Lincoln Electric LECS-5100-400-W0, LECS-5100-125-W0, LECS-5100-200-W0, LECS-5100-275-W0, LECS-5100-125-D0 User Manual
...
USER GUIDE
June 5, 2019
Copyright 2019
Lincoln Electric Cutting Systems
Table of contents
Unpacking the machine iii
Technical Support | On-site Service xi
Statement of Warranty xii
Safety Information 1
Table Specications 5
Site Preparation 6
Grounding the Machine 8
Power/Air/Water Requirements 9
Slats and Waterbed 10
Powering up the 5100 11
Water table operation 12
Filling the water table 13
Downdraft Operation 16
FlexCut 125 Plasma Controls and Settings (See FlexCut 125 manual) 18
FlexCut 200 Plasma Controls and Settings (See FlexCut 200 manual) 20
Performing First Cut (straight torch) 22
Performing First Cut (bevel) 23
Overview of the Visual Machine Designer 24
Using the Shape Library in VMD 37
Running a Job 39
Cut Quality 41
Build Your Own Cut Chart 42
Nesting 43
Bevel 48
Red Dot Accessory 59
Basic Maintenance 60
Basic Troubleshooting 66
Torchmate 5100
ii
C
B
DETAIL C
DETAIL B
Unpacking your new machine
Your new Torchmate 5100 CNC machine is delivered assembled, but you will need to remove the shipping
material and gantry locks before operation. Verify all items have been shipped without damage before you accept the
order from the shipping company. Notify Lincoln Electric® 775-673-2200 to report any shipping damages. Your machine
was fully tested at the factory, a metal cut sample can be found in the bed of the machine.
Qty. Description Part Number
1 Lincoln Electric Torchmate
1 Lincoln Electric Torchmate
1
Lincoln Electric Torchmate
1
Lincoln Electric Torchmate
1 Lincoln Electric Torchmate
1 Lincoln Electric Torchmate
1
Lincoln Electric Torchmate
1
Lincoln Electric Torchmate
To unpackage your new Torchmate 5100 is simple. Your machine will arrive on a atbed truck and wrapped in plastic.
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.
TM
5100 Water Table with FlexCutTM 125 Plasma Unit LECS-5100-125-W0
TM
5100 Water Table with FlexCutTM 200 Plasma Unit LECS-5100-200-W0
TM
5100 Water Table with Spirit® II 275 Plasma Unit
TM
5100 Water Table with Spirit® II 400 Plasma Unit
TM
5100 Down draft with FlexCutTM 125 Plasma Unit LECS-5100-125-D0
TM
5100 Down draft with FlexCutTM 200 Plasma Unit LECS-5100-200-D0
TM
5100 Down draft with Spirit® II 275 Plasma Unit
TM
5100 Down draft with Spirit® II 400 Plasma Unit
LECS-5100-275-W0
LECS-5100-400-W0
LECS-5100-275-D0
LECS-5100-400-D0
The plasma unit, along with all the connection cables will be secured to a separate pallet. To remove the plasma power
supply from the pallet, team lift or forklift the plasma power supply and set aside until the machine is placed in its nal
operational location. The plasma unit will sit on the oor near the cable carrier exit on the monitor side.
A 6,600lb + forklift with 8’+ long forks is required to place the machine in its operational position. Use the forklift access
ports on the machine. Do not lift the machine from the cable carrier side.
Torchmate 5100 models ship with factory installed gantry
locks. The yellow locking devices MUST BE removed before
the machine can be made operational.
DO NOT REPLACE THE BOLTS FROM THE GANTRY LOCKS
AS THIS WILL CAUSE DIRECT DAMAGE TO THE MACHINE.
Do Not Fork Lift From
Cable Carrier Side Of
Machine!
A
DETAIL A
iii
User Guide
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. Screw them halfway into the pads to get the most movement for
leveling. Once the machine is placed, then level the table. When the machine is level, then follow the WATER FILL
process.
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.
Then the table is ready to be lled with water. (if water table)
Torchmate 5100
iv
Unpacking your new machine (Monitor Arm Assembly)
4. REINSERT BOLTS
AND SECURE IN PLACE
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. Remove the bolt from behind the monitor and
two bolts on the swing bracket.
2. Lift the monitor up and secure with the removed bolt.
3. Grab the arm and swivel it 180 degrees into
place.
4. Re-insert the bolts to secure the arm in place.
2. LIFT MONITOR
1. REMOVE BOLT
1. REMOVE BOLTS 2x,
ONE TOP AND ONE ON BOTTOM
2. REINSTALL BOLT
3. ROTATE ENTIRE MONITOR
ARM 180 DEGREES
v
User Guide
Unpacking your new machine (Electrical Connections)
INPUT
To Plasma
(for accessories)
Internally the 5100 comes pre-wired and ready to run. All systems are test red 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. The table has a single 120v NEMA 5-15P plug that powers the table and computer/
monitor. The plasma power supply chosen requires 3-phase electrical connections along with numerous other connections that are required by your specic power supply to interface with the machine.
