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Lincoln Electric FineLine 12864 Operator's Manual

300hd plasma system
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Operator's Manual
FineLine
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www.lincolnelectric.com/register
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www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10560
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I
s s
u
e
D
a
e t
© Lincoln Global, Inc. All Rights Reserved.
*This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to
non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR.
300HD Plasma System
®
Dec-19
For use with machines having Code Numbers:
12864

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Summary of Contents for Lincoln Electric FineLine 12864

  • Page 1 Operator’s Manual FineLine 300HD Plasma System ® For use with machines having Code Numbers: 12864 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM10560 Dec-19 © Lincoln Global, Inc. All Rights Reserved. *This information is subject to the controls of the Export Administration Regulations [EAR].
  • Page 2 We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s...

  • Page 3: Table Of Contents

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System Table of Contents 1.0 Safety Warnings ..................5 1.1 General Precautions ................5 1.2 California Proposition 65 ..............5 1.3 Ultraviolet Radiation Protection ............5 1.4 Fire Prevention ..................5 1.5 Noise Protection ................... 6 1.6 Toxic Fume Prevention ................
  • Page 4 FineLine 300HD Plasma System BK8053-000107 Rev A.01 4.0 Operation ....................49 4.1 Status Lights and Buttons ..............49 4.2 Operational Sequence................ 51 4.3 FineLine Plasma Console App – Operation ........53 4.4 FineLine Plasma Console App – Diagnostics ........59 5.0 LC300M Torch Consumables ...............

  • Page 5: Safety Warnings

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 1.0 Safety Warnings WARNING 1.3 Ultraviolet Radiation Protection 1.1 General Precautions Plasma cutting produces ultraviolet radiation similar to Whereas plasma cutting has been used a welding arc. This ultraviolet safely for years, it does require certain radiation can cause skin and precautions to ensure the safety of the eye burns.

  • Page 6: Noise Protection

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 1.7 Health Support Equipment WARNING The System creates electric and magnetic fields that 1.5 Noise Protection may interfere with certain types of health support The System generates high equipment, such as noise levels while cutting. pacemakers.

  • Page 7: Electric Shock Prevention

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System • Wear insulated gloves and shoes while WARNING operating or performing maintenance on the System. 1.8 Electric Shock Prevention • Make sure the System is switched off at the wall disconnect before servicing the The System uses high open Power Supply or torch.

  • Page 8: Explosion Prevention

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 • Clear the compressed gas cylinder WARNING connection point by opening the valve momentarily prior to installing a regulator. 1.9 Explosion Prevention • Never lubricate compressed gas cylinder valves or pressure regulators with any The System uses compressed type of oil or grease.

  • Page 9: Safety Standards Booklet Index

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 1.10 Safety Standards Booklet Index For further information concerning safety practices to be exercised with plasma arc cutting equipment, please refer to the following publications: • AWS Standard AWN, Arc Welding and Cutting Noise, obtainable from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126.
  • Page 10 FineLine 300HD Plasma System BK8053-000107 Rev A.01 • 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. • CGA booklet TB-3, Hose Line Flashback Arrestors, obtainable from the Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202.

  • Page 11: Specifications

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 2.0 Specifications 2.1 System Description The FineLine 300HD Plasma System is designed for mechanized plasma cutting ® applications. The 300HD System includes the FineLine 300HD Power Supply, FineLine Automatic Gas Console, FineLine Arc Start Console, FineLine Plasma Console App, and Magnum PRO LC300M Plasma Torch.

  • Page 12: Compliance

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 2.2.2 Supplied Optionally • Oxygen Supply Gas Hose............BK200362-XX • H17 Supply Gas Hose ............. BK200363-XX • Air Supply Gas Hose ............... BK200364-XX • Nitrogen or Argon Supply Gas Hose ........BK200365-XX • Supply Gas Hose Fittings Kit ............BK300421 •...

  • Page 13: Fineline 300Hd Power Supply

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 2.4 FineLine 300HD Power Supply K4900-1 Input Voltage and Current:  Duty Cycle ..................100%  Input Voltage ±10%..........380-415 / 460 / 575  Input Amperes ..............122 / 107 / 93 ...

