m 35 ft 10 7 m 40 ft 12 2 m 45 ft 13 7 m 50 ft 15 2 m 55 ft 16 8 m 60 ft 18 3 m 65 ft 19 8 m 70 ft 21 3 m 75 ft 22 9 m 80 ft 24 4 m 85 ft 25 9 m 90 ft 27 4 m 95 ft 29 0 m 100 ft 30 5 m Parts List Fin
53. 00PC User s Manual 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 MATERIAL 4 PREFLOW GAS 1 PIERCE DELAY CLR CURRENT 5 PLASMA GAS 2 MAINT STATUS 9 VOLTAGE SHIELDING GAS 3 GAS PURGE ENT 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 Menu Plasma Gas Menu Shield Gas Menu Maint Menu 4 Gas Purge Menu Status Menu Preflow Gas Menu Pierce Delay 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 200PC User s Manual Arrow Keys The Arrow keys are used
54. 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 Z49 2 Fire Prevention in the Use of Cutting and Welding Processes obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 9 ANSI Standard Z87 1 Safe Practices For Occupation and Educational Eye and Face Protection obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 10 ANSI Standard Z88 2 Respiratory Protection obtainable from the American National Standards Institute 11 West 42nd Street New York NY 10036 11 OSHA Standard 29CFR 1910 252 Safety and Health Standards obtainable from the U S Government Printing Office Washington D C 20402 12 NFPA Standard 51 Oxygen Fuel Gas Systems for Welding Cutting and Allied Processes obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 13 NFPA Standard 51B Cutting and Welding Processes obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 14 NFPA Standard 70 National Electrical Code obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 15
55. 10 6 1 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 200PC User s Manual Stainless Steel Cutting 30 Amps Air Plasma Air Shield Shield Cap Nozzle Electrode 277121 277137 9 7 91 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 20 Operation FineLine 200PC User s Manual Stainless Steel Cutting 50 Amps Air Plasma Nitrogen Shield
56. 151 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 pm in Gn msec Gn 1 4 118 165 105 200 300 125 3 8 20 74 30 0 123 125 1135 225 400 1 2 125 90 140 250 130 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 in psi psi psi psi volts ipm in in msec in 5 8 127 70 i40 275 600 130 3 4 130 55 900 135 1 20 74 45 0 134 40 150 300 1200 1 25 145 25 200 140 500 155 15 225 Edge start or moving pierce recommended Metric Retaining Cap 277151 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 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 6 2 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 27 7 0 900 3 3 20 130 1340 3 4 1200 25 20 74 45 0 133 1040 33 76 32 145 625 5 1 3 6 500 38 154 385 5 6
57. 3 PHASE gt o N Figure 7 1 230 60 Hz Transformer Configuration 460V 3 PHASE tte 3 gt o Figure 7 2 460 60 Hz Transformer Configuration Maintenance and Troubleshooting FineLine 200PC 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 and 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 suppl
58. 300 165 1 5 180 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 1200 25 157 1050 52 82 4 1 32 170 495 6 4 4 2 8 3 300 38 179 260 6 9 4 4 Edge start or moving pierce recommended 1 Revised on 7 2 07 4 29 Operation FineLine 200PC User s Manual Aluminum Cutting 30 Amps Air Plasma Nitrogen Shield Outer Cap Shield Cap Nozzle Electrode 277145 277120 277130 aD Retaining Cap Swirl Ring Torch Main Body 2 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 pm in Gn msec Gn 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
59. 40 09 AG 031 6d rm OC 5 von Cows 0 852 lt M AGI Uik 1 Dru 2 S Oah san ese bs 2 3 PA P jx HL D Eu HELD D oj iar 3 8 91 SIN Eem em 0 EIN en Xvid zx 1 n enp 9d Sd E 8 enh mm EG 198 ___ A ____ L ___ __ L 1 12 55 eva 194 sou 043 798 o9 E 692 NAST fp i gt gt DJ o ozn ein D 13 2 229 129 619 419 90 SIJ 9 EIJ 20 09 69 083 Es O OJO OOOOOOOOOOO zu SER SSSR SSSR SS 58588655 7323 3 3 9 9 3 3 188688 8 Figure 8 22 Automatic Gas Console I O P C Board 8 26 Parts List FineLine 200PC User s Manual Automatic Gas Console Interface P C Board Assembly 505600 R44 R45 650 RS1 22 010 0 Q 0 5 2 5 3 90 R59 C17 C33 U7 TP1 DeL 4 5 me 0 mee C20 1 5 C19 0 D0 9 2 J3 gt J9 BLANK PCB
60. 5 1 Altering the Current Set POIL eese diit e tette see 5 1 Setting the Pierce Delay eese eene t Ce E RED 5 2 Altering Gas 5 3 5 4 Altering Arc Voltage Control and X Y Machine Parameters eee 5 5 saving a User Created Cutting Condition 5 6 Gas Cam MCA DEEP DE 5 6 5 7 dies 5 8 Vie wins EP 5 9 DIaenostes eode 5 13 Setting the Default Delay Parameter s 5 14 Restoring Factory Default Cutting Conditions sese 5 15 Measurement System 5 16 Communication ledio ecco ode quite cu Oe te ae 5 17 Parameter Transi ut 5 18 Viewing Serial Communication 5 19 Configuring the Optional Hydrogen 5 20 an Arc OD DELAY fiesta sm Dedi 5 2 S terc putate dena 5 22 Section 6 Serial Communication 6 1 Initializing the Pimelme System ote test pae
61. 5 13 Automatic Gas Console Advanced Functions FineLine 200PC 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 maintenance 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 DISRBLED FINELINE 200PC PRESS F3 TO ENABLE DISRBLE DEFAULT PIERCE DELAY PRESS ENT TO RETURN THE MAINTENANCE MENU CURRENT MODE DEFAULT PIERCE DELAY InnerLogic Inc Figure 5 13 Default Pierce Delay Screen 5 14 Automatic Gas Console Advanced Functions FineLine 200PC User s Manual Restoring Factory Default Cutting Conditions To restore a factory default cut
62. 57 55 6 99 5 96 4 First aid measures 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 treatment 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 ext
63. 706041 4 704009 5 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 200PC User s Manual Quantity Description 2 pem LAE Receptacle 9 position Receptacle 7 position Transformer 12V LED panel mount Input 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 OUTLET Hydrogen Optional FineLine 200PC User s Manual Hydrogen Manifold Microprocessor P C Board Assembly 200285 INNERLDGIC INC BLANK PCB PN 200284 RO ASSEMBLY PN 200285 8 5424 gt gt 11 ELT MOV1 Move AUXIN2 1 LED7 LEDS LED2 LEDI LED8 LED6 LED3 422 ENABLE TXI RU S Rle R18 LR R19 R20 SEI D27 D28 RP1 2 V1 PRESS Ve PRESS 257 C33 859 ERROR AUX 2 0 5 24V 5 LED1O LEDI LEDI2 LED13 1 14 LEDIS LEDI6 Figure C 3 Hydrogen Manifold Microprocessor P C Board C 6 Hydrogen
64. 77286 277146 277117 277298 277214 277138 277140 277142 277283 277141 277139 277143 277259 277110 277153 Quantity 3 3 3 FineLine 200PC User s Manual Description Nozzle 200A Stainless H17 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 50 704 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 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 Swirl Ring 150A Mild Steel 150A Stainless 150A Aluminum Swirl Ring 200A Mild Steel 200A Stainless Air 200A Aluminum Swirl Ring 200A Stainless H17 Inner Retaining Cap 30 50A Stainless Air Inner Retaining Cap 30 50 70A Mild Steel 70A Stainless Air 30 50 70 Aluminum 8 29 Parts List Part Number 271151 277152 277113 277266 716012 500024 500018 820209 277056 277086 277087 260105 277 154 Quantity 1 RP
65. EE SUPPLY 8 1 Remote High Frequency Console 8 7 Torch Valve Assembly 8 9 Shielded Torch Leads io rr tete bab asc etie etel tee suci edid 8 10 Gas Hose PACK AGS 8 11 Coolant and Power DR Rd 8 12 Work Ground Cable ede 8 13 Torch Consumables Mild Steel Cutting 8 14 Torch Consumables Stainless Steel Cutting Air 8 15 Torch Consumables Stainless Steel Cutting H17 Plasma eese 8 16 Torch Consumables Aluminum Cutting 8 17 Torch Consumables Marking 8 18 8 19 Power Supply Microprocessor P C Board oe me Depos odictor Ro OG RR 8 22 A C Detect P C Board toe aiden RR UO GUI YU TAN eave S OUS 8 23 Relay P C BO ged 8 24 Power Supply IO de td 8 25 Automatic Gas Console JO P C diete vecsaansqusnceseecadesoe rather 8 26 Automatic Gas Console Interface P C Board eese 8 27 Consumiable Spare Parts Kit
66. EPHONE NUMBER 24 Hour Emergency Contact 989 636 4400 Local Emergency Contact 989 636 4400 Hazards Identification 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 Potential 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 200PC 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