All electrical, air, and interface connections
to the machine will be o of the BULKHEAD
Electrical Bulkhead
5100 - Table Power and Air connections:
Attach the supplied 120v 15A plug into a wall outlet. This will power the electronics and table functions.
Star Ground
Star Ground
1/4” OD TUBING
PUSH
CONNECT
ETH 0
EXT. NETWORK
ETH 1
FLEX NET
1/4” QUICK
CONNECT
PLASMA
INTERFACE
P1
1/4” QUICK
CONNECT
P2
PLASMA
ARC VOLATGE
P3
P4
CAN
AUXILARY
INTERFACE
I/O
120v Power Cord
15’, NEMA 5-15p
5100 - Pneumatic Connection:
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 or collision sensors will also be provided shop air by tapping into the two
provided output 1/4” Tubing Push-Connects.
POWER
ENTRY
BOTTOM
VIEW
FRONT
VIEW
Torchmate 5100
vi
Unpacking your new machine (FlexCut™ 125)
GROUND CONNECTION
CONNECT GROUND LEAD PER LOCAL
AND NATIONAL ELECTRIC CODE
INPUT CORD STRAIN RELIEF
ROUTE INPUT CORD THROUGH RELIEF
AND TWIST NUT TO TIGHTEN
POWER CONNECTION BLOCK
CONNECT EACH PHASE OF A
THREE PHASE CONDUCTOR HERE
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.
Connect black, red and white leads to power.
In all cases, the green or green/yellow grounding wire
must be connected to the grounding pin of the plug,
usually identied by a green screw. Attachment plugs
must comply with the Standard for Attachment Plugs
and Receptacles, UL498.The product is considered
acceptable for use only when an attachment plug as
specied is properly attached to the supply cord.
Air or Gas Inlet (1/4”
Female Quick Connect)
from bulkhead:
Star Ground
Star Ground
3-ph
Main Power
ETH 0
EXT. NETWORK
ETH 1
FLEX NET
P1
PLASMA
INTERFACE
PLASMA
ARC VOLATGE
P3
P2
CAN
INTERFACE
AUXILARY
P4
I/O
120v Connection
CNC Interface
Cable
Main Power
Switch
Torch Lead
Work (ground)
Connection to
Star
POWER
ENTRY
BOTTOM
VIEW
FRONT
VIEW
FlexCut 125
Back
vii
FlexCut 125
Front
User Guide
Unpacking your new machine (FlexCut™ 200/FlexCool™ 35)
FlexCut 200 and FlexCool 35:
FlexCut 200 is liquid cooled and is supplied with the FlexCool 35. For complete instructions on the FlexCut 200
and the FlexCool 35 see their corresponding user guides.
Unpacking the FlexCool 35:
The packaging of the cooler is designed to withstand shipping abuse. If any
shipping damage has occurred, contact your certied Lincoln distributor
or service center. When unpacking the unit, avoid thrusting sharp objects
through the carton, which may damage the machine. Below is the recommended procedure for unpacking the cooler:
• Cut and remove banding straps around skid and carton
• Remove carton
• Cut and remove banding straps around skid and cooler
• Remove cooler, literature, and other items
Save the instruction manual and service directory supplied with the
FlexCool 35 for parts orders and future maintenance service.
Mounting the FlexCool 35 underneath the FlexCut 200:
The FlexCool 35 can be mounted underneath the FlexCut 200 machine or by
itself on a at surface.
No power source should ever be installed underneath the FlexCool 35.
Securing the FlexCut 200 to the FlexCool 35:
1. Begin by setting the FlexCool 35 on a hard at surface.
2. Remove the two 7/16” bolts and the locking bracket from the
front mounting bracket
3. Lift the FlexCut 200 and place on top and slightly forward of the
FlexCool 35
4. Carefully guide the FlexCut 200 so that the quick lock feet on the
bottom of the power source slide into the channels of the mount
ing brackets on top of the FlexCool 35. Be sure all 4 feet are within
the channels.
5. Slide the FlexCut 200 all the way back so that it is sitting exactly
overtop of the FlexCool 35. The feet should be all the way at the
back of the channels.
6. Replace the locking bracket into the front mounting bracket of the
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 re testing.
Pour .75 gallons (2.84 liters) of coolant into the coolant reservoir ll hole through a funnel.
Use the coolant purge command in the machine UI menus to help prime the system.
While priming, add additional coolant to keep the reservoir full. The cooler is “FULL” when the coolant lies just below the
coolant reservoir opening.