  • Page 14: Cooling System And Torch Coolant

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 2.5 Cooling System and Torch Coolant Cooling System (located inside the Power Supply):  Discharge pressure ............. 175 psi (12.1 bar)  Flow rate ............1.5 gal/min (5.7 liters/min)  Coolant fluid ............ Propylene glycol solution ...

  • Page 15: Gas Supply

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 2.6 Gas Supply Plasma gas types: Mild Steel ..................Oxygen Stainless Steel ............Air, Nitrogen, or H17 Aluminum ....................Air Shield gas types: Mild Steel ................Oxygen or Air Stainless Steel ..............Air or Nitrogen Aluminum ................

  • Page 16: Fineline Automatic Gas Console (Agc)

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 2.7 FineLine Automatic Gas Console (AGC) Part Number ..................BK300350 Weight .................. 15.7 lbs (7.12 kg) Physical Dimensions and Mounting: 6.51” (165mm) 11.08” 7.30” (281mm) (185mm) 2.70” (69mm) 4.56” 4.56” (116mm) (116mm) Ø 0.28” (7.1mm) 3 MOUNTING HOLES FOR ¼”...

  • Page 17: Fineline Arc Start Console (Asc)

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 2.8 FineLine Arc Start Console (ASC) Part Number ..................K4901-1 Weight ................... 18.9 lbs (8.57 kg) Physical Dimensions and Mounting: 12.77” (324mm) 8.00” 10.98” (203mm) (279mm) Ø 0.31” (7.9mm) 4 MOUNTING HOLES FOR ¼” (M6) BOLTS 5.29”...

  • Page 18: Magnum Pro Lc300M Plasma Torch

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 2.9 Magnum PRO LC300M Plasma Torch Torch Part Number ................BK602622 Torch Weight (with consumables) ......... 2.10 lbs (0.95 kg) Torch Handle Part Number ............... BK602621 Torch Handle Weight ............. 0.95 lbs (0.43 kg) Torch Clamp Part Number ..............

  • Page 19: Fineline Plasma Console App & Cutlinc Server

    The Fineline Plasma Console App is the user interface for the FineLine Plasma System. CutLinc Server is the communication hub for the FineLine Plasma System. They are already integrated into certain Lincoln Electric HMIs. Other HMIs require both to be integrated by the OEM or end-user.

  • Page 20: Airborne Noise Emissions

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 2.12 Airborne Noise Emissions The 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.

  • Page 21: Installation

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 3.0 Installation 3.1 Component Placement 3.1.1 Power Supply The Power Supply should be lifted by a forklift, pallet jack or crane. In order to prevent damaging the Power Supply when lifting with a forklift or pallet jack, the forks should be of adequate length to protrude on the far side of the Power Supply.
  • Page 22 FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.1.2 Automatic Gas Console (AGC) The AGC must be mounted within 8 ft. (2.44m) of the torch. Secure the AGC to the mounting surface using three ¼” or M6 bolts. Refer to the mounting pattern shown in Section 2.7.
  • Page 23 BK8053-000107 Rev A.01 FineLine 300HD Plasma System 3.1.3 Arc Start Console (ASC) The ASC should be mounted in a convenient location that is away from other electronic control devices. The high voltage pulse generated inside the unit may interfere with the operation of sensitive control electronics. The ASC is usually mounted on the gantry of the cutting machine or on the cutting table.
  • Page 24 FineLine 300HD Plasma System BK8053-000107 Rev A.01 BLANK PAGE This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 24 of 118...

  • Page 25: Connection Diagram

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.2 Connection Diagram Coolant Supply Hose Coolant Return Hose Torch Leads Power Supply Input Output Side Side PS Electrode Lead PS Nozzle Lead ASC Control Cable Output Input Side Side Torch Interconnect Leads Cable Gas Hose Shield Hose...

  • Page 26: Radio Frequency (Rf) And Electromagnetic Interference (Emi)

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.3 Radio Frequency (RF) and Electromagnetic Interference (EMI) 3.3.1 Overview This section describes the proper grounding of the System components to minimize Radio Frequency (RF) and Electromagnetic Interference (EMI). The Arc Start Console (ASC), by nature of its function in the plasma system, is a source of RF/EMI along with other system components such as drive amplifiers.
  • Page 27 BK8053-000107 Rev A.01 FineLine 300HD Plasma System Each plasma system component as well as any other related equipment (CNC, motor drives, etc.) must have a separate ground connection to the star ground point even if bolted to the gantry or Power Supply. Grounds are not to be daisy-chained. For components mounted to the cutting table gantry, it is acceptable to create a star ground at the gantry with a single ground cable connecting the gantry star ground with the cutting table star ground.

  • Page 28: Power Supply Input Connections - Primary Power

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.4 Power Supply Input Connections - Primary Power ** Before connecting primary power, check the data plate on the Power Supply to verify the voltage required ** Refer to chart below for recommended fuse, wire sizes, and type of copper wires. Fuse the input circuit with the recommended super lag fuses or delay type breakers (also called “inverse time”...
  • Page 29 BK8053-000107 Rev A.01 FineLine 300HD Plasma System Voltage Selection Jumper 380-415V 460V 575V Access Panel Removed Route through Strain Relief. Disconnect Box Figure 2: Primary Power Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 30: Power Supply Input Connections - Gas Supply

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.5 Power Supply Input Connections - Gas Supply Connectors are sized for 3/8” 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.

  • Page 31: Power Supply Output Connections

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 3.6 Power Supply Output Connections Refer to Figure 4 and Figure 5 for the physical location of all connections. Remove the access panel as shown in Figure 4 to begin; replace when installation is complete. When making brass fitting connections, use two opposing wrenches and only tighten enough to make water or gas seals.
  • Page 32 FineLine 300HD Plasma System BK8053-000107 Rev A.01 Access Panel Removed Circuit Breaker for P1 Connector, 24VDC, 3.5A Route through opening. To ASC To Star Ground To AGC To ASC Figure 4: Power Supply Output Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
  • Page 33 BK8053-000107 Rev A.01 FineLine 300HD Plasma System From Power Supply Route through Strain Relief. From Power Supply Figure 5: Power Supply Output Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 34: Arc Start Console Output Connections

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.7 Arc Start Console Output Connections Refer to Figure 6 for the physical location of all connections. Secure the cover on the ASC when installation is complete. When making brass fitting connections, use two opposing wrenches and only tighten enough to make water or gas seals.
  • Page 35 BK8053-000107 Rev A.01 FineLine 300HD Plasma System Torch Nozzle Lead Torch To Star Electrode / Ground Coolant Supply Torch Leads Torch Torch CTP Coolant Sensor Lead Return From ASC Figure 6: ASC Output Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 36: Automatic Gas Console Input Connections

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.8 Automatic Gas Console Input Connections Refer to Figure 7 for the physical location of all connections. Make connections in the order shown below. When making brass fitting connections, use two opposing wrenches and only tighten enough to make gas seals. The fittings are subject to damage if over tightened.
  • Page 37 BK8053-000107 Rev A.01 FineLine 300HD Plasma System To Star Ground From Power Supply From AGC Figure 7: AGC Input Connections This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 38: Automatic Gas Console Output Connections

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.9 Automatic Gas Console Output Connections Refer to Figure 8 for the physical location of all connections. Plasma Hose 1) Connect the plasma hose, which exits from the torch leads about 6 ft. (1.83m) from the torch end, to the fitting on the output side of the AGC labelled with the symbol shown.

  • Page 39: Torch Connections

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 3.10 Torch Connections Refer to Figure 9 for the physical location of all connections. When making brass fitting connections, use two opposing wrenches and only tighten enough to make water or gas seals. The fittings are subject to damage if over tightened. Torch Leads (Torch End) Torch Leads and Torch Handle...

  • Page 40: Mount The Torch

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.11 Mount the Torch Refer to Figure 10 for the physical location of all connections. Torch Handle 1) Hold the torch stationary and thread the Torch Leads torch handle onto the torch until hand- tight.

  • Page 41: Install Consumables

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 3.12 Install Consumables DANGER Electric Shock Can Kill. Remove primary power from the System before installing or removing consumables. WARNING Hot Parts Can Burn Skin. Do not touch hot parts bare-handed. Always use gloves when handling the torch as it can be hot after cutting, especially with high amperages and long cut times.

  • Page 42: Ethernet Connections

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.13 Ethernet Connections Refer to Figure 11 for the physical location of all connections. Replace the access panel on the Power Supply when installation is complete. Power Supply to Ethernet Router/Switch 1) Route the bayonet connector end of an Ethernet cable through the opening in the rear of the Power Supply.

  • Page 43: Emergency Stop (Estop) Circuit

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 3.14 Emergency Stop (EStop) Circuit The FineLine 300HD System incorporates an EStop circuit meeting Performance Level (d) Category 3 requirements as per ISO 13849-1 and IEC 62061 standards. The EStop circuit employs a Safety Relay which controls both the Power Supply and AGC outputs, disabling both when the EStop is engaged.

  • Page 44: Cnc Interface

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.15 CNC Interface The AGC provides an optional CNC interface (P6) for legacy products and robotic applications. The following I/O is provided: • Start Input (24Vdc, 20ma) o Pin 1 (+), Pin 2 (-) •...

  • Page 45: Software Installation

    3.16 Software Installation 3.16.1 CutLinc Server Installation and Commissioning If the System uses a non-Lincoln Electric HMI (CNC Controller or Industrial Computer), the CutLinc Server must be installed and commissioned. This is not required when using a Lincoln Electric provided HMI.
  • Page 46 3.16.2 Plasma Console App Installation If the System uses a non-Lincoln Electric HMI (CNC Controller or Industrial Computer), the Plasma Console App must be installed. Installation of the Plasma Console App is not required when using a Lincoln Electric provided HMI.

  • Page 47: Fill The Cooling System

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 3.17 Fill the Cooling System To avoid freeze damage and coolant leakage during shipment, the System is delivered with very little coolant. DO NOT OPERATE the System until it has been filled with coolant. Important: Never turn on the System when the coolant reservoir is empty or if the reservoir cap is not installed.

  • Page 48: Installation Checklist

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 3.18 Installation Checklist  System is located within the specified operating environment and the components have been placed as specified. Refer to Sections 2.0 and 3.1.  System is properly grounded according to local and national codes. ...

  • Page 49: Operation

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 4.0 Operation 4.1 Status Lights and Buttons 4.1.1 Power Supply Status DC Power Temperature ON Button Icon Name Color Description Blinking Green Performing initial power up sequence. Steady Green No errors/faults. Status Error. Record error code and refer to Blinking Red Section 7.0 for troubleshooting.
  • Page 50 FineLine 300HD Plasma System BK8053-000107 Rev A.01 4.1.2 Plasma Console App System ON Button Icon Name Color Description Not ready. System outputs are disabled. Grey Press to enter ready state. System Grey System outputs are being enabled. This may take up (no icon) to 8 seconds.

  • Page 51: Operational Sequence

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 4.2 Operational Sequence 4.2.1 Power Up the System Apply power to the Ethernet router/switch and HMI. Start the Plasma Console App. Apply primary (wall) power to the System. The status light on the Power Supply will initially blink green, and then: •...
  • Page 52 FineLine 300HD Plasma System BK8053-000107 Rev A.01 Initiate a start signal via the CNC, which will trigger the following sequence: a. Cooling system starts circulating coolant (cooling fans start). b. Gas preflow is initiated. c. Power supply output is energized; the DC Power light is steady red. d.

