Lincoln Electric TORCHMATE 5100 User Manual
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Lincoln Electric TORCHMATE 5100 User Manual

Lincoln Electric TORCHMATE 5100 User Manual

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USER GUIDE
March 31, 2021
Copyright 2021
Lincoln Electric® Cutting Systems

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Summary of Contents for Lincoln Electric TORCHMATE 5100

  • Page 1 USER GUIDE March 31, 2021 Copyright 2021 Lincoln Electric® Cutting Systems...

  • Page 2: Table Of Contents

    Table Specifications ................7 Site Preparation ..................8 Power/Water/Air Requirements ............9 Slats and Cutting Bed ............... 13 Powering Up the Torchmate 5100 ..........14 Water Table Operation ..............15 Filling the Watertable ..............16 Downdraft Operation ................ 19 FlexCut 125 Plasma Controls & Settings ........20 FlexCut 200 Plasma Controls &...

  • Page 3: Unpacking Your New Machine

    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 Use ALL of the leveling feet to secure and level the table. Make sure the table does not rock or have any movement once level. The table is now ready to be filled with water (if water table). LEVELING FEET AND ALTERNATIVE DRAIN VIEW Torchmate 5100...
  • Page 5 Unpacking: 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 The 1/4” industrial quick disconnect input on the bulkhead will distribute the air to the plasma power supply along with table operations. Any accessories will also be provided shop air by tapping into the two output 1/4” tubing push-connects Torchmate 5100...
  • Page 7 Unpacking: FlexCut 125 The FlexCut 125 will have two barrel connectors to attach to the bulkhead. When moving your FlexCut 125, use a 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 0.75 gallons (2.84 liters) of coolant into the coolant reservoir fill hole through a funnel.
  • Page 9 The FlexCut 200 does not come with an SO cord installed for the main power connection. Use Power Connection Block: Input Cord Strain Relief: Connect each phase of a three Route input cord through three-phase supply line. A 1.75 inch (45 phase connector here relief and twist nut to tighten.
  • Page 10 For full wiring instructions, see the corresponding manuals for the FlexCut 200 and FlexCool 35. FROM CABLE CARRIER STAR GROUND FROM CABLE CARRIER Star Ground ETH 0 ETH 1 POWER PLASMA AUXILARY EXT. NETWORK FLEXNET RESERVED ENTRY INTERFACE INTERFACE Star Ground 5100 BULKHEAD Torchmate 5100...
  • Page 11 Unpacking: FineLine 170HD / 300HD The 5100 with the FineLine HD systems will be professionally installed at a customers location. Due to the weight of the power supplies, 700lbs+, there are requiremnts that need to be met when handling the equipment.

  • Page 12: Technical Support | On-Site Service

    Lincoln Electric Cutting Systems provides a number of technical support opportunities with the purchase of your new Torchmate 5100 CNC cutting machine. The following is a brief outline of available options. Onsite visits are available at an additional cost, call 775-673-2200 for additional information.

  • Page 13: Safety Information

    Safety Information Torchmate and Lincoln Electric Cutting Systems equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation and thoughtful operation. WARNING: DO NOT INSTALL, OPERATE, OR REPAIR THIS EQUIPMENT WITHOUT READING THE SAFETY WARNINGS CONTAINED THROUGHOUT THIS MANUAL.
  • Page 14 To reduce your exposure to these chemicals; work in a well ventilated area, and work with approved safety equipment, such as respiratory protection approved for the contaminants present and their airborne concentrations. Torchmate 5100...
  • Page 15 Cutting flame and sparks can cause FIRE OR EXPLOSION: • Fire and explosion can be caused by hot slag, sparks, oxygen fueled cutting flame, or the plasma arc. • Have a fire extinguisher readily available. Provide a fire watch when working in an area where fire hazards may exist.
  • Page 16 • Connect the work cable to the workpiece as close as possible to the area being cut or gouged. • Do not work next to cutting power source. For more information on electromagnetic interference please visit: http://torchmate.com/white-papers/EMI-Reduction Torchmate 5100...
  • Page 17 AUTOMATIC OPERATION: • Any computer numerical control (CNC) machine may begin to operate automatically without warning. Only a trained individual familiar with the software, machine, and computer system should operate this equipment. • All untrained persons should not work on or near a CNC machine. •...
  • Page 18 NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103 • ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 Torchmate 5100...
  • Page 19 Cut Speed configuration) • Up to 450 ipm Software Plate Capacity • Easy-To-Use Lincoln Electric User Interface • Holds Up To 4” (102mm) 5’x10’ (1524mm x 3048mm) Mild Steel • CAM with Irregular Part Nesting Weight • Popular Shape Library •...

  • Page 20: Site Preparation

    Site Preparation When installing a Lincoln Electric CNC Cutting System in your shop, there are many factors that will influence the potential productivity, ease of use of the machine and the safety of the operator. The main factors to prepare for include: the physical placement of the machine, the availability of power, an EMI ground, compressed air, other input gases, and ventilation.
  • Page 21 Site Preparation - HD Lincoln Electric FineLine® High Definition Power Supplies have a larger power box and a gas controller to mix several different types of gases utilized in HD plasma cutting. The placement of these products with the 5100 must be within 6’...
  • Page 22 1/4” tubing push-connects. The FineLine power supplies require a dedicated, 3/8 I/D hose for all inlet gas connections. Quick-connect fittings must not be used when connecting air to the FineLine power supply. Torchmate 5100...
  • Page 23 Power to Plasma: The plasma power supply chosen requires 3-phase electrical connections and numerous other connections needed by your specific power supply to interface with the machine; consult the specific plasma power supply’s user manual for more details. Depending on the particular model plasma cutter, an input power cord may not be included. Fuse the input circuit with the recommended super lag fuses or delay type breakers.
  • Page 24 If the work piece is painted or dirty, it may be necessary to expose the bare metal to make a good electrical DETAIL A connection. The ground rod is not included with GROUND ROD machine. Torchmate 5100...

  • Page 25: Slats And Cutting Bed

    Slats and Cutting Bed The 5100 water table/downdraft table 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 26 Power Up the 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 rear of the machine. The power button for the plasma power supply is located on the front of the unit.

  • Page 27: Water Table Operation

    The water level is controlled in the Plate Setup menu in the VMD software to raise and lower the machine in the 5100 water table configuration. Lincoln Electric Cutting Systems recommends PlateGuard™ Water Table Additive to maintain the water in the table. See the PlateGuard specifications for more details.

  • Page 28: Filling The Watertable

    Press the Water Fill tab. If the Machine Settings window does not open, in the upper left corner press MAIN MENU. In the SELECT A PANEL window, left click on CONFIGURATION.wap. Press OK, and the Machine Settings panel will open. Torchmate 5100...
  • Page 29 Filling the Water Table: Step 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. Start to fill the table with water. Once the internal tank fills past 2" in the tank, the LOW WATER Step 4: indicator will no longer display.
  • Page 30 Now to control the water level function, you will use the WATER LEVEL controls in the Plate Setup menu. Torchmate 5100...

  • Page 31: Downdraft Operation

    (open) is dependent on where the job is located in the cutting bed when Plate Origin is established. Lincoln Electric recommends utilizing a filtration system rated for plasma cutting applications, with automatic filter cleaning to extend life between filter servicing.
  • Page 32 PRIMARY AIR, GAS PRESSURE GAUGE AND REGULATOR KNOB HOME BUTTON ON/OFF SWITCH TORCH CONNECTION WORK LEAD CONNECTION MENU CONTROL KNOB/BUTTON PURGE BACK AIR OR GAS INLET (1/4”IN. NPT QUICK CONNECT) RECONNECT PANEL ACCESS INPUT CORD STRAIN RELIEF 14-PIN CNC INTERFACE Torchmate 5100...
  • Page 33 FlexCut 125 Specifications and Consumables Please refer to the FlexCut operator's manual for complete installation and operation guidelines. Do not overtighten the consumables. Only tighten until the parts are seated properly. Rated Output: Product Product Input Power Current/ Input Current @ Output Gas Pressure Gas Flow...
  • Page 34 SHIELD GAS REGULATOR PLASMA GAS REGULATOR BACK AIR OR GAS INLET (1/4”IN. NPT QUICK CONNECT) 115V/15A AUXILIARY POWER RECEPTACLE 15 AMP CIRCUIT BREAKER ETHERNET CONNECTOR 10 AMP CIRCUIT BREAKER FLEXCOOL CONNECTOR INPUT CORD STRAIN RELIEF CNC INTERFACE CONNECTOR Torchmate 5100...
  • Page 35 FlexCut 200 Specifications and Consumables Please refer to the FlexCut operator's manual for complete installation and operation guidelines. Do not overtighten the consumables. Only tighten until the parts are seated properly. Rated Output: Product Product Input Power Current/ Input Current @ Output Gas Pressure Gas Flow...
  • Page 36 Press the power button on the face of the FIneLine to cycle the power. Controls » FRONT LIFTING EYE COOLENT FILL STATUS LEDS POWER ON/OFF BUTTON BACK FILTER ACCESS PANEL (SIDE) INPUT / OUPUT ACCESS PANEL INPUT POWER ACCESS PANEL POWER CORD STRAIN RELIEF COOLENT HOSE CONNECTORS GAS SUPPLY CONNECTORS Torchmate 5100...
  • Page 37 FineLine Specs and Consumables Please refer to the FineLine operator's manual for complete installation and operation guidelines. Do not overtighten the consumables. Only tighten until the parts are seated properly. Rated Output: Product Product Input Power Current/ Input Current @ Output Gas Pressure Gas Flow...

  • Page 38: Overview Of The Visual Machine Designer

    Jogging - Controls the torch movement on the machine along with program run speed. AVHC/Dashboard - Control the AVHC and displays the coordinates of the head along with all of the indicators being monitored on the machine. Accessory Toggle - This hosts the on/off toggle button for the laser pointer accessory. Torchmate 5100...
  • Page 39 Job Group The Job Group covers any “job” type functions. This group directly deals with selecting a job, creating a job (Shape Library), Nesting, and other Job type functions. Select Job: Allows the operator to choose the job which they would like to load.
  • Page 40 On/Off Dwell - Add time delay to sending signals to the associated tool. • Pierce Count - Counts the processes ARC ON commands. • Activate - Toggles the tool to get a ON command. Toggle to turn off. • State - Indicates the ON/OFF status of the tool. Torchmate 5100...
  • Page 41 Job Group: Log On: LOG ON switches users of the VMD software. • ADMIN - Opens the MACHINE SETTINGS (password protected). • OPERATOR - Displays the standard user with the standard interface. • PRODUCTION OPERATOR (default) - Standard user with a simplified interface.
  • Page 42 • Arc Voltage - Voltage feedback comparison value. If using sample voltage this will adjust during cutting. • Feedrate - Displays/sets to the optimal feedrate in the cut charts for the thickness of material and amperage set. Torchmate 5100...
  • Page 43 View Screen: Graphics View: The machine limits are displayed in blue. The head is represented with white crossed lines. • Plasma assigned tool paths are displayed in red. • Plate Marker assigned tool paths are displayed in green. • Rapid travels will be a dashed grey line. •...
  • Page 44 Toggles between ACTIVE RUN and DRY RUN. • ACTIVE RUN - Activates your torch to fire when you RUN a job. • DRY RUN - Deactivates your torch from operation. If in DRY RUN, the torch will simulate all movements without firing the torch. Torchmate 5100...
  • Page 45 Jogging Jogging allows the user to move the head by pressing on the direction. The Jogging group has several types of jogs that can be executed, allowing the user finite control over the direction, distance, and speed the head will move. Jog: The JOG keys are assigned to the movement of torch to the origin of the operators console.
  • Page 46 • Auto - The torch will maintain the distance entered in CUT HEIGHT and profile the material based on the SET VOLTAGE and the CURRENT VOLTAGE being read from the plasma power supply. Torchmate 5100...
  • Page 47 AVHC & Dashboard: IHS (Initial Height Sense): This setting turns OHMIC DETECTION on or off. • ON - The head will detect material when the ohmic cap comes into contact with the grounded, conductive material on the table. Once detected the head will retract to the TRANSFER HEIGHT setting.
  • Page 48 Move the head and use the indicator for setting PLATE ORIGIN, setting plate alignment, dry run a job, or for Step 3: visualizing a point on the plate. Once done using the laser, toggle the laser to OFF. Step 4: By changing to ACTIVE RUN, the laser will power off automatically. Torchmate 5100...
  • Page 49 Oxy Controls The VMD can control OXY cutting torches with the OXY tab. This allows SET and CAPTURE time delays. OXY: Lifter: Controls the lifter stations UP/DOWN position. • Up will raise the lifter. • Down will lower the lifter. Pre-Heat: Sets and alters the Pre-Heat time required for the OXY cutting.

  • Page 50: Using The Shape Library In Vmd

    Once named, press SAVE. The VMD will LOAD the job to active and toggle to ‘NO KERF’. Torchmate 5100...
  • Page 51 Using the Shape Library in VMD: In the upper left of the screen, press SELECT JOB. Step 5: This will open the Select a Job screen. Select the job from the list. If you didn’t save in the JOBS folder, you will need to press BROWSE and locate your job.

  • Page 52: Running A Job

    In the PROCESS SETUP tab, enter in the material thickness and amperage you are planning to cut. This will populate the CUT PARAMETERS with the appropriate settings for the thickness/ amperage. If using a different material thickness parameter than being cut, the outcome will not be to specification. Torchmate 5100...
  • Page 53 Running a Job: Plate Setup: Press PLATE SETUP. Use the jog keys in PLATE SETUP to move the torch body to the lower left corner of the material you are planning to cut. 2. Press SET PLATE ORIGIN. This establishes the PROGRAM ZERO of the program, or the ABSOLUTE X 0: Y 0 of the job.

  • Page 54: Quality Test Cut

    Set the IHS (ohmic detection) to ON. Set the IHS MODE to ALWAYS. Set the Machine to Active Run (If Dry Run is displayed, press once to toggle to Active Run) Verify that the FEED RATE OVERRIDE is set to 100% Torchmate 5100...
  • Page 55 Set the Machine to Active Run (If Dry Run is displayed, press once to toggle to Active Run) Quality Test Cut: PRESS RUN JOB. This will move the torch to the plate and start the job. (PLASMA TORCH WILL FIRE! WEAR APPROPRIATE EYE PROTECTION.) The sample cut includes a plasma marked ‘5100’...

  • Page 56: Vmd Nest

    Once all the parameters and consumables are established, press NESTING. The Nesting browse window displays the previous nested jobs. To start a new nest, press NESTED JOBS. Select NEW NESTED JOB and the ADD NESTED JOB dialog opens. Torchmate 5100...
  • Page 57 VMD Nest: In this dialog, enter a name for your nest in NESTED JOB NAME. This will become the file name of your project. Enter the dimentions of the plate being used. This will establish the material limits for the nest. Press SAVE.
  • Page 58 LAYER MAP separates the layers present in the job. Select the appropriate process for the layers to be PLASMA, PLASMA MARKING, IGNORE. Once the directory is assigned, will display all of the files in the source location. Select the parts you want to add to the nest, and press ADD. Torchmate 5100...
  • Page 59 VMD Nest: Verify: When VERIFY is checked, the operations will be moved to the Part Import Preview screen. This screen allows the operator to evaluate the drawings, toggle layers, assign layers to processes. The left side hosts the parts that have been imported. By selecting each part displays the part, shows the layers that are present, and gives the part details.
  • Page 60 Start the nest: Once the quantities are entered, select NESTING. Then press NEST. A prompt will ask ALL or SELECTED. In the display will show the parts layed out in the material area assigned. Torchmate 5100...
  • Page 61 VMD Nest: Complete the nest: In the right toolbar select COMPLETE NEST. Open Nest in VMD: After pressing COMPLETE NEST, the job will auto load into the VMD software. In the AVHC tab, set CUT PARAMETERS to PROGRAM DEFINED and process the job. User Guide...

  • Page 62: 5100 Bevel

    Z - Moves up/down while controlling the height of the torch 45° 45° Bevel Cuts Available: BEVEL KNIFE EDGE BEVEL KNIFE EDGE WITH LAND BEVEL K-CUT NO LAND BEVEL K-CUT WITH LAND BEVEL UNDERCUT KNIFE EDGE BEVEL UNDERCUT WITH LAND Torchmate 5100...

  • Page 63: Create A Bevel Cut

    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 64 Once the MACHINE SELECTION window opens, select the FLEXCUT 200 (or other power supply/oxy). Press OK. Select EDIT MATERIAL. The MATERIAL window will display. Locate the thickness of material planning to be cut. SELECT it and press OK. Torchmate 5100...
  • Page 65 Create a Bevel Cut: The NEST SETTINGS dialog will display which amperage is appropriate for the material that was selected along with the 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 66 5. K-Cut with Land Each process has different variables that can be entered for each type of cut. Cuts with Lands will process two cuts per bevel to accommodate the land portion. After entering the parameters for the bevel, press OK. Torchmate 5100...
  • Page 67 Create a Bevel Cut: 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. This will APPLY the appropriate tool path for your cut.
  • Page 68 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. The ADD JOB window will appear. Torchmate 5100...
  • Page 69 Create a Bevel Cut 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 70 Press NEST SETTINGS at the top of the screen. This will open the NEST properties. In the upper left, verify that the POST is set to your Plasma power supply. At the bottom of the NEST SETTINGS, verify the AMPS and AIR. Torchmate 5100...
  • Page 71 Create a Bevel Cut: 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. At the bottom of the Nest Settings, verify the AMPS and AIR for the POST to write the CUT SETTINGS for your part.
  • Page 72 In the TOP tool bar area, press CLOSE JOB. The NESTED JOB MANAGER will display. Press the X in the upper right to exit out of the software. The file can then be brought into VMD for cutting. Torchmate 5100...

  • Page 73: General Maintenance

    General Maintenance As with all equipment, follow the maintenance and proper operating procedures outlined in the guides included with this machine. By practicing a consistent maintenance and cleaning schedule, will ensure the reliability and productivity of the machine. Follow all guidelines and safety precautions outlined in the user guide of the table, along with the equipment attached to the machine.
  • Page 74 LECS recommends Mobil SHC Mobilith SHC 100 lithium based grease. This product can be sourced and purchased locally. Load the grease cartridge into a grease gun and grease each zerk. The arrows indicate all the zerks that need to be greased. Side Linear Rail (Y-Axis) Zerk Torch Carriage Linear Rail (X-Axis) Zerk Torchmate 5100...
  • Page 75 Basic Maintenance: Electronic Controlled Lubricators: - pn #TMS-151-3025-00 The system is comprised 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 76 6 months and the cartridge will need to be replaced. Use this chart to help determine the proper setting for your application. If you notice "pooling" of the lubricant, then adjust the dip switches to a longer period of time. Torchmate 5100...

  • Page 77: Cut Quality

    Cut Quality 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. In plasma arcs used for cutting, the gas forms into a vortex.
  • Page 78 Minimal bevel One side may be straight the Cut may not go all the Torch may contact another excessively beveled material and short out way through material Longest consumable life or damage tip Can be caused by worn tip Torchmate 5100...
  • Page 79 What Causes Bad Cuts: Instances where the metal was not fully cut indicate a few problems: Ground clamp is not properly attached to the material 2. Air pressure drop or surge Moisture in the air line 4. Drop in power 5.
  • Page 80 Once established, these coupons can be used as a visual cut chart or you can use the provided sheet to document your settings. Torchmate 5100...

  • Page 81: Build Your Own Cut Chart

    Build Your Own Cut Chart Use this template to create your own custom cut charts using the line speed test. Material Thickness Amperage Cut Speed Pierce Delay Pierce Height Cut Height Type User Guide...

  • Page 82: Basic Troubleshooting

    If this screen is displayed for longer than 1 minute, turn off power to the machine for 1 minute. Turn the power Accumove Controller Connecting Screen back on. If the same condition exists, check Fuse #3 inside the electrical cabinet. Torchmate 5100...
  • Page 83 Machine Faults: Problem Solution WATER LEVEL LOW is illuminated. The water cannot LOGIN as ADMIN, under the WATER FILL TAB, follow the be raised any higher. steps to add sufficient water to the table. Check brake relay connection & double terminated pin at servo drive.
  • Page 87 Lincoln Electric is a responsive manufacturer, but the definition of specifications, and the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

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