Be certain to replace the reservoir ll cap when the reservoir is full. Operation of the FlexCool 35 without the reservoir
cap can cause unnecessary contamination and could be hazardous to others. See the FlexCool 35 manual for complete
instructions and safety precautions.
Torchmate 5100
viii
Unpacking your new machine (FlexCut™ 200/FlexCool™ 35)
The FlexCut 200 does not come with an SO
cord installed for the main power connection.
Use a three-phase supply line. A 1.75 inch (45
Input Cord Strain Relief:
Route input cord through
relief and twist nut to tighten.
mm) diameter access hole for the input supply
is located on the case back.
Connect L1, L2,L3 and ground per connection
diagrams and National Electric Code.
To access the input power connection block,
remove the seven screws and the left case side
of the machine as shown.
Connections between the FlexCut 200 and FlexCool 35:
1. Connect the 115v from the FlexCool 35 to the 115v connection on the back of the FlexCut 200.
2. Connect the ARCLINK cable into the FlexCut 200 to the
FlexCool 35.
3. The two coolant supply lines from the FLEXSTART box will
be coming out the cable carrier. Attach the supply lines to
the FLEXCOOL 35.
4. On the gantry by the FLEXSTART box, remove the zip tie
and connect the two hoses and ARCLINK barrel connector to
the FLEXSTART.
Ground Connection:
Connect Ground Lead per local
and national electrical codes
115 V
AC**
ARC LINK
Power Connection Block:
Connect each phase of a three
phase connector here
FROM
COOLER
COOLANT RETURN
COOLANT SUPPLY
FROM
POWER
SOURCE
TO
STAR
GROUND
ARCLINK
GROUND
FLEXSTART box mounted to gantry on the
5100. Hoses and cables are run into the
cable carrier.
TO
FLEXSTART
ix
COOLANT RETURN
COOLANT SUPPLY
User Guide
Unpacking your new machine (FlexCut™ 200/FlexCool™ 35)
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
carrier to the NOZZLE, ARC LINK, ELECTRODE.
7. Connect the WORK to the STAR GROUND BLOCK on
the machine.
CABLE CARRIER
STAR GROUND
FROM
CABLE CARRIER
FROM
TO
Star Ground
PLASMA GAS
SHIELD GAS
WORK
NOZZLE
ARC LINK
ELECTRODE
ETH 1
ETH 0
FLEX NET
EXT. NETWORK
PLASMA
INTERFACE
P1
PLASMA
ARC VOLATGE
CAN
INTERFACE
AUXILARY
P4
POWER
ENTRY
I/O
P3
P2
8. Connect the CNC interface cable to the BULKHEAD
P1 and P2.
9. Connect the ETHERNET connector to the back of
the FLEXCUT 200. Attach the other end to the ETH1
port to the Fiber Optic box. Attach the ber optic and
power cable to the converter box.
For full wiring instructions, see the corresponding
manuals for the FlexCut 200 and FlexCool 35.
Star Ground
TO
5100 BULKHEAD
CNC INTERFACE
ETHERNET
Torchmate 5100
x
Technical Support | On-Site Service
Lincoln Electric Cutting Systems provides numerous technical support opportunities with the purchase of your new
Torchmate 5100 CNC cutting machine. The following is a brief outline of available options. On-site visits are available at
an additional cost call 775-673-2200 for additional information.
• Phone Support
Phone support is available Monday – Friday 7:00 am-4:00 pm PST. Lincoln Electric will make every eort 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.
Technical support includes, machine assembly/set-up, troubleshooting, conguration, and quality
related issues. Operational or CAD training is not included in phone technical support.
• Email
Lincoln Electric will return emails to the support@Torchmate.com email address within 24 hours
Monday-Friday
• Webinars and LiveStream
Lincoln Electric provides live webinars from time to time to assist customers in the optimization and
operation of CNC systems. Please subscribe to our newsletter for dates and times.
http://torchmate.com/webinars
• Torchmate Training Seminars
Lincoln Electric provides a number of training opportunities at our Reno, Nevada campus and at
select Regional locations. Please call 775-673-2200 for details or visit
http://torchmate.com/seminars
• Torchmate Online Training
Lincoln Electric maintains a number of operational training resources at
http://torchmate.com/training
• Torchmate YouTube Channel:
Lincoln Electric provides a wide selection of how to tutorials on our YouTube page.
https://www.youtube.com/user/torchmatedotcom
xi
User Guide
Statement of Warranty
30 Day guarantee
Warranty
If Buyer is not satised 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. All sales become nal after this 30 day period. Buyer should determine the
satisfactory performance of the Goods by using the software, and inspecting and
bench running the motors and/or accessory items. Any items to be returned for full
refund must be in new, unused (except for bench testing), and saleable condition at
the sole determination of the Seller. Items that, in the Seller’s judgment, have been
used or modied in any way, or kits that have been partially or fully completed will
be subject to a restocking fee to be determined by the Seller. A return merchandise
authorization number (RMA) must be obtained by the customer prior to any return.