  • Page 53: Fineline Plasma Console App - Operation

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 4.3 FineLine Plasma Console App – Operation 4.3.1 Overview The FineLine Plasma Console App is the user interface for the entire System. It runs on the HMI, which can be a CNC Controller or Industrial Computer. Screen Navigation and System ON Button Press the navigation buttons along the bottom of the screen to access all the settings and parameters described in this section.
  • Page 54 FineLine 300HD Plasma System BK8053-000107 Rev A.01 4.3.2 Pop-Up Warnings and Notifications A pop-up window displays various conditions, errors and notifications as well as description of the issue. All codes are recorded in the error log (Diagnostics > Error Log). Refer to Section 7.0 for troubleshooting. Common Examples Action Required Alert / Error and Icon...
  • Page 55 BK8053-000107 Rev A.01 FineLine 300HD Plasma System 4.3.3 Prepare to Cut or Mark Press the Material button and then select the Material Type, Thickness, and Process. The Plasma Console App uses those selections to automatically set the Current (Amps), Gas Types, and Pressures. Select the Material Type Press the Material Type button and then select the material to be...
  • Page 56 FineLine 300HD Plasma System BK8053-000107 Rev A.01 4.3.4 Review Current, Gas Types and Pressures Current (Amps), Gas Types, and Pressures are automatically set to default values based upon Material Type, Thickness, and Process selections, but they can be changed to suit the application or operator’s experience. Changes to Material Type, Thickness, or Process will automatically reset Current (Amps), Gas Types, and Pressures to default values based upon the cutting charts.
  • Page 57 BK8053-000107 Rev A.01 FineLine 300HD Plasma System 4.3.5 View and Install Torch Parts Press the View Torch Parts button to see the required consumables to cut or mark based upon the active selections on the Material screen. The picture and part number of each consumable are displayed for reference.
  • Page 58 FineLine 300HD Plasma System BK8053-000107 Rev A.01 4.3.7 Verify Gas Pressures Press the Gases button to verify the cutting and marking gas pressures. The Actual value and the Set Point value are displayed. Gases will purge automatically when switching between oxidizing gas or oxygen containing gas to combustible gas and vice versa.

  • Page 59: Fineline Plasma Console App - Diagnostics

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 4.4 FineLine Plasma Console App – Diagnostics 4.4.1 Diagnostics > Pressures/Coolant Tab Press the Diagnostics button followed by the Pressures/Coolant tab to access the screen and settings described below. Input Pressure The values displayed are measured at the Power Supply. Coolant Press the Fill/Flush button to circulate coolant through the System during the initial filling or during maintenance.
  • Page 60 FineLine 300HD Plasma System BK8053-000107 Rev A.01 4.4.3 Diagnostics > Electrical Tab Press the Diagnostics button followed by the Electrical tab to access the screen described below. This screen displays the Automatic Gas Console and Power Supply electrical parameters. 4.4.4 Diagnostics > Cut Info Tab Press the Diagnostics button followed by the Cut Info tab to access the screen described below.
  • Page 61 BK8053-000107 Rev A.01 FineLine 300HD Plasma System 4.4.5 Diagnostics > Error Log Tab Press the Diagnostics button followed by the Error Log tab to access the screen described below. Filters along the right side of the screen can be used to limit the data displayed based upon Error # or Date.
  • Page 62 FineLine 300HD Plasma System BK8053-000107 Rev A.01 4.4.7 Diagnostics > Versions Tab Press the Diagnostics button followed by the Versions tab to access the screen described below. This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.

  • Page 63: Lc300M Torch Consumables

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 5.0 LC300M Torch Consumables 5.1 Maximizing Consumable Life Use the following guidelines to maximize consumable parts life: The System utilizes the latest advancement in technology for extending the life of the torch consumable parts. To maximize the life of the consumable parts, it is imperative that the shutdown procedure of the arc is carried out properly.

  • Page 64: Cut Quality

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 5.2 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 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.

  • Page 65: Piercing Thick Materials

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 5.3 Piercing Thick Materials Care must be taken when piercing thick materials in order to prevent damage to the shield cap and nozzle. As with all thicknesses, the pierce height must be set high enough so the metal ejected while piercing does not come into contact with the shield cap.

  • Page 66: Selecting Consumables

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 5.5 Selecting Consumables Mild Steel – Oxygen Plasma / Air Shield* Outer Shield Retaining Swirl Nozzle Electrode Torch Ring BK602365 BK602340 BK602338 BK602312 BK602354 BK602300 BK602622 BK602365 BK602342 BK602338 BK602314 BK602356 BK602301 BK602622 BK602365 BK602343 BK602339...

  • Page 67: Replacing Consumables

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 5.6 Replacing Consumables DANGER Electric Shock Can Kill. Remove primary power from the System before installing or removing consumables. WARNING Hot Parts Can Burn Skin. Do not touch hot parts with bare hands. Always use gloves when handling the torch as it can be hot after cutting, especially with high amperages and long cut times.
  • Page 68 FineLine 300HD Plasma System BK8053-000107 Rev A.01 Thread the retaining cap onto the torch until it is fully seated. Apply lubricant to the o-ring on the shield cap. Push the shield cap onto the retaining cap until it is fully seated or push the shield cap into the outer cap until it is fully seated.

  • Page 69: Cutting Charts

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 5.7 Cutting Charts The cutting charts shown on the following pages are intended to give the operator the best starting point to use when making a cut on a particular material type and thickness.
  • Page 70 FineLine 300HD Plasma System BK8053-000107 Rev A.01 Mild Steel - 30 Amps - Oxygen Plasma / Oxygen Shield Shield Cap Nozzle Electrode BK602340 BK602312 BK602300 Outer Cap Retaining Cap Swirl Ring Torch BK602365 BK602338 BK602354 BK602622 Imperial* Material Travel Cutting Pierce Pierce Kerf...
  • Page 71 BK8053-000107 Rev A.01 FineLine 300HD Plasma System Mild Steel - 80 Amps - Oxygen Plasma / Air Shield Shield Cap Nozzle Electrode BK602342 BK602314 BK602301 Outer Cap Retaining Cap Swirl Ring Torch BK602365 BK602338 BK602356 BK602622 Imperial* Material Travel Cutting Pierce Pierce Kerf...
  • Page 72 FineLine 300HD Plasma System BK8053-000107 Rev A.01 Mild Steel - 140 Amps - Oxygen Plasma / Air Shield Shield Cap Nozzle Electrode BK602343 BK602315 BK602309 Outer Cap Retaining Cap Swirl Ring Torch BK602365 BK602339 BK602358 BK602622 Imperial* Material Travel Cutting Pierce Pierce Kerf...
  • Page 73 BK8053-000107 Rev A.01 FineLine 300HD Plasma System Mild Steel - 200 Amps - Oxygen Plasma / Air Shield Shield Cap Nozzle Electrode BK602345 BK602317 BK602304 Outer Cap Retaining Cap Swirl Ring Torch BK602365 BK602332 BK602359 BK602622 Imperial* Material Travel Cutting Pierce Pierce Kerf...
  • Page 74 FineLine 300HD Plasma System BK8053-000107 Rev A.01 Mild Steel - 300 Amps - Oxygen Plasma / Air Shield Shield Cap Nozzle Electrode BK602346 BK602318 BK602305 Outer Cap Retaining Cap Swirl Ring Torch BK602365 BK602369 BK602360 BK602622 Imperial* Material Travel Cutting Pierce Pierce Kerf...

  • Page 75: Maintenance

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 6.0 Maintenance WARNING DANGER Electric Shock Can Kill. • The System utilizes potentially fatal A.C. and D.C. voltages. Do not touch electrically hot parts. • Only qualified maintenance personnel should perform maintenance on the System. •...

  • Page 76: Routine Maintenance

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 6.1 Routine Maintenance These tasks should be performed on a monthly basis unless otherwise noted. In excessively dirty environments or in heavy usage situations, these tasks should be performed more frequently. 6.1.1 Power Supply Examine the sheet metal case for dents or other damage and repair as required.
  • Page 77 BK8053-000107 Rev A.01 FineLine 300HD Plasma System 6.1.3 Arc Start Console (ASC) Open the cover of the ASC and verify that all leads and hoses are tightened securely. Only tighten the fittings enough to make a coolant or gas seal. The fittings are subject to damage if over tightened.

  • Page 78: Coolant Filter Replacement (Without Coolant Flush)

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 6.2 Coolant Filter Replacement (without coolant flush) Important: When handling coolant, wear nitrile gloves and safety glasses. Remove primary (wall) power from the System. Use a Torx T27 screwdriver to loosen the four screws on the right side of the Power Supply that secure the coolant filter access panel.

  • Page 79: Coolant Flush And Filter Replacement

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 6.3 Coolant Flush and Filter Replacement Important: Never turn on the System when the coolant reservoir is empty. Important: When handling coolant, wear nitrile gloves and safety glasses Important: Only use approved coolant. Commercially available antifreeze contains corrosion inhibitors that will damage the cooling system.
  • Page 80 FineLine 300HD Plasma System BK8053-000107 Rev A.01 Blow compressed air (100 psi maximum) into the coolant supply hose. This will force the remaining coolant from the torch, torch leads, and supply hose into the reservoir and into the bucket through the pump supply hose. DO NOT blow air into to the coolant supply fitting on the back of the Power Supply.

  • Page 81: Consumable Inspection

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 6.4 Consumable Inspection When the cut quality is not satisfactory, use the following guidelines for determining which consumable parts need to be changed. Inspect all parts for dirt, debris, and excess o-ring lubricant and clean as necessary. Part Inspect For Corrective Action...

  • Page 82: Software/Firmware Updates

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 6.5 Software/Firmware Updates 6.5.1 Power Supply Firmware With the System powered, unzip the update installer onto the HMI’s local drive and then open the unzipped folder. Run ‘SystemUpdate.exe’ Select ‘Connect through Ethernet.’ Select ‘I do not know the IP address of the welder.’...
  • Page 83 AGC Firmware, Plasma Console App, and CutLinc Server are all updated or installed using a FineLine ServicePack: • FineLine ServicePack AO (p/n BK602650) is for Lincoln Electric HMIs, like Burny and Visual Machine Designer (VMD). • FineLine ServicePack SA (p/n BK602651) is for non-Lincoln Electric HMIs.
  • Page 84 FineLine 300HD Plasma System BK8053-000107 Rev A.01 BLANK PAGE This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 84 of 118...

  • Page 85: Troubleshooting

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 7.0 Troubleshooting WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.

  • Page 86: Error Codes

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 7.2 Error Codes Contact your Lincoln Electric service department for resolution of errors not described in this section. Plasma Console Specific Errors Error Possible Description Code Resolution RS422 Port did not open properly Invalid entry.
  • Page 87 Power Supply Specific Errors Error Status Description Possible Resolution Code Light 10000 Switchboard A Primary Over Current Report issue to Lincoln Electric service department. 10001 Switchboard B Primary Over Current 10003 Switchboard A Fault 10004 Switchboard B Fault 10006 Secondary Over Current...

  • Page 88: Power Supply (Ps) Interconnect Cable

    Read the error conde blinking on the front of the power supply and report the fault to Lincoln Electric service department for assistance. This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
  • Page 89 BK8053-000107 Rev A.01 FineLine 300HD Plasma System Automatic Gas Console Specific Errors Error Telnet Description Possible Resolution Code 20776 0x0308 REG: invalid read command 20779 0x030B REG: CRC 22816 0x0B00 CRC: invalid input 22817 0x0B01 CRC: incorrect CRC 23082 0x0C0A RS485 termination resistors not detected 23331 0x0D03 FM: memory card not ready...
  • Page 90 FineLine 300HD Plasma System BK8053-000107 Rev A.01 Automatic Gas Console Specific Errors Error Telnet Description Possible Resolution Code 24109 0x100D EX: pac timeout 1) Verify have OCV. 2) Verify preflow gas pressure 3) Verify ASC powered and discharging. 4) Verify consumables 24110 0x100E EX: remote power off Check EStop...

  • Page 91: Parts List

    8.0 Parts List For System components not shown in this section, refer to parts.lincolnelectric.com or contact your Lincoln Electric service department. 8.1 FineLine 300HD Power Supply (KP4900-1) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S.
  • Page 92 FineLine 300HD Plasma System BK8053-000107 Rev A.01 This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 92 of 118...
  • Page 93 BK8053-000107 Rev A.01 FineLine 300HD Plasma System This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 93 of 118...
  • Page 94 FineLine 300HD Plasma System BK8053-000107 Rev A.01 This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 94 of 118...
  • Page 95 BK8053-000107 Rev A.01 FineLine 300HD Plasma System This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 95 of 118...
  • Page 96 FineLine 300HD Plasma System BK8053-000107 Rev A.01 This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 96 of 118...
  • Page 97 BK8053-000107 Rev A.01 FineLine 300HD Plasma System This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 97 of 118...
  • Page 98 FineLine 300HD Plasma System BK8053-000107 Rev A.01 This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 98 of 118...
  • Page 99 BK8053-000107 Rev A.01 FineLine 300HD Plasma System This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 99 of 118...
  • Page 100 FineLine 300HD Plasma System BK8053-000107 Rev A.01 This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 100 of 118...
  • Page 101 BK8053-000107 Rev A.01 FineLine 300HD Plasma System This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 101 of 118...
  • Page 102 FineLine 300HD Plasma System BK8053-000107 Rev A.01 This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 102 of 118...