67. FineLine 200PC User s Manual FineLine 200PC High Density Plasma Cutting System With Automatic Gas Console Revision H 7 12 07 Manual Part Number 718059 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 200PC User s Manual Limited Warranty KALIBURN expressly warrants that this product shall be free from defects in materials and workmanship under proper and normal use for the intended function of such equipment for a period of one 1 year for the FineLine 200PC torch and leads and three 3 years for the FineLine 200PC power supply and automatic gas console This product is intended for commercial use and is not intended for personal family or household purposes There are no warranties that extend beyond the description on the face hereof 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 freight charges of any kind are covered under this warranty
68. Line 200PC User s Manual Remote High Frequency Console Note See Figure 8 5 Item Number Part Number Quantity Description 1 715051 2 Coolant return fitting left hand 2 715050 1 Coolant supply fitting right hand 3 709227 1 Strain relief 4 710147 1 Lock nut 5 709001 1 4 6 707001 1 Line filter 7 706019 1 Transformer 5000V 20 mA 8 702069 1 15 9 708057 1 Door interlock switch 10 500014 1 Spark gap assembly 11 740039 3 Spark gap electrode 12 505043 1 High frequency inductor 13 740072 1 Standoff 14 800041 1 15 500505 1 console p c board assembly 16 715021 1 Coolant supply fitting right hand 17 500503 1 Cathode manifold 18 205010 1 sensor lead filter assembly 19 200287 1 Transformer insulating plate 22 500098 1 Ground cable 8 7 FineLine 200PC User s Manual Parts List Us cll igh Frequency Console Figure 8 5 Remote H Parts List FineLine 200PC User s Manual Torch and Torch Valve Assembly Item Number Part Number Quantity Description 1 277475 2 500549 3 820134 4 277000 5 500740 6 820209 7 500024 8 500018 Not shown 716008 Not shown 200390 m Torch valve assembly includes bracket Torch valve bracket Torch handle Torch main body Torch solenoid plasma hose O ring O ring O ring O ring lubricant Consumable remo
69. Manual Automatic Gas Console Specifications Stock Number dubai needs 200865 9 in 229 mm orden ee 25 in 635 mm Depth aei sem telas bn e esae 23 8 in 605 mm ty 80 10 36 2 Gas Supply Requirements Plasma gas types Mild Steel Oxygen or Air Air 17 optional ee o ei Shield gas types MIO STC CL accetto tiet etn tan favet Oxygen or Air Stainless Steel Air or Nitrogen 22 Nitrogen PreflOW BAS todo Air or Nitrogen Plasma gas flow rate maximum Oxygen 40 scfh 1132 liters hour HT asus e 36 scfh 1019 liters hour Shield gas flow rate maximum PRY PEN M 19 scfh 538 liters hour Air Nitrogen 150 scfh 4245 liters hour Preflow gas flow rate maximum 25 scfh 708 liters hour Inlet gas pressures ME 120 psi 8 3 bar PM 120 psi 8 3 bar INTE a ttes Dee a tease ade ee MEC 120 psi 8 3 bar HUT 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 b
70. Melting Point Solubility in Water by weight pH Evaporation Rate Butyl Acetate 1 Dynamic Viscosity Pour point FineLine 200PC User s Manual Issue Date 03 02 2006 Lower 2 6 V Estimated Upper 12 5 Estimated 371 700 F Literature 0 3 mbar 9 25 Literature 187 4 369 3 F Literature 2 62 Literature 1 04 20 C 20 Literature No test data available No test data available 100 96 Not applicable 0 02 Estimated 48 6 mPs 9 25 C Literature lt 57 lt 71 F Literature 10 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 11 Toxicological Information Acute Toxicity Ingestion 11050 Rat 20 000 34 000 mg kg Skin Absorption LD50 Rabbit gt 20 000 mg kg Repeated Dose Toxicity In rare cases repeated excessive
71. O THE MAINTENANCE MENU CURRENT MODE CUT ERRORS InnerLogic Inc FINELINE 200PC Figure 5 9 Cut Errors Screen 5 9 Automatic Gas Console Advanced Functions FineLine 200PC 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 VIEW PRESENT ERRORS VIEW PREVIOUS 5 1 VIEW PREVIOUS ERRORS 2 VIEW PREVIOUS ERRORS 3 VIEW PREVIOUS ERRORS 4 VIEW PREVIOUS ERRORS 5 FINELINE 200PC PRESS MENU THEN RETURN STATUS SCREEN PRESS ENT TO SELECT AN OPTION FROM THE MENU CURRENT MODE CUT ERRORS InnerLogic Inc Figure 5 10 Error Selection Screen 5 10 Automatic Gas Console Advanced Functions FineLine 200PC User s Manual Viewing Actual Errors 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 0 TRANSFERRED ARC LOST BEFORE UPSLOPE 0 TRANSFERRED ARC LOST DURING UPSLOPE 0 0 8 TRANSFERRED ARC LOST DURING CUT TRANSFERRED ARC LOST DURING DOWNSLOPE FINELINE 200PC 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
72. Selection Screen 5 17 Automatic Gas Console Advanced Functions FineLine 200PC 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 200PC PRESS F3 ENABLE DISABLE INOVA PARAMETER TRANSMIT PRESS ENT RETURN TO THE MAINTENANCE MENU CURRENT MODE PARAMETER TRANSMIT InnerLogic Inc Figure 5 17 Inova Parameter Transmit Screen 5 18 Automatic Gas Console Advanced Functions FineLine 200PC 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 outgoi
73. Stock Number Torch main DOGS oce EU oS ite 277000 Torch handle assembly 820134 2 in 50 8 mm Length Torch main body entente 4 65 in 118 mm Torch main body handle assembly 13 85 in 352 mm Weight including handle and valves 4 lb 1 8 kg 1 13 2 335 4 65 118 Figure 2 3 Torch Dimensions 2 6 Specifications FineLine 200PC User s Manual Airborne Noise Emissions The FineLine 200PC 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 200PC when operating at 200 amps 135 arc volts The measurements were made with a sound level meter Distance From Torch A Weighted Sound C Weighted Sound Pressure Level Pressure Level meter horizontal 1 6 meters 110 dB 107 dB above the workpiece The maximum noise level 18 127 dB at a distance of 3 inches 76 2 mm from the torch while cutting at 200 amps 135 arc volts This page intentionally left blank Installation FineLine 200PC User s Manual Section 3 Installation Initial Inspection systems undergo full testing before being shipped from KALIBURN In the unlikely event
74. TURING 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 200PC User s Manual Product Name Propylene Glycol Industrial 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 14 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 materia
75. 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 PEEFLOW SUBSTANCE MILD STEEL HOT GAS AIR THICKNESS 0 125 inches 022 0 PROCESS CUTTING 5 TORCH PARTS psi 080 0 CURRENT SET POINT 50 AMPS 5 DELA GAS OXYGEN y PIERCE DELAY TIME 0000 ns PSE 05 0 n PRESS TO CHANGE CURRENT MODE PLASMA InnerLogic Inc Figure 5 3 Altering Gas Types 5 3 Automatic Gas Console Advanced Functions FineLine 200PC User s Manual 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 numer
76. a 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 in Gn msec 1 4 165 95 250 250 400 135 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 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 4 1 25 81 75 13 3 6 16 1260 4 7 7 6 1000 20 167 940 6 9 3 7 H17 17 5 Hydrogen 32 596 Argon 5096 Nitrogen 1 Revised on 7 2 07 4 26 Operation FineLine 200PC 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 Nozzle Electrode 277117 277293 277292 N 0 0 Outer Cap Retaining Cap Swirl Ring Torch Main Body 271154 271152 271139 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
77. ack 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 200PC User s Manual Remote High Frequency Console Specifications Stock NUMDET 205500 5 35 136 Widths 13 5 343 Depth aea sena e e E 10 in 25 mm burn 22 lb 10 kg Spark gap distance 025 in 635 mm 8 00 203 4 312 8 j 13 50 343 12 75 324 12 00 305 1 e 1000 254 O POWER LEADS GROUND OUT IN P1 9pm eo o COOLANT 5 35 136 Innerlogic Inc Figure 2 2 Remote High Frequency Console Mounting Dimensions 2 5 Specifications FineLine 200PC User s Manual Torch Specifications
78. ailable substance types are as follows e Mild Steel Cold Rolled e Mild Steel Hot Rolled e Stainless Steel e Aluminum e Other PREFLOW SUBSTANCE MILD STEEL HOT GAS AIR THICKNESS 0 125 inches 022 0 PROCESS CUTTING E TORCH PARTS t OR CURRENT SET POINT 50 AMPS gt S DELAY GAS OXYGEN PIERCE DELAY TIME 0000 ms Yoo D m PRESS TO CHANGE CURRENT MODE MATERIAL InnerLogic Inc Figure 4 5 Selecting Material Substance 4 6 Operation FineLine 200PC 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 keypad 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 PREFLOW SUBSTANCE MILD STEEL HOT GAS AIR THICKNESS 0 125 inches 022 0 PROCESS CUTTING TORCH PARTS psi 080 0 CURRENT SET POINT 50 AMPS a 5 DELAY GAS OXYGEN zi PIERCE DELAY TINE 0000 PSE 055 0 X USE THE NUMERICAL KEYPAD TO ENTER THICKNESS CURRENT MODE MATERIAL InnerLogic Inc Figure 4 6 Setting Material Thickness 4 7 Operation FineLine 200PC 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
79. ains extinguished when there is a problem with the gas system Check the message screen on the automatic gas console for errors e 3 Phase Power Indicator Illuminates when 3 phase power is satisfactory Remains extinguished when there is a problem with main 3 phase power to the system Coolant Flow Indicator Illuminates when the coolant flow through the system is satisfactory Remains extinguished when the coolant flow through the system is restricted 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 200PC User s Manual e Coolant Temperature Indicator Illuminates when the torch coolant temperature is satisfactory Remains extinguished when the coolant temperature is too hot If the torch coolant indicator goes out leave the unit energized until it illuminates Automatic Gas Console Display 6 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 s AC POWER DC POWER FINELINE 200PC cas PRECISION PLASMA CUTTING SYSTEM Power coorant FLow LeveL TEMPERATURE INNERLOGIG Figure 4 1 Front Panel Controls 4 2 Operation Automatic Gas Console Keypad FineLine 2
80. al 1 1 Ultraviolet Radiation Protection 1 1 NOISE Protection 1 1 Toxic Fiume 1 1 Electric SHOCK Prevention 1 2 Pine Prev s do Ed 1 3 Explosion Prevention vod ds 1 3 Health Support Equipments e 1 4 Safety Standards Booklet Index 1 4 Section 2 Specifications 2 1 System Description IRR NE qure HEU e pde rap 2 1 System Compobenis gt lt DURAS Sua 2 2 Power Supply Sp cifications iiu coe VEERA 2 2 Automatic Gas Console Specifications 2 4 Remote High Frequency Console Specifications 2 2 5 Toreh 2 6 Airborme Norse Emissions 2 7 Section 3 entere 3 1 alus 3 1 System Interconnection 3 1 Power Supply Installation I p pes du va dus pu 3 3 Remote High Frequency Installation 2 meme enne 3 3 Torch Installation oie ee
81. amps 575 VAC 3 60HZ 42 amps Open Circuit Voltage ede ae 300 VDC 8 200 amps Maximum Output Voltage 190 VDC Duty C ole 10096 28 kW Maximum Ambient Temperature 104 F 40 C Specifications FineLine 200PC User s Manual Dimensions Mad 30 in 762 mm Height including AGC suus 48 in 1219 mm 43 1092 Weight including AGC 700 Ib 317 kg Torch Cooling System Discharge 150 psi 10 2 bar Flow tate d et iT 1 gal min 3 8 liters min Coolant Propylene glycol deionized water Coolant tank capacity 3 2 gal 12 liters 9000 __ 06165 PLASMA SYSTEMS 48 1 219 i 39 991 C et 3 C Gs 6 2 CS py e e CoS COS CS CI Hes 1 In 30 762 43 1 092 Figure 2 1 Power Supply Dimensions Specifications FineLine 200PC User s
82. anced Functions FineLine 200PC 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 TO ENTER THE TIME DELAY BETWEEN THE RECEPTION OF A STOP SIGNAL AND THE EXTINCTION OF THE ARC FINELINE 200PC PRESS ENT 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 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 DIGNUM Se Remove primary power from the FineLine system Insert the floppy disk containing the software update into the floppy disk drive Apply pri
83. arting point when troubleshooting the system MESSAGES Waiting For Start Signal PRESS ENT TO EXIT FINELINE 200PC CURRENT MODE MESSAGES InnerLogic Inc Figure 5 8 Message Screen 5 8 Automatic Gas Console Advanced Functions FineLine 200PC 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 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 into 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 414 ERRORS 8 PERCENT ERROR 2 1 PIERCES 1216 ERRORS 12 PERCENT ERROR 1 2 PIERCES 1 ERRORS 0 PERCENT ERROR 0 PIERCES 0 ERRORS 0 PERCENT ERROR 0 4 PIERCES 0 ERRORS 0 PERCENT ERROR 0 PIERCES 0 ERRORS 0 PERCENT ERROR 0 PRESS F3 TO VIEW ERRORS PRESS CLR TO RESET COUNT PRESS ANY OTHER KEY TO RETURN T
84. ate Unit will not energize when the ON button is pressed Power supply will not stay on when the front panel ON button is pressed and released No arc at the torch Possible Cause Primary disconnect fuse blown 2 Fuse Fl or F4 blown 3 White light or associated wiring bad 4 Transformer TR2 or associated wiring bad 1 door open 2 Low coolant level 3 Fuse F4 blown 4 Faulty ON switch or associated wiring The ON switch is normally open 5 Faulty OFF switch or associated wiring The OFF switch is normally closed 6 Relay CRI coil open 1 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 defective QNIN 1 Incorrect torch consumables installed Incorrect gas pressure settings 3 Check the control panel status LED s and troubleshoot accordingly 4 Check the spark gap assembly inside the RHF console for proper arcing after a start signal is applied Open the RHF door and pull up on the door interlock switch plunger to defeat the interlock If there is no spark skip to the next test 5 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 6 Pilot arc resistor PAR or p
85. c volt increments The positioner must be rigid to ensure cut quality and a torch collision sensor is highly recommended 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 200PC User s Manual 3 Phase Input Current Recommended Input Voltage at Maximum Output Fuse Size VAC amps amps 208V 60Hz 115 170 230V 60Hz 104 150 380V 50Hz 63 90 415V 50Hz 58 80 460V 60Hz 52 75 575 60Hz 42 60 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
86. ce away from the cutting area 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 200PC system uses compressed gases Use proper techniques when handling compressed gas cylinders and other compressed gas equipment Observe the following guidelines to protect against explosion Never operate the FineLine system in the presence of explosive gases or other explosive materials 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
87. ct a pressurized hose may cause damage to the system Installation The hydrogen manifold must be installed on the cooling system shelf of the FineLine 200PC 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 may 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 13 on the rear of the FineLine 200PC 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 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 2 Hydr
88. d 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 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 200PC system generates high noise levels while cutting Depending on the size of the cutting area distance from the cutting torch and arc current cutting level acceptable noise levels may be exceeded Proper ear protection should be used as defined by local or national codes See Section 2 for noise emission levels Toxic Fume Prevention Care should be taken to ensure adequate ventilation in the cutting area Some materials give off toxic fumes that can be harmful or fatal to people in the vicinity of the cutting area Also some solvents decompose and form harmful gases when exposed to ultraviolet radiation These solvents should be removed from the area prior to cutting 1 1 Safety FineLine 200PC 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 c
89. e 200PC 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 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 the cutting machine or on the cutting table See Figure 2 2 for RHF console mounting dimensions Torch Installation The FineLine 200PC 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 ar
90. e star ground point for all other ground connections e Inspect the torch leads frequently Never use the system if the leads are damaged in any way e Do not stand wet damp areas when operating or performing maintenance on the system Wear insulated gloves and shoes while operating or performing maintenance on the system Make sure the 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 the 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 1 2 Safety FineLine 200PC User s Manual will give the capacitors inside the unit time to discharge 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 200PC 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 distan
91. eLine 200PC User s Manual Torch Consumables Mild Steel Cutting 271145 217153 277120 277140 277130 77140 277115 277153 277122 277142 277131 c G 277150 277153 277125 277142 277131 D 5920 9 s 277151 277284 277283 D c G 277293 277139 277266 277289 277143 277291 O30 c G Figure 8 11 Torch Consumables Mild Steel Cutting Parts List FineLine 200PC User s Manual Torch Consumables Stainless Steel Cutting Air Plasma Outer Ca Figure 8 12 Torch Consumables Stainless Steel Cutting Air Plasma Parts List FineLine 200PC User s Manual Torch Consumables Stainless Steel Cutting H17 Plasma Outer Ca Figure 8 13 Torch Consumables Stainless Steel Cutting H17 Plasma Parts List FineLine 200PC User s Manual Torch Consumables Aluminum Cutting Figure 8 14 Torch Consumables Aluminum Cutting Parts List FineLine 200PC User s Manual Torch Consumables Marking Outer Cap Shield Cap Retaining Cap Nozzle Swirl Ring Electrode Torch body 277154 277145 277152 277120 277140 277190 277000 Figure 8 15 Torch Consumables Marking Parts List FineLine 200PC User s Manual Automatic Gas Console Assembly 200865 Note See Figures 8 16 and 8 17 Item Number Part Number Quantity Description 1 500032 1 decal membrane switch 2 501146 1 aluminum display panel 3 500860 1 display window 4 710199 4 Alumi
92. epress and hold the button until no air is seen inside the clear filter housing 8 Hill 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 3 17 This page intentionally left blank Operation FineLine 200PC User s Manual Section 4 Operation Power Supply Front Panel Controls 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 Deenergizes the FineLine system and turns off the cooling fans and coolant pump Power On Button Indicator Energizes FineLine system and turns on the cooling fans and coolant pump Illuminates to show that the system is energized AC Power Indicator 3 Illuminates when 3 phase power is applied to the FineLine system DC Power Indicator 4 Illuminates when then main contactor has been energized and D C current is flowing through the torch Status Indicators 5 e RHF Door Indicator Illuminates when the RHF console door is closed securely Remains extinguished when the RHF console door is open Gas Console Indicator Illuminates when the automatic gas console is operational Rem
93. equested in command 30 the will transmit the most significant word of the electrode part number If requested in command 30 the will transmit the least significant word of the electrode part number If requested in command 30 the will transmit the most significant word of the swirl ring part number If requested in command 30 the will transmit the least significant word of the swirl ring part number If requested in command 30 the will transmit the most significant word of the nozzle part number If requested in command 30 the will transmit the least significant word of the nozzle part number If requested in command 30 the will transmit the most significant word of the retaining cap part number If requested in command 30 the will transmit the least significant word of the retaining cap part number Serial Communication Command 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 Parameter 27 28 29 30 Hex String AA nn FA 0D nn FA IB AA nn FA IC 0D AA nn FA ID 0D AA nn FA IE 0D 6 6 FineLine 200PC User s Manual Additional Information If requested in command 30 the will transmit the most significant word of the shield cap part number If requested in command 30
94. er 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 Torch Height Control Voltage Set Point 1 11 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 0A 0D AA nn FA OB 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 06 200 Amps Cutting 072 8 Amps Marking 08 9 Amps Marking 09 10 Amps Marking Pierce Delay Time in ms Valid Range 0 to 5000 Preflow psi x 10 Valid Range 0 to 1200 00 Oxygen 01 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 If requested in command 30 the will transmit the recommended arc voltage x 100 Range 0 to 20000 Serial Communication Command Torch Height Control Pierce Height Torch Height Control Cutting Height
95. flow gases The FineLine 200PC 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 Five nozzle sizes 30 50 70 100 and 200 amps are available to produce excellent cut quality throughout the cutting range Specifications FineLine 200PC User s Manual System Components The FineLine 200PC consists of the following components Standard Components Power Supply Automatic Gas Console Remote High Frequency RHF Console RHF Console Control Cable Torch and Handle Assembly Torch Lead Set Torch Solenoid Valve Assembly Torch Solenoid Valve Control Cable Water and Power Leads Gas Hose Package Work Ground Lead System Manual Consumable Spare Parts Kit see Section 8 for details Power Supply Specifications Stock Number 208 VAC 30 60 200411 230 460 30 60Hz 200412 380 V AC 200415 AIS V AC 30 S ETZ osos 200414 575 3 60H 200413 Input Current at Maximum Output 208 30 60H 115 230 460 30 60Hz 104 52 amps 380 VAC 30 30H ici rie oce tiere leitete 63 amps 415 VAC 3 50HZ n tests 58
96. g arc is established the following LED s will go out LED 14 HOLD OUT e LED 27 HIGH FREQ LED 4 PREFLOW e LED e 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 7 7 Maintenance and Troubleshooting FineLine 200PC 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 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 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 e Coolant Flow LED Extinguishes when there is a problem with the torch coolant system Check the coolant pump fuse F2 and verify that 230V is present between TB3 13 and TB3 14 Also check for clogs in the coolant leads and coolant filter deionization car
97. ged 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 200PC 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 VIEW MESSAGES SET COMMUNICATION NODE VIEW CUT ERRORS INOVA PARAMETER TRANSMIT RESTORE FACTORY DEFAULTS VIEW SERITAL COMMUNICATION PRESSURE DIAGNOSTICS CONFIGURE HYDROGEN MANIFOLD DEFAULT PIERCE DELAY SET ARC OFF DELAY MEASUREMENT SYSTEM FINELINE 200PC PRESS MENU THEN TO RETURN STATUS SCREEN PRESS ENT SELECT AN OPTION FROM THE MENU CURRENT MODE MAINTENANCE InnerLogic Inc Figure 5 7 Maintenance Screen 5 7 Automatic Gas Console Advanced Functions FineLine 200PC 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 st
98. ght 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 18 4 5 aon 6 138 2050 2 1 4 9 2 3 1 Revised on 7 2 07 4 23 Operation FineLine 200PC 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 Nozzle Electrode Pc didi DD Outer Cap Retaining Cap Swirl Ring Torch Main Body 271154 217113 217141 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Nitrogen 17 Nitrogen Nitrogen Voltage Speed Height Height Delay Width in psi psi psi psi volts in in msec Gn 3 16 138 115 105 200 200 100 1 4 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 5 138 2865 2 7 5 1 2 5 28 67 46 13 300 6 139 2625 3 0 5 5 2 7 H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen 1 Revised on 7 2 07 4 24 Operation FineLine 200PC User s Manual Stainless Steel Cu
99. gnetic fields e Stay as far away from the FineLine power supply torch torch leads and remote high frequency console as possible Route the torch leads as close as possible to the work ground cable e Never place your body between the torch leads and work ground cable Keep the work ground cable and the torch leads on the same side of your body e Never stand in the center of a coiled up set of torch leads or work ground cable Safety Standards Booklet Index For further information concerning safety practices to be exercised with plasma arc cutting equipment please refer to the following publications 1 AWS Standard AWN Arc Welding and Cutting Noise obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 2 AWS Standard C5 2 Recommended Practices for Plasma Arc Cutting obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 3 AWS Standard FSW Fire Safety in Welding and Cutting obtainable from the American Welding Society 550 NW LeJeune Road Miami FL 33126 1 4 Safety FineLine 200PC 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 Z49
100. hanging 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 B 1 Electromagnetic Compatibility FL 200PC 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 6 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 p
101. he following pages are intended to give the operator the best starting point to use when making a cut on a particular material type and thickness Small adjustments may have to be made to achieve the best cut Also remember that the arc voltage must be increased as the electrode wears in order to maintain the correct cutting height Cutting Chart Index Shield Gas Mild Steel Cutting Oxygen Mild Steel Cutting Oxygen or Air Mild Steel Cutting Air Mild Steel Cutting Air Mild Steel Cutting Air Mild Steel Cutting Air Stainless Steel Cutting 1 Stainless Steel Cutting i Nitrogen Stainless Steel Cutting Nitrogen Stainless Steel Cutting Nitrogen Stainless Steel Cutting Nitrogen Stainless Steel Cutting i Nitrogen Stainless Steel Cutting Nitrogen Stainless Steel Cutting Nitrogen Stainless Steel Cutting Nitrogen Stainless Steel Cutting i Nitrogen Aluminum Cutting Nitrogen Aluminum Cutting Nitrogen Aluminum Cutting Nitrogen Aluminum Cutting Air Nitrogen Aluminum Cutting Air Nitrogen Aluminum Cutting Air Nitrogen Mild Steel Marking Nitrogen Nitrogen Stainless Steel Marking Nitrogen Nitrogen Aluminum Marking Nitrogen Nitrogen 4 13 Operation FineLine 200PC User s Manual Mild Steel Cutting 30 Amps Oxygen Plasma Oxygen Shield Shield Cap N
102. ical 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 025 0 PROCESS CUTTING TORCH PARTS Sea oe psi 80 0 S CURRENT SET POINT 50 AMPS 5 ERA GAS OXYGEN PIERCE DELAY TIME 0000 ns PSE 05 0 ni USE THE NUMERICAL KEYPAD TD ENTER PLASMA GAS PRESSURE CURRENT MODE PLASMA InnerLogic Inc Figure 5 4 Altering Gas Pressures 5 4 Automatic Gas Console Advanced Functions FineLine 200PC 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 DUTPUT VOLTAGE 115 PHASE 1 115 DUTPUT CURRENT AMPS PHASE 2 VOLTS PARAMETER TX STATUS READY PHASE 3 VOLTS ARC VOLTAGE 10 0 VOLTS SPEED 180 IPM CUTTING HEIGHT 0 100 INCHES USE THE SCROLL KEYS PIERCE HEIGHT 0 135 INCHES EDIT CUT PARAMETERS FINELINE 200PC PRESS F3 TO TRANSMIT CUTTING PARAMETERS TO TORCH HEIGHT CONTROL PRESS MENU THEN lt ane TO RETURN TO STATUS SCREEN CURRENT MODE VOLTAGE InnerLogic Inc Figure 5 5
103. id outlet port as shown Preflow Gas Hose 17 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 Connect the Plasma Gas Hose to the solenoid plasma inlet port as shown Postflow Gas Hose Connect the Postflow Gas Hose to the solenoid postflow inlet port as shown Torch Solenoid Control Cable e Connect the Torch Solenoid Control Cable plug marked P15 to the torch solenoid assembly as shown Connect the Torch Solenoid Control Cable plug labeled P12 to the connector labeled P12 on the rear of the power supply 3 11 Installation FineLine 200PC User s Manual Figure 3 5 Torch Connections 3 12 Installation FineLine 200PC 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 fittings are subject to damage if over tightened Air Inlet 21 e Air must be supplied to the unit at all times regardless of
104. igure 5 16 Figure 5 17 Figure 5 18 Figure 5 19 Figure 5 20 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 FineLine 200PC User s Manual Torch DIMENSIONS soo 2 6 System Interconnection eoe eoa neo ed 3 2 Primary Power Connections site esse eene eee 3 4 Power Supply Output Connections currus 3 7 Torch Leads to RHF Console Connections esee 3 9 Torch 5 3 12 Automatic Gas Console Input Connections 3 13 Automatic Gas Console Output Connections eene 3 14 Freezing Points of Aqueous Propylene Glycol Solutions 3 16 Controls 4 2 Automatic Gas Console Keypad 4 3 4 4 Sereen A 4 5 selecting Material Substance ise trea 4 6 Setting Material 4 7 PTO CESS Raton 4 8 Toreh Parts a 4 9 Voltage Scree docto a 4 10 Altering the Current Point 5 1 Setting the Pierce Delay Time 5 2 Altering
105. ilot arc transistor 7 10 Maintenance and Troubleshooting FineLine 200PC User s Manual PAT is not closing properly Check the relay for proper operation Also check the PAR and PAT LED s on the microprocessor p c board and PAT drive p c board 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 zd 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 TR5 Check for signs of arcing 4 Check for 120VAC on the input side of filter FL1 inside the RHF console after a start signal has been given If 120V is not present check associated wiring back to the power supply The arc will not transfer to the 1 Loose work ground connection workpiece 2 Pierce height too high 3 Incorrect damaged or worn consumables The gas console screen is blank 1 Blown gas console fuse F10 2 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
106. in 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 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 3 6 Installation FineLine 200PC User s Manual DICERE eo 9
107. in contactor CON and on the primary side of the power transformer 7 12 Maintenance and Troubleshooting FineLine 200PC User s Manual 7 With a start signal applied check for 300 VDC at the FineLine output terminal block between Electrode and Work If 300 V is present the chopper is working properly 8 If 300 VDC is not present at the output terminal block check the chopper status LED s when a start signal is applied a LED s 1 through 5 off go to step 9 b LED s 1 through 5 on LED 6 off go to step 10 c LED s 1 through 5 on LED LED 7 off go to step 11 d Only some of LED s 1 through 5 on replace chopper 9 Check the 120 VAC supply to the chopper between P1 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
108. inguished 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 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 additiona
109. ion 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 18 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 FineLine 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 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
110. l 115 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 Hazard No Fire Hazard No Reactive Hazard No Sudden Release of Pressure Hazard No Superfund Amendments and Reauthorization Act of 1986 Title 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 4 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 200PC User s Manual Product Name P
111. l information Page 2 of 8 2 Propylene Glycol MSDS FineLine 200PC 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 Precautions Prevent from entering into soil ditches sewers waterways and or groundwater See Section 12 Ecological Information 7 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 8 Exposure Controls Personal Protection Exposure Limits Component List Type Value Propylene glycol WEEL TWA 10 mg m3 Aerosol Personal Protection Eye Face Protection Safety glasses sh
112. lace The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Plasma cutting equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed plasma cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the plasma power source so that good electrical contact is maintained between the conduit and the plasma power source enclosure Maintenance of the Plasma Cutting Equipment The plasma cutting equipment should be routinely maintained according to the manufacturer s recommendations 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 FL 200PC User s Manual Plasma Cutting Cables The plasma cutting cables should be kept as short as possible a
113. lf life Method 1 28E 11 cm3 s 10h Estimated OECD Biodegradation Tests Biodegradation Exposure Time Method 81 96 28 d OECD 301F Test 95 8 96 64 d OECD 306 Test Biological oxygen demand BOD BOD5 BOD 10 BOD 20 BOD 28 69 96 70 86 96 Chemical Oxygen Demand 1 53 mg mg Theoretical Oxygen Demand 1 68 mg mg ECOTOXICITY Data for Component Propylene glycol Material is practically non toxic to aquatic organisms an acute basis LC50 EC50 gt 100 mg L in the most sensitive species tested Fish Acute amp Prolonged Toxicity LC50 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 LC50 saltwater Mysidopsis bahia static 96 h 18 800 mg l Aquatic Plant Toxicity EC50 green alga Selenastrum capricornutum biomass growth inhibition 19 000 mg l Toxicity to Micro organisms EC50 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 practices 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 MANUFAC
114. 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 200PC 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 and can be ordered in one gallon containers PN 500695 3 15 Installation FineLine 200PC User s Manual This solution provides freezing protection down to 13 9 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 10090 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 to
115. lled from the automatic gas console Setting up a cut is as simple as entering the material type material thickness and process cutting or marking 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 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 gas inlets and outlets are connected to the rear of the automatic gas console For cutting mild steel the FineLine 200PC 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 17 596 hydrogen 32 596 argon 5090 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 post
116. lso 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 1 Operation FineLine 200PC User s Manual the cutting speed is too slow 3 Top dross usually occurs when the torch standoff distance is too high 4 Bottom dross usually occurs when the cutting speed is either too slow slow speed dross or too fast high speed dross Low speed dross is easily removed while high speed dross usually requires grinding or chipping off When using oxygen as the shielding gas bottom dross can sometimes be removed by increasing the shield gas pressure However increasing the shield pressure too much can cause cut face irregularities see below Bottom dross also occurs more frequently as the metal heats up As more pieces are cut out of a particular plate the more likely they are to form dross 5 When using oxygen as a shielding gas cut face irregularities usually indicate that the shield gas pressure is too high or the torch standoff distance is too low 6 A concave cut face usually indicates that the torch sta
117. m msec mm 2 5 4885 1 9 106 2 5 3 4 100 3 4660 2 0 25 74 19 1 5 113 2555 927 3 6 250 22 6 116 2075 4 0 1 Revised on 7 2 07 4 15 Operation FineLine 200PC User s Manual Mild Steel Cutting 70 Amps Oxygen Plasma Air Shield Shield Cap Nozzle Electrode 277150 277125 277131 1 9 S f lt gt 6 22 7 Retaining Cap Swirl Ring Torch Main Body 217154 277153 277142 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 pm in Gn msec Gn 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 75 140 150 250 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 2 5 100 2 5 2 0 5 25 80 2 113 3265 2 6 25 200 6 115 3105 2 7 3 0 2 2 1 Revised on 7 2 07 4 16 Operation FineLine 200PC User s Manual Mild Steel Cutting 100 Amps Oxygen Plasma Air Shield Shield Cap Nozzle Electrode 277286 277284 277282 Retaining Cap Swirl Ring Torch
118. m 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 cooling system Section 3 for more information on torch coolant requirements 7 3 FineLine 200PC User s Manual Maintenance and Troubleshooting FineLine 200PC User s Manual 230 460V 60 Hz TRANSFORMER CONFIGURATIONS 230V 60 Hz and 460V 60 Hz power supplies are shipped with a dual voltage main transformer TR1 The primary taps on TRI are labeled with their corresponding voltages To change the operating voltage for these systems perform the following procedures 230V 60Hz Operation For 230V operation install a 4 AWG jumper wire from to on each primary winding of the transformer total of 3 wires Install a second 4 AWG jumper wire from 230V to 230V on each primary winding of the transformer total of 3 wires Now install a 4 AWG jumper wire fr
119. mary power to the system and wait until the 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 1 2 3 oo 11 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 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 keypad Wait for the AGC 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 Updated Successfully message to appear 12 13 Reinstall the floppy disk drive cover 15 Remove the floppy disk from the floppy disk drive Remove primary power from the system Apply primary power to the system 5 22 FineLine 200PC User s Manual Serial Communication FineLine 200PC User s Manual Section 6 Serial Communicat
120. n 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 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
121. n removed from the system Wait at least five minutes after turning off power and then use a voltmeter to verify that the capacitors are fully discharged before touching the 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 TB5 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 208 VAC If the voltage is not present check for primary voltage on the ma
122. nd should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the plasma cutting installation and adjacent to it should be considered However metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece 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
123. ndoff 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 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 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 Usea 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 4 12 Operation FineLine 200PC User s Manual Cutting Charts The cutting charts shown on t
124. ng data is displayed in decimal base 10 format Note that incoming data is appended to show an 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 R3 ROO R01 R13 PRESS CLR TO CLEAR SCREEN PRESS ENT TO EXIT SERIAL COMM ON FINELINE 200PC CURRENT MODE SERIAL COMMUNICATION InnerLogic Inc Figure 5 18 View Serial Communication Screen 5 19 Automatic Gas Console Advanced Functions FineLine 200PC 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 disable the hydrogen manifold 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 200PC 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 Adv
125. nk Parts List Section 8 Parts List Power Supply Note See Figures 8 1 to 8 4 FineLine 200PC User s Manual Item Number Part Number Quantity Description 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 Not shown 32 33 34 35 36 708088 708111 708090 708089 501163 501164 501162 501161 707200 500557 706205 500559 706200 706201 706204 706203 706202 709086 709007 709058 709012 709011 709076 709033 201450 709002 709001 709124 709061 709128 709060 500810 200092 200292 500518 708062 505024 500052 500513 1 1 1 2 2 1 1 1 1 Off switch red Off actuator red On switch green On actuator green illuminated Light housing Bulb White lens Red lens L1 inductor 2 control transformer 208 230 460 V 60 Hz TR2 control transformer 575 V 60 Hz 2 control transformer 380 415 V 50 Hz TR 1 main transformer 208 V 60 Hz 38 TR 1 main transformer 230 460 V 60 Hz 30 TR 1 main transformer 380 50 Hz 30 TR 1 main transformer 415 V 50 Hz 38 TR 1 main transformer 575 V 60 Hz 30 TB4 terminal block marker strip 14 position terminal block 14 position F2 F11 fuse holder F10 fuse AGC fuse F3 F4 fuse AGC 5A F6 F7 F9 F11 fuse AGC 1 2A F5 F8 fuse AGC 1A Microprocessor p c board assembly P8 P12 P13
126. num standoff 5 500861 1 AGC EL display 6 706044 1 Transformer 241 7 16 7 500568 Fan 8 501147 1 Fan guard filter 9 7709003 2 Receptacle 9 position 10 700404 1 Filter bracket 11 702037 5 Filter 12 709179 1 Terminal block 10 position 13 709192 1 Terminal block marker strip 10 position 14 505039 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 1 Motorized regulator assembly 0 15 psi 23 709007 1 Terminal block 14 position 24 7709009 1 Terminal block marker strip 14 position 25 200082 Solenoid valve assembly 3 gang 26 500907 1 Solenoid valve bracket 27 200083 1 Solenoid valve assembly 4 gang 28 501170 1 Power supply 29 505041 1 Video card upper p c board 30 505049 CPU middle p c board 31 505600 1 Interface p c board assembly lower p c board Not shown 200110 1 Video CPU Interface p c board assembly 33 201080 1 I 0 p c board assembly 34 708078 3 Transducer 0 150 psi 35 708109 1 Transducer 0 15 psi Parts List FineLine 200PC User s Manual QUICK DATA SEE DETAIL BELOW 2 INNERLOGIC s DISPLAY DETAIL le lo 1 E f 1 tl t S 12345678910 Figure 8 16 Gas Console Exterior 8 20
127. o 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 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 will transmit the machine type 100 z FineLine 100PC 150 FineLine 150PC 200 FineLine 200PC 260 FineLine 260PC Sends a global command to all systems and sets the node focus to system nn Maintenance and Troubleshooting FineLine 200PC 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
128. o 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 086 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 029 0 PROCESS CUTTING TORCH PARTS an psi 080 0 CURRENT SET POINT 50 Alps 5 GAS OXYGEN y PIERCE DELAY TINE 0000 ms 72 0 USE THE NUMERICAL KEYPAD TO ENTER DELAY CURRENT MODE DELAY InnerLogic Inc Figure 5 2 Setting the Pierce Delay Time 5 2 Automatic Gas Console Advanced Functions FineLine 200PC User s Manual Altering Gas
129. ogen Optional FineLine 200PC User s Manual P12 P8 P7 P16 8j 8j Figure C 2 Hydrogen Manifold Mounting Location C 3 Hydrogen Optional FineLine 200PC User s Manual Operation The hydrogen manifold is fully integrated with the operating software of the FineLine 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 H17 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
130. om on the first primary winding to OV on the second primary winding and another 74 AWG jumper wire from on the second primary winding to on the third primary winding Connect the three phase primary power from the main contactor to one of the 230V connections on each primary winding See Figure 7 1 When the primary voltage of is changed the control transformer TR2 must also be rewired for the correct service voltage For 230V operation connect the white wire of control transformer TR2 to TB1 13 and the red white wire to TB1 14 460V 60Hz Operation For 460V operation install a 4 AWG jumper wire from to 230V on each primary winding total of 3 wires Now install a 4 AWG jumper wires from on the first primary winding to OV on the second primary winding and another 4 AWG jumper wire OV on the second primary winding to OV on the third primary winding Connect the three phase primary power from the main contactor to each of the 230V connections that are without jumper wires See Figure 7 2 When the primary voltage of TR1 is changed the control transformer TR2 must also be rewired for the correct service voltage For 460V operation connect the white wire of control transformer TR2 to 1 13 and the black wire to TB1 14 7 4 FineLine 200PC User s Manual Maintenance and Troubleshooting Ll 5 _ O HO 31 OI 022 E OCH 0 Z OTHO T Hoez OLHO Occ XOT