Shipments of returned items not marked with a valid RMA will be refused.
Electronics and motors are warranted by their manufacturer to the original purchaser
for 12 months from the date of Torchmate, Inc.’s sale invoice. Mechanical components
are standard industrial parts and are not warranted except by their respective
manufacturers. If any of the warranted items are found by Seller to be defective, such
Goods will, at Seller’s option, be replaced or repaired at Seller’s cost. No defective
goods are to be returned without written authorization of seller. The sole purpose
of the stipulated exclusive remedy shall be to provide the Buyer with free repair and
replacement of defective Goods in the manner provided herein. This exclusive remedy
shall not be deemed to have failed of its essential purpose so long as the Seller is
willing and able to repair or replace defective Goods in the prescribed manner. The
foregoing warranty is in lieu of all other warranties, express or implied, including
those of merchantability or tness for any purpose not expressly set forth herein. No
armation of Seller, by words or action, other than as set forth in this Section shall
constitute a warranty. Seller’s warranty does not apply to any Goods which have been
subjected to misuse, mishandling, misapplication, neglect (including but not limited
to improper maintenance), accident, improper installation, modication (including
by not limited to use of unauthorized parts or attachments), or adjustment or repair
performed by anyone other than Seller or one of Seller’s authorized agents. When
returning products to Seller packaging must be adequate or all warranty is null and
void. Buyer will pay for the cost of Shipping to and from the Seller for all warranty
repairs.
Any claim by Buyer with reference to the Goods sold hereunder shall be deemed waived
by the Buyer unless submitted in writing to seller within the earlier of (i) thirty (30)
days following the date Buyer discovered or by reasonable inspection should have
discovered, any claimed breach of foregoing warranty, or (ii) 12 months following the
date of shipment. Any cause of action for breach of the foregoing warranty shall be
brought within one year from the date the alleged breach was discovered or should
have been discovered, whichever occurs rst.
Torchmate 5100
xii
Statement of Warranty (cont.)
Seller’s liability (whether under the theories of breach of contract or warranty,
negligence, or strict liability) for its Goods shall be limited to repairing or replacing
Goods found by Seller to be defective, or at Seller’s option, to refunding the purchase
price of such Goods or parts thereof.
In no event shall seller be liable for consequential damages arising out of or in
connection with this agreement, including without limitation, breach of any obligation
imposed on seller hereunder. Consequential damages shall include without limitation,
loss of use, income or prot, or loss sustained as the result of injury (including death)
to any person, or loss of or damage to property (including without limitation property
handled or processed by the use of the goods). Buyer shall indemnify seller against all
liability, cost or expense which may be sustained by seller on account of any such loss,
damage, or injury.
Upon buyer’s receipt of shipment, Buyer shall immediately inspect the Goods. Unless
Buyer provides Seller with written notice of any claim for shortage, overcharge, or
damage of Goods within ten (10) days from invoice date, such Goods shall be deemed
nally inspected, checked and accepted by Buyer and no allowances shall be made
thereafter. In absence of shipping and packaging instructions, Seller shall use its own
discretion in the choice of carrier and method of packing. Seller shall not be responsible
for insuring shipments unless specically requested by Buyer and any insurance or
special packaging so requested shall be at Buyer’s expense and valuation.
Title to any Goods sold and risk of loss of such Goods passes to Buyer upon delivery by
Seller to carrier and any claims for losses or damages shall be made by Buyer directly
with carrier.
A. In addition to the rights and remedies conferred upon Seller by law, Seller shall not
be required to proceed with the performance of any order or contract if the Buyer
is in default in the performance of any order or contract with Seller, and in case
of doubt as to Buyer’s nancial responsibility, shipments under this order may be
suspended.
B. No delay or omission by Seller in exercising any right or remedy provided for herein
shall constitute a waiver of such right or remedy and shall not be constituted as a
bar to or a waiver of any such right or remedy on any future occasion.
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, uids and machinery at the end of the life cycle in
accordance with federal and local regulations.
The invalidity or unenforceability of any one or more phrases, sentences, or sections
shall not aect the validity or enforceability of the remaining portions of this
Agreement.
Limitation of
liability
Disclaimer of
consequential
damages
Acceptance and transportation
Title and
risk of loss
General
conditions
Severability
xiii
User Guide
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.
DO NOT INSTALL,
OPERATE, OR REPAIR
THIS EQUIPMENT
WITHOUT READING
THE SAFETY WARNