Lincoln Electric Torchmate 5100 Series User Manual
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Lincoln Electric Torchmate 5100 Series User Manual

Lincoln Electric Torchmate 5100 Series User Manual

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USER GUIDE
June 5, 2019
Copyright 2019
Lincoln Electric Cutting Systems

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Summary of Contents for Lincoln Electric Torchmate 5100 Series

  • Page 1 USER GUIDE June 5, 2019 Copyright 2019 Lincoln Electric Cutting Systems...

  • Page 2: Table Of Contents

    Table of contents Unpacking the machine Technical Support | On-site Service Statement of Warranty Safety Information Table Specifications Site Preparation Grounding the Machine Power/Air/Water Requirements Slats and Waterbed Powering up the 5100 Water table operation Filling the water table Downdraft Operation FlexCut 125 Plasma Controls and Settings (See FlexCut 125 manual) FlexCut 200 Plasma Controls and Settings (See FlexCut 200 manual) 20 Performing First Cut (straight torch)
  • Page 3 Use a razor knife to remove the wrap from the machine. Inspect the contents and verify that there is no damage to the machine or its contents in the bed. If damaged, do not accept the shipment and contact Lincoln Electric Cutting Systems.
  • Page 4 Unpacking your new machine (Leveling Feet) When placing the machine, you will need to install the adjustable feet into the pads prior to leveling the machine. With the machine lifted and secured, screw in all of the adjustable feet into each of the pads. DO NOT USE a hydraulic lift to secure the machine when installing the leveling feet.
  • Page 5 Unpacking your new machine (Monitor Arm Assembly) Unfolding and securing the Monitor Arm Assembly requires a few bolts to be removed and reused to secure the arm in place. Remove the bolts that are indicated in the drawing and reuse them to secure the arm 1.
  • Page 6 Unpacking your new machine (Electrical Connections) Internally the 5100 comes pre-wired and ready to run. All systems are test fired and disconnected at the facility before packaging and shipping. For shipping purposes, the plasma power supply is disconnected from the system and will require a connection to the machine.
  • Page 7 Unpacking your new machine (FlexCut 125) ™ FlexCut 125: FlexCut 125 will have two barrel connectors to attach to the bulkhead. When moving your FlexCut 125, use team lift or hoist. A 10 ft.(3m) power cord is provided with the FLEXCUT 125. Three Phase Input Only. Connect green lead to ground per National Electric Code.
  • Page 8 FlexCool 35. Torque both 7/16” bolts to 50 in-lbs. Filling the Coolant Reservoir: USE ONLY LINCOLN ELECTRIC TORCH COOLANT - BK500695 1.5 gallons of coolant are preloaded into the machine at the facility for live fire testing. Pour .75 gallons (2.84 liters) of coolant into the coolant reservoir fill hole through a funnel.
  • Page 9 Unpacking your new machine (FlexCut 200/FlexCool ™ ™ The FlexCut 200 does not come with an SO cord installed for the main power connection. Power Connection Block: Input Cord Strain Relief: Connect each phase of a three Route input cord through phase connector here Use a three-phase supply line.
  • Page 10 Unpacking your new machine (FlexCut 200/FlexCool ™ ™ Connections between the FlexCut 200 and 5100: 5. From the cable carrier, connect the PLASMA GAS and SHIELD GAS to the FlexCut 200. 6. Attach the PLASMA connections from the cable FROM carrier to the NOZZLE, ARC LINK, ELECTRODE.

  • Page 11: Technical Support | On-Site Service

    • Phone Support Phone support is available Monday – Friday 7:00 am-4:00 pm PST. Lincoln Electric will make ev- ery effort to handle phone calls promply. Due to the nature of machine diagnoses and the varied capabilities of machine operators we cannot guarantee hold wait times for phone-in technical support.

  • Page 12: Statement Of Warranty

    Statement of Warranty 30 Day guarantee If Buyer is not satisfied with the performance of the Goods within 30 days from the date the Goods were shipped from the Seller, Buyer may return the Goods in the original carton(s) for a full refund less Shipping, Handling, Damages and Freight Charges.
  • Page 13 C. The sale of Goods shall be governed by the laws of the State of Maryland. Seller agrees to comply with all applicable laws of the United States. D. The purchasers of products from Lincoln Electric Cutting Systems are responsible to dispose of consumables, fluids and machinery at the end of the life cycle in accordance with federal and local regulations.

  • Page 14: Safety Information

    Safety First Torchmate and Lincoln Electric Cutting Systems equipment is designed and built with safety in mind. Safe operation requires that the user follow proper installation, training, and safe operating procedures. THIS MACHINE CREATES ELECTRO-MAGNETIC FIELDS DURING OPERATION WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
  • Page 15 FUMES AND GASES can be dangerous. • Plasma cutting or gouging may produce fumes and gases hazardous to your health. Avoid breathing these fumes and gases. When cutting or gouging, keep your head out of the fumes. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone and general area.
  • Page 16 ARC RAYS can burn. • Plasma Arc Rays can injure your eyes and/or burn your skin. The plasma arc process produces very bright ultraviolet and infrared rays. These will damage your eyes and burn your skin if you are not properly protected. •...
  • Page 17 CYLINDER may EXPLODE if damaged. • Use only compressed gas cylinders containing the correct gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

  • Page 18: Table Specifications

    +/-45° Rotation (dependent on material thickness and power supply configuration) Traverse Speed • 1,500 ipm (0.635 mps) Software • Easy-To-Use Lincoln Electric User Interface Cut Speed • CAM with Irregular Part Nesting • Up to 1500 ipm • Popular Shape Library...

  • Page 19: Site Preparation

    Site Preparation When installing a Lincoln Electric CNC Cutting System in your shop, there are many factors that will influence the po- tential productivity, ease of use of the machine and the safety of the operator. The main factors to prepare for include the physical layout and placement of the machine in the shop, the availability of power, an EMI ground, compressed air and other gases, and ventilation.
  • Page 20 Site Preparation (HD) Burny Kaliburn Spirit II power supplies have a larger power box and a gas box. The placement of these products need to be moved to the cable carrier side within 6’ of the end of the cable chain. 5100 HD 113.25”...

  • Page 21: Grounding The Machine

    Grounding Your Machine Proper grounding must be provided to ensure personnel safety and to suppress high frequency noise. The foundation of good grounding is an effective earth ground rod. A star ground point connects to the rod with a short, heavy conductor. A simple copper clad steel rod can be driven into the ground to create a Grounding Rod.

  • Page 22: Power/Air/Water Requirements

    Power/Air/Water Requirements and Installation (non-HD) Please refer to the FlexCut/Spirit II operators manual for a complete installation and operation guidelines. Only a quali- fied electrician should connect the input leads to the Torchmate 5100 CNC unit and FlexCut/Spirit II Plasma unit. Con- nections should be made in accordance with all local and national electrical codes.

  • Page 23: Slats And Waterbed

    Slats inside the cutting bed. The 5100 WT/DD has an array of slats inside the cutting area. These slats hold your material level for cutting. They are considered a “consumable” item and will need to get replaced on a regular schedule. •...

  • Page 24: Powering Up The 5100

    Powering up the Torchmate 5100 To power up your Torchmate 5100 CNC machine, the following items need to be powered up; Machine and Plasma Unit. The machine will power the controller, computer, and touchscreen. The switch is located on the backside of the machine. Once switched on, the computer and all the electronics will power up.

  • Page 25: Water Table Operation

    Water Table Operation The 5100 in Water Table configuration, the water level is controlled by the HMI to raise and lower the machine. The button RAISE switches a valve to use compressed air to “push” the water to the cutting bed. While pressing LOWER releases the air from the lower chamber.

  • Page 26: Filling The Water Table

    Filling the Water Table The 5100 has an automated water level feature that is controlled on the RUN panel. There is a process that needs to be followed to properly fill the table to allow proper operation. Connect your air supply to the air inlet on the machine to proceed.
  • Page 27 Filling the Water Table 3. Press the EXHAUST button. This opens the external exhaust vent to allow the air to transfer out of the empty water tank while the water fills up. 4. Start to fill the table with water. Once the internal tank fills past 2” in the tank, the LOW WATER indicator will no longer display.
  • Page 28 Filling the Water Table 5. Once the WATER FULL indicator turns on, turn the input water off to the table. Close the EXHAUST by pressing the EXHAUST button. 6. Raise the water into the main chamber by pressing and holding the RAISE WATER button. Once the water reaches the top of the slat, then release the RAISE WATER button.

  • Page 29: Downdraft Operation

    Downdraft Operation The 5100 in Downdraft configuration, there are 4 zones that are controlled by the program. The “zone” that is active (open) is dependent on where the job is located in the cutting bed when PROGRAM ZERO is established. Each zone is controlled by pneumatic actuators to open/close the dampers inside the table to allow for proper air flow.
  • Page 30 User Guide...

  • Page 31: Flexcut 125 Plasma Controls And Settings (See Flexcut 125 Manual)

    FlexCut 125 Plasma Controls and Settings Please refer to the complete operation and user manual for your FlexCut 125 located with the plasma unit. When the machine is turned on, an auto-test executes; during this test the Control Panel light up. Controls »...
  • Page 32 FlexCut 125 Plasma Cutter Consumable Use Please refer to the FlexCut operators manual for a complete installation and operation guidelines. Do not over tighten the consumables. Only tighten until the parts are seated properly. Rated Output: Product Product Input Power Current/ Input Current @ Output...

  • Page 33: Flexcut 200 Plasma Controls And Settings (See Flexcut 200 Manual)

    FlexCut 200 Plasma Controls and Settings Please refer to the complete operation and user manual for your FlexCut 200 located with the plasma unit. When the machine is turned on, and auto-test is executed; during this test the screen will change. Controls »...
  • Page 34 FlexCut 200 Plasma Cutter Consumable Use Please refer to the FlexCut operators manual for a complete installation and operation guidelines. Do not over tighten the consumables. Only tighten until the parts are seated properly. Rated Output: Product Product Input Power Current/ Input Current @ Output...

  • Page 35: Performing First Cut (Straight Torch)

    Performing Your First Test Cut (straight torch NON BEVEL) The LINE SPEED TEST.gm and 5100 Test Cut.gm is provided to determine the proper feed rate in IPMs to cut the material thickness to the amperage you have set on the plasma power supply. These have been included in your pre-loaded first cut on the Torchmate 5100 models.

  • Page 36: Performing First Cut (Bevel)

    Performing Your First Test Cut (BEVEL) With the BEVEL head, the plasma torch body is pre-loaded with 125 amp consumables (FlexCut 125) or 150 amp (FlexCut 200) for a 1/2” MS material cut from the factory. We highly suggest your first cut is our pre-loaded, *FC125/200 BEVEL TEST CUT 105A/150A.gm to ensure your machine has transported in the same condition it has left the factory.

  • Page 37: Overview Of The Visual Machine Designer

    Overview of the Visual Machine Designer Visual Machine Designer (VMD) is the driver software to all ACCUMOVE® CNC controllers. The majority of the control of the table can be found on the main screen while hosting features that can create and manipulate files. This quick guide will give you an overview of the features along with it’s operation.
  • Page 38 Job Group: The JOB GROUP at the top, covers any “job” type functions. This group directly deals with selecting a job, creating a job (Shape Library), or Alter job functions. Select Job: This is how to open jobs into the VMD. In the SELECT JOB area shows the “HOT FOLDER”...
  • Page 39 Job Group: (cont) Tool Library: In TOOL LIBRARY configures and controls the tool outputs on the machine. KERF and DWELL times can be added along with programming the offset to the plate marker acessory. Log On: LOG ON switches users of the VMD software. OPERATOR is the standard user.
  • Page 40 View Screen: The VIEW SCREEN in the VMD uses colors and will display the machine limits, head location, and job location. There are four tabs along the top that will show a visual of the job, g-code of the job, or a graph of the lifter station. If you have a FlexCut 200 attached to the machine, you can directly control the FlexCut 200 by using the Plasma Contol tab.
  • Page 41 View Screen: (cont) Plasma Console: (FlexCut 200/SPII) The Plasma Console controls the settings of the plasma from the HMI. This allows the operator to directly control the plasma power supply without having to navigate away from the HMI. The settings that can be changed are: •...
  • Page 42 Datum / Program Zero Group: This group controls the startup of the machine along with setting jobs to start from a certain location on the table. DATUM: Datum has several features. When first starting up your machine, datum will power your motors and move the machine to establish it’s MACHINE ZERO.
  • Page 43 CUT PARAMETERS and AVHC: Once you have your job ready to run, getting the settings correct and understanding their function is crucial to getting quality cuts on your table. This covers go over the Cut Parameters and the AVHC settings. Cut Parameters: All the parameters in the Cut Parameters and AVHC tab set the torch in proper position in relation to the material during...
  • Page 44 CUT PARAMETERS and AVHC:(cont) AVHC (Automatic Voltage Height Control): Sample Voltage is a toggle On or OFF. • On (with MODE: AUTO): At the beginning of the cut the controller learns the proper Arc Voltage and maintains the desired Cut Height value entered in CUT PARAMETERS. •...
  • Page 45 Oxy and Water Controls: The VMD can control OXY cutting torches with the OXY tab. This allows to SET and CAPTURE time delays. The WATER LEVEL tab, controls the water level in the table along with a LOW WATER indicator. OXY: LIFTER controls the lifter stations UP/DOWN position.
  • Page 46 RUN Group and Jogging: This group controls the start and stop of a job plus allows you to alter states of the plasma. Jogging allows the user to move the head by pressing on the direction. Also, the jog is tabbed so being about to move the head to the proper location anywhere on the table.
  • Page 47 Jog: (cont) Continuous Jog: By pressing a direction will move the torchbody in the direc- tion you are pressing. When released the head will stop. Incremental Jog: By pressing a directional arrow, it will move the torch body in the direction you are pressing, while using the Increment Distance slider bar to move it that distance.
  • Page 48 Jog and Dashboard: Point Jog: Point Jog allows the user to define where they want the head to travel to and from what source location. Select where you want the torch to start, what feed rate to travel and the X / Y coordinates and press MOVE TO POSITION. CUT TO POSITION works the same way except it will go through the IHS sequence and fire the torch.
  • Page 49 Dashboard: (cont) Dashboard: DASHBOARD Indicators: • OK TO MOVE: Indicates when the plasma has pierced through the material and is ready to start the program. • IHS: Indicates when the material is detected via OHMIC. • Breakaway: Indicates if the breakaway circuit is open/closed Extended: EXTENDED tab displays details about the job and it’s ACTIVE...

  • Page 50: Using The Shape Library In Vmd

    Using the Shape Library in VMD In the VMD, you can generate one of 35 standard shapes without needing to generate them in your CAD software. Access the Shape Library: To get to the Shape Library, press SHAPE LIBRARY on the top center of the VMD screen.
  • Page 51 Using the Shape Library in VMD (cont) Save your Shape: Once you press OK, you will be prompted to SAVE your shape. Double click the JOBS folder. By default, the name of the file will be the shape you selected or can be changed to a user defined naming convention.

  • Page 52: Running A Job

    Running a Job When you have a GM format file to run or shape generated in the VMD ready to cut there is a simple process to follow to get the job produced through the VMD. Datum: When you first start the Visual Machine Designer and are connected to the Accumove controller the machine needs it's configuration loaded and motors powered on.
  • Page 53 Running a Job (cont) Cut Parameters and AVHC Settings: The final step is entering the cut chart settings into the Cut Parameters and AVHC panels based on the material thickness and amperage on the plasma. For this example, will be entering the settings for 3/16” material using a FlexCut 200 plasma power supply set at 100 amps with 100 amp consumable stack.

  • Page 54: Cut Quality

    Cut Quality: The total goal is to make sure the cuts coming off of your table are the best possible. Line Speed Test: This means that there is minimal dross accumulation on the underside of your cut parts and minimal bevel on the sides. We have provided a file to cut to verify the feed rate for the material you are planning to cut with the amperage set on the power supply.

  • Page 55: Build Your Own Cut Chart

    Build Your Own Cut Chart The FlexCut manual includes a factory cut chart. Use this template to create your own custom cut charts using the line speed test. Material Thickness Amperage Voltage Cut Speed Pierce Delay Pierce Height Cut Height Type Torchmate 5100...

  • Page 56: Nesting

    VMD On-Board Nesting: The VMDNest is an onboard irregular part nesting CAM software. This allows IMPORTING DXF and DWG files without needing an offsite CAM software to generate the proper G-Code. The NESTING will apply the kerf correction along with the appropriate lead ins to all features.
  • Page 57 Nesting Add Parts: ITEM LIST will open along with the NEST LAYOUT. To add parts, go to the right toolbar and press PARTS. This will open the parts list. Select IMPORT CAD DRAWINGS for DXF/ DWG files. This will bring up the PART SELECTOR. Apply Tool Paths: At the top of the screen will be FILE TYPE, SOURCE, and DESTINATION.
  • Page 58 Nesting VERIFY: The two checkboxes: VERIFY and ARTWORK. Verify will display the parts to look at layers and other details on the individual parts. Artwork will change the tool-paths to an ONLINE toolpath and bypass the lead in, kerf adjustments. By checking VERIFY, then pressing ADD will open the PART IMPORT PREVIEW.
  • Page 59 Nesting Add Parts: Once all of the settings are made in the TOOLING PROPERTIES, press SAVE and it will maintain those settings for that material and amperage. The left side of the screen select the parts you want to IMPORT and Press ADD. This will bring up the ITEM LIST again but with the parts populating the left side.
  • Page 60 Nesting If your nest does not need editing or is just a single part then in the right toolbar select Complete Nest: COMPLETE NEST. This will open the CREATE JOB DIALOG. Enter the location you want the job to save and verify the amperage you are cutting. Then press OK. In the NEST screen at the bottom left, press BACK (RUN) button and will return you to Open nest in VMD: the VMD RUN screen.

  • Page 61: Bevel

    5100 Bevel Understanding the capabilities of the bevel head and the cuts that can be programmed is the first step in getting qual- ity cuts on the 5100. The mechanics of the bevel can support up to 50° of movement in the A and C axis. (limited by consumables).
  • Page 62 Create a Bevel Cut To program a bevel cut requires the file to be processed through the QuickCAM Pro software package. This walkthrough will cover importing a basic shape (DXF), apply two separate bevel cuts, and export the G-CODE for the machine to cut. DXF Part To start, have a DXF part from your CAD software generated.
  • Page 63 Create a Bevel Cut (cont.) Select the file you want to create the CUT FILE out of and press OPEN. In order to get the proper POST and material set up for the cut file, navigate to the bottom of the layout and select EDIT MACHINE. Once the MACHINE SELECTION window opens, select the FlexCut 200 (or other power supply/OXY).
  • Page 64 Create a Bevel Cut (cont.) The NEST SETTINGS dialog will display which amperage is appropriate for the material that was selected along with air combination you are using. The AMPERAGE can be changed if the thickness is within multiple Amperages. CUT GAS can be altered based on the material and amperage being used.
  • Page 65 Create a Bevel Cut (cont.) Once the bevel type is selected, it will bring up the options for that bevel process. 1. Knife Edge 2. Undercut 1. Knife Edge 2. Undercut 3. Knife with Land 4. Undercut with Land 5. K-Cut with Land 3.
  • Page 66 Create a Bevel Cut (cont.) The image will display THICKER lines where the bevels have been applied. If multiple bevel cuts need to be applied, select the lines and assign the bevel type. To apply the tool path to the job after all the bevels have been entered, press the APPLY PATH function.
  • Page 67 Create a Bevel Cut (cont.) After pressing the APPLY PATHS button, Save your file by going to FILE/SAVE. When the dialog comes up to SAVE THE NESTED SHEET press YES. Now go to FILE/EXIT In the QuickCAM Bevel dialog, select ORDER PROCESSING. In the ORDER PROCESSING window, press ADD JOB.
  • Page 68 Create a Bevel Cut (cont.) Enter a name into JOB NAME: If METRIC is required, check METRIC. Press SAVE The EDIT JOB GROUP window will populate. Press SAVE. To add the part to the NEST, press ADD ITEM. User Guide...
  • Page 69 Create a Bevel Cut (cont.) The BROWSE window will open. Locate and select the job; the file will have a .DRW extention. Press OPEN. The JOB MANAGER will show the loaded job and display the tool path to the job in the lower left.
  • Page 70 Create a Bevel Cut (cont.) In the CENTER, enter the size of material you have for the NEST. Enter 1 in the # OF SHEETS Press NEST SETTINGS at the top of the screen. This will open the NEST properties. In the upper right, verify that the POST is set to your Plasma power supply.
  • Page 71 Create a Bevel Cut (cont.) After pressing POST PROCESS, the POST SETTINGS dialog will open. This will state the POST to use in a drop-down dialog. Verify that the plasma power supply is correct. The default PATH is C:\DOWNLOADS To save to the HOT FOLDER in VMD, change the PATH to C:\CONTROLLER DATA\JOBS To save to a Flash Drive, or another drive, press the three dots and open the BROWSE dialog.

  • Page 72: Red Dot Accessory

    Red Dot Indicator Accessory: The Red Dot Indicator on the 5100 allows the operator to get exact placement of the torch body on the table by emitting a laser “DOT” onto the plate. The DOT will show where the torch body is at in relation to to the plate. This works for setting the PROGRAM ZERO or using the PLATE ALIGNMENT feature.

  • Page 73: Basic Maintenance

    Basic Maintenance: The 5100 requires basic maintenance to keep the machine working and moving properly. The operator will be responsible for several tasks as outlined in this basic guide. • Regular cleaning ensures that the table runs as precisely as possible. A build up of dust can put stress on parts and cause excessive wear or lead to cutting problems.
  • Page 74 Electronic Controlled Lubricators: The system comprises of replaceable, electronically controlled oil cartridges which apply the proper amount of lubricant onto the gear rack. The felt roller follows the gear and applies small amounts of oil to the surface of the gear rack to reduce friction, keeping the machines performance optimal and extending the life of the gear rack.
  • Page 75 Electronic Controlled Lubricators (cont.) To set the lubricators, you will remove the top lid to expose the dip switches. The dip switches will arrive all in the OFF position. To adjust, get a flat head screwdriver to move the dip switches UP to activate that switch. An LED indicator will illuminate the “position”...
  • Page 76 Cut Bevel Basics • Beveled edges are caused by the motion of the plasma gas as it is emitted from the nozzle. In plasma cutting it is unavoidable. A high-definition plasma cutter produces less bevel than a standard cutter. • Torch height, air pressure, air quality, cut direction, and consumable condition all influence bevel.
  • Page 77 How Torch Position Affects Bevel How torch position a ects bevel Correct torch height Torch angled to Incorrect torch height Incorrect torch height Correct torch height Torch angled to material Incorrect torch height Incorrect torch height Torch square to material Torch square to material material Torch too high...
  • Page 78 What Causes Bad Cuts • Instances where the metal was not fully cut indicate a few different problems: 1) Ground clamp not properly attached to the material 2) Air pressure drop or surge 3) Moisture in the air line 4) Drop in power 5) Contact with the material by the torch (Most plasma cutters go into a low power mode on contacting the material, causing the cut to not fully penetrate the material).

  • Page 79: Basic Troubleshooting

    Basic Troubleshooting This will cover the most basic operational faults you might encounter with your 5100 machine. Machine Faults: Symptom Description Resolution “Please Enable The Drives” Error The drives for the machines are Release BOTH EMERGENCY STOP but- Message disabled. tons and press the green “ENABLED”...
  • Page 80 Machine Faults: Symptom Description Resolution WATER LEVEL LOW is illuminated, The LOW WATER level sensor is LOGIN as ADMIN, under the WATER the water cannot be raised any tripped, preventing the water from FILL tab, follow the steps to add suffi- higher being raised.
  • Page 81 Torchmate 5100...
  • Page 82 Lincoln Electric Cutting Systems is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric Cutting Systems is solely within the control of, and remains the sole respon- sibility of the customer.

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