131. ontaining 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 200PC 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 wall mounted disconnect should be installed and fused according to local and national electrical codes The disconnect should be located as close as possible to the power supply so it can be turned off in case of an emergency e 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 th
132. ould 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 exposure 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 Page 3 of 8 A 3 Propylene Glycol MSDS Product Name Propylene Glycol Industrial Grade Flammable Limits In Air Autoignition Temperature Vapor Pressure Boiling Point 760 mmHg Vapor Density air 1 Specific Gravity 20 1 Freezing Point
133. ozzle Electrode 277145 277120 277130 1 9 S lt gt 6 22 Retaining Cap Swirl Ring Torch Main Body 217154 277153 277140 277000 Imperial Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Oxygen Oxygen Air Voltage Speed Height Height Delay Width ga in psi psi psi psi volts pm in in msec Gn 20 036 120 105 080 062 18 048 121 97 090 16 060 125 78 4110 065 14 075 35 85 6 2 126 65 105 100 12 1105 127 55 11 120 129 50 070 1120 1125 10 2135 131 40 Metric Material Preflow Plasma Shield Postflow 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 1 120 2615 2 0 1 6 1 5 124 2020 2 6 2 8 1 7 2 35 85 6 2 1615 100 126 27 2 5 1455 18 3 128 1285 2 9 3 1 1 Revised on 7 2 07 4 14 Operation FineLine 200PC User s Manual Mild Steel Cutting 50 Amps Oxygen Plasma Oxygen or Air Shield Shield Cap Nozzle Electrode 217115 277122 277131 D c m 55 Outer Cap Retaining Cap Swirl Ring Torch Main Body 277154 277153 277140 277000 217142 Imperial Cold Rolled Steel Oxygen Shield Swirl Ring 277140 Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air
134. r 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 200PC 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 a particular regulator is adjusting the corresponding valve status will display N A PREFLOW 123 VALVE STATUS OFF PLASMA 123 psi VALVE STATUS OFF SHIELD 123 psi VALVE STATUS OFF POSTFLOH 15 4 psi VALVE STATUS DN PRESS TO TOGGLE PREFLOW VALVE ON OFF DRESS TO TOGGLE PLASMA VALVE ON OFF BAS PRESS TO TOGGLE SHIELD VALVE ON OFF BAS PRESS ENT TO RETURN TD THE MAINTENANCE MENU CURRENT MODE PRESSURE DIAGNOSTICS InnerLogic Inc FINELINE 200PC Figure 5 12 Pressure Diagnostics Screen
135. rch 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 Temperature 0 10 20 30 40 50 60 Propylene Glycol Percent by Weight in Water Figure 3 8 Freezing Points of Aqueous Propylene Glycol Solutions 3 16 Installation FineLine 200PC 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 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 Coolant Flow LED will remain out until the coolant has filled the entire system and begins flowing back into the tank The coolant pump will turn off if the coolant level drops below the minimum level inside the reservoir If this happens add more coolant solution to the reservoir and return to Step 3 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 D
136. 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 6 2 Serial Communication FineLine 200PC User s Manual Troubleshooting Serial Communication When troubleshooting serial communication with the FineLine system switch to the View Serial Communication Screen to view incoming and outgoing data See Section 5 for information on the Serial Communication Screen 6 3 Serial Communication Note RS 422 Serial Commands FineLine 200PC 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 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 integ
137. reen as shown 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 xm SUBSTANCE MILD STEEL HOT GAS AIR THICKNESS 0 125 inches psi 025 0 PLERSE PROCESS CUTTING WAIT m TORCH PARTS s d CURRENT SET POINT 50 AMPS gt SHIELD P DELAY GAS OXYGEN PIERCE DELAY 0000 ms psi 099 0 PRESS F3 TO SAVE SETTING FOR 0 125 in MILD STEEL HOT CURRENT MODE STATUS InnerLogic Inc 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 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 Operation FineLine 200PC 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 av
138. ropylene 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 Section 302 Extremely Hazardous 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
139. sult 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 change 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 A 8 Electromagnetic Compatibility FL 200PC User s Manual Appendix B Electromagnetic Compatibility EMC Background The 380V 50Hz and 415V 50Hz FineLine 200PC plasma cutting systems are manufactured to comply with the European standard EN 50199 Electromagnetic compatibility EMC
140. t Delay Width in psi psi psi psi volts ipm in in msec in 3 16 35 60 36 13 135 80 100 200 200 090 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 5 35 60 36 13 135 2030 2 5 5 1 200 2 3 H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen 1 Revised on 7 2 07 4 22 Operation FineLine 200PC 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 Nozzle Electrode 277125 277131 0 0 Outer Cap Retaining Cap Swirl Ring Torch Main Body 271154 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 pm in in msec Gn 10 195 132 120 060 1150 200 085 3 16 134 100 070 175 25 80 25 2 1 4 140 75 090 200 300 090 3 8 148 50 120 225 450 Material Preflow Plasma Shield Postflow Arc Travel Cutting Pierce Motion Kerf Thickness Air Air Nitrogen Air Voltage Speed Height Hei
141. t 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 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 DUTPUT VOLTAGE 115 PHASE 1 115 OUTPUT CURRENT AMPS PHASE 2 VOLTS PARAMETER TX STATUS READY PHASE 3 VOLTS ARC VOLTAGE 110 0 VOLTS TRAVEL SPEED 180 CUTTING HEIGHT 0 100 INCHES USE THE SCROLL KEYS PIERCE HEIGHT 0 135 INCHES EDIT CUT PARAMETERS FINELINE 200PC PRESS F3 TO TRANSMIT CUTTING PARAMETERS TO TORCH HEIGHT CONTROL PRESS MENU THEN crenus TO RETURN STATUS SCREEN CURRENT MODE UOLTAGE InnerLogic Inc Figure 4 9 Voltage Screen 4 10 Operation FineLine 200PC 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
142. talling the torch parts do not use an excessive amount of 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 200PC User 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 mus
143. tatus is returned in the following form bits O fault 1 ok LSB Bit 0 RHF Door LSB Bit 1 AC Power 1 58 Bit 2 Coolant Flow LSB Bit 3 Coolant Level LSB Bit 4 z 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 Cutting height in mils inches 1000 Valid Range 0 to 999 Also updates the Inova height control if used Serial Communication Command 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 45 46 47 48 49 50 51 52 254 Hex String nn 2C 00 AA nn FA 2D 0D nn FA 2E 00 01 0D 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 0D AA nn FA 34 0D AA C8 FA FE 00 nn 0D 6 8 FineLine 200PC User s Manual Additional Information 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 t
144. 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 200PC 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 200PC 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 200PC User s Manual Installation 3195 8 31895 39VI 10A 31975 318 310SNOO 71091409 VAONI ALOW3Y VAONI 318 2 10 1 02 3105 09 lfidNI YAMOd F 393IdAYOM Qv3l AYOM 50 41 1 1009 15 OR 2 SQV31 HOYOL 58731 N3MOd 318 1041405 GIONdIOS 1 YANOILISOd VAONI 35 5 99V AlddNS YAMOd iagram D 10n 3 1 System Interconnect Figure Installation FineLin