  • Page 103: Fineline Automatic Gas Console (Bk300350)

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 8.2 FineLine Automatic Gas Console (BK300350) Part Number Description 9EG9546-1 PCB, Machine Connector 9EG9536-1 PCB, Machine Interface BK300361 PCB, Processor Engine (Programmed) BK300360 Proportional Valve, 5 Gang Assembly BK8108-000009 PCB, Proportional Valve Control, 5 Gang Assembly BK7036-000003 O-Ring, Pressure Transducer BK8108-000008...

  • Page 104: Fineline Arc Start Console (Kp4901-1)

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 8.3 FineLine Arc Start Console (KP4901-1) This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 104 of 118...
  • Page 105 BK8053-000107 Rev A.01 FineLine 300HD Plasma System This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 105 of 118...
  • Page 106 FineLine 300HD Plasma System BK8053-000107 Rev A.01 This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 106 of 118...

  • Page 107: Torch And Related Parts

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 8.4 Torch and Related Parts Part Number Description BK602621 Torch Handle BK602622 Magnum PRO LC300M Plasma Torch BK700223 Torch Clamp BK1111-200207 Cooling Tube BK716012 O-Ring Lubricant BK602396 Electrode Removal Socket (10mm, 6-point deep socket, ¼” square drive) BK277086 Electrode Removal Driver (¼”...

  • Page 108: Asc Control Cable

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 8.5.5 Work Ground Lead Part Number Length K4902-XX Where -XX is the length in feet. -25, -50, -75, -100 ft. lengths available. 8.5.6 Power Supply Electrode Lead Part Number Length K4903-XX Where -XX is the length in feet. -25, -35, -50, -75, -100 ft.

  • Page 109: Wiring & Flow Diagrams

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 9.0 Wiring & Flow Diagrams 9.1 FineLine 300HD Power Supply Wiring Diagram This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 109 of 118...

  • Page 110: Cooling System (Inside Power Supply) Flow Diagram

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 9.2 Cooling System (Inside Power Supply) Flow Diagram This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 110 of 118...

  • Page 111: Automatic Gas Console (Agc) Wiring Diagram

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 9.3 Automatic Gas Console (AGC) Wiring Diagram This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 111 of 118...

  • Page 112: Automatic Gas Console (Agc) Flow Diagram

    FineLine 300HD Plasma System BK8053-000107 Rev A.01 9.4 Automatic Gas Console (AGC) Flow Diagram This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 112 of 118...

  • Page 113: Arc Start Console (Asc) Wiring Diagram

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System 9.5 Arc Start Console (ASC) Wiring Diagram This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 113 of 118...
  • Page 114 FineLine 300HD Plasma System BK8053-000107 Rev A.01 BLANK PAGE This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 114 of 118...

  • Page 115: Appendix A Electromagnetic Compatibility (Emc)

    BK8053-000107 Rev A.01 FineLine 300HD Plasma System Appendix A Electromagnetic Compatibility (EMC) A.1 Background CE marked Systems are manufactured to comply with the European standard EN 60974-10 (Electromagnetic compatibility (EMC) – Product standard for arc welding equipment). These have been tested in accordance with CISPR 11, EMC classification –...
  • Page 116 FineLine 300HD Plasma System BK8053-000107 Rev A.01 A.3 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: • other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the plasma cutting equipment;...
  • Page 117 BK8053-000107 Rev A.01 FineLine 300HD Plasma System A.4.3 Plasma Cutting Cables The plasma cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level. A.4.4 Equipotential Bonding Bonding of all metallic components in the plasma cutting installation and adjacent to it should be considered.
  • Page 118 FineLine 300HD Plasma System BK8053-000107 Rev A.01 BLANK PAGE This information is subject to the controls of the Export Administration Regulations [EAR]. This information shall not be provided to non-U.S. persons or transferred by any means to any location outside the United States contrary to the requirements of the EAR. Page 118 of 118...

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