145. the will transmit the least significant word of the shield cap part number If requested in command 30 the will transmit the most significant word of the outer cap part number If requested in command 30 the will transmit the least significant word of the outer cap part number 01 Send material type 02 z Send material thickness 03 z Send current set point 04 z Send pierce delay time 05 z Send preflow gas type 06 Send preflow pressure 07 Send plasma gas type 08 Send plasma gas pressure 09 z Send shield gas type 10 z Send shield gas pressure 11 2 Send recommend arc voltage 12 z Send recommended pierce height 13 z Send recommended cutting height 15 Send recommended travel speed 16 Send torch body part number msw 17 Send torch body part number 15 18 Send electrode part number msw 19 Send electrode part number Isw 20 z Send swirl ring part number msw 2 Send swirl ring part number Isw 22 Send nozzle part number msw 23 Send nozzle part number 15 24 z 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 15 28 Send outer cap part number msw 29 Send outer cap part number lsw 32 Send process select 33 z Send software version 34 z Send cutting chart version 35 z Send number of pierces 36 Send number of pierce errors 48 Send cutting condition type 51 z Send arc off dela
146. the cutting current or material type Oxygen Inlet Q3 e Oxygen must be supplied to the unit when mild steel is being cut Nitrogen Inlet Q3 e Nitrogen must be supplied to the unit when aluminum is being cut or stainless steel is being cut at 50 70 100 or 200 amps Auxiliary Inlet e The auxiliary inlet is reserved for future use 29 03 62 0 POSTFLOW PLASMA SHIELD PREFLOW AUXI D OUT OUT L Figure 3 6 Automatic Gas Console Input Connections 3 13 Installation FineLine 200PC User s Manual 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 Q3 Connect the Preflow Hose to the preflow outlet as shown 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 Q7 Connect the Plasma Hose to the plasma outlet as shown Note that the plasma outlet has right hand threads Postflow Outlet Connect the Postflow Hose to the postflow outlet as shown that the postflow outlet has right hand threads Figure 3 7 Automatic Gas Console Output Connections 3 14 Installation FineLine 200PC
147. ting 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 RESTORE DEFAULTS FOR THE ABOVE SETTING PRESS aee THEN THEN oas TO RESTORE ALL DEFAULT SETTINGS PRESS THEN THEN TO RESTORE CORRUPTED USER DATA PRESS F3 TO CHANGE SUBSTANCE TYPE CURRENT MODE RESTORE DEFAULTS InnerLogic Inc FINELINE 200PC Figure 5 14 Restore Factory Defaults Screen 5 15 Automatic Gas Console Advanced Functions FineLine 200PC 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
148. to the input terminal block TB5 as shown in Figure 3 2 TB5 is located on the base of the power supply behind the left side cover Be sure to connect the primary ground cable to the ground stud on the input terminal block TB5 Location Disconnect Box Connections Relief Figure 3 2 Primary Power Connections 3 4 Installation FineLine 200PC 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 2 1 Route one end of the 10AWG Power Supply Nozzle Lead through the upper strain relief on the rear of the power supply and connect it to the Nozzle terminal 2 Route the other end of the Power Supply Nozzle Lead through the strain relief on the RHF console and connect it to the Pilot terminal on the RHF console printed circuit board Power Supply CTP Sensor Lead 3 1 Route the end of 14AWG Power Supply Sensor Lead with the ring terminal thro
149. tridge Level LED Extinguishes when the coolant level in the tank has dropped below the required minimum level Add more coolant to clear the error e Coolant Temperature LED Extinguishes when the coolant temperature has risen above the maximum operating temperature Ensure that the heat exchanger fan is running and that the heat exchanger is free from dust Blow out the heat exchanger and fan with clean dry oil free compressed air Leave the unit running until the LED illuminates 7 8 Maintenance and Troubleshooting FineLine 200PC 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 The following chart lists the errors and the corresponding number of blinks LED22 Number of Blinks Error 1 No transferred arc established 2 TAC lost before current slope up 5 lost during current slope up 4 TAC lost while cutting 5 TAC
150. tting 100 Amps Air Plasma Nitrogen Shield This gas combination gives medium cut quality and minimum dross levels Shield Cap Nozzle Electrode 277284 277282 Retaining Cap Swirl Ring Torch Main Body 217154 217151 217283 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 pm in Gn msec Gn 1 4 141 100 135 200 250 092 3 8 25 94 35 0 147 80 4170 225 350 095 1 2 154 55 210 250 450 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 6 140 2595 32 5 0 250 2 3 10 25 94 35 0 148 1935 4 4 5 8 450 2 4 12 152 1540 5 0 6 2 1 Revised on 7 2 07 4 25 Operation FineLine 200PC 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 277297 277135 91 Retaining Cap Swirl Ring Torch Main Body 217154 277266 277139 277000 Imperial Material Preflow Plasm
151. ugh 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 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 5 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 3 5 Installation FineLine 200PC User s Manual Power Supply Coolant Return Hose 6 1 Connect one end of the Power Supply 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 7 1 Route one end of the 1 OAWG Work Ground Lead through the middle stra
152. units only PAR CR2 relay R7 R8 3 ohm pilot arc resistor PAT IGBT drive p c board assembly PAT IGBT 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 I O 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 1 relay socket CRI hold down clip TB6 terminal block marker strip 4 position TB6 terminal block 4 position Bulb power on switch LED lens green Fan 120V Drain petcock Fan guard terminal block large Strain relief F2 fuse MDL 5A Fan front panel R9 2 ohm pilot arc resistor 8 2 Parts List FineLine 200PC User s Manual FINELINE 200PC UTTING SYSTEM INNERLOGIG UVvwvwvwwwwwwwwwwwwwwww 12345678 9101112 1314 9 12345678 91011121314 9565666 e sol Front panel fans not shown item numbers 42 and 82 Figure 8 1 Power Supply Front View 8 3 Parts List FineLine 200PC User s Manual 10 1112 13 14 9 5 678 ojoje
153. val tool Figure 8 6 Torch and Torch Valve Assembly 8 0 Parts List FineLine 200PC User s Manual Shielded Torch Leads Part Number Length 200304 10 10 ft 3 0 m 200304 15 15 ft 4 6 m 200304 20 20 ft 6 1 m 200304 25 25 ft 7 6 m 200304 30 30 ft 9 1 m 200304 35 35 ft 10 7 m 200304 40 40 ft 12 2 m 200304 45 45 ft 13 7 m 200304 50 50 ft 15 2 m 4 Figure 8 7 Shielded Torch Leads Parts List FineLine 200PC User s Manual Gas Hose Package Part Number Length 200317 20 20ft 6 1 m 200317 25 25ft 7 6 m 200317 30 30 9 1 m 200317 35 35 ft 10 7 m 200317 40 40 ft 12 2 m 200317 45 45 13 7 m 200317 50 50 ft 15 2 m 200317 55 55 ft 16 8 m 200317 60 60 18 3 m 200317 65 65 19 8 m 200317 70 70 21 3 m 200317 75 75 22 9 m 200317 80 80 ft 24 4 m 200317 85 85 ft 25 9 m 200317 90 90 ft 27 4 m 200317 95 95 ft 29 0 m 200317 100 100 ft 30 5 m PLASMA GAS HOSE PREFLOW GAS HOSE E SHIELD GAS HOSE POSTFLOW GAS HOSE TORCH SOLENOID CONTROL CABLE JUU CEA ec Figure 8 8 Gas Hose Package Parts List Coolant and Power Leads FineLine 200PC User s Manual Part Number Length 2
154. y satisfactory 12V interlock power supply satisfactory 15V analog power satisfactory 24V gas 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 15 analog power satisfactory Blinks to show serial transmission to automatic gas console Blinks to show serial transmission from automatic gas console 7 6 Maintenance and Troubleshooting FineLine 200PC 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 e LED 7 PUMP e LED5 LATCH The following LED s should illuminate in sequence after a start signal is received LED 8 START LED 4 PREFLOW LED 14 HOLD OUT LED 2 CON LED 9 CHOPPER LED 1 PAR LED 10 PAT LED 27 HIGH FREQ LED 11 TAC LED 24 PLASMA LED 12 MOTION After a transferred cuttin
155. y time 52 z Send machine type Serial Communication Command 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 Set Cutting Height 33 34 35 36 37 38 39 40 41 42 43 Hex String AA nn FA 20 00 0D AA nn FA 21 00 0D 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 00 01 0D AA nn FA 29 00 01 0D AA nn FA 2A 0D AA nn FA 2B 0D 6 7 FineLine 200PC User s Manual Additional Information 00 z Cutting 01 Marking If requested in command 30 the will transmit the software version x 10 If requested in command 30 the will transmit the cutting chart version x 10 If requested in command 30 the will transmit the number of pierces Range 0 to 9999 If requested in command 30 the 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 838 is transmitted The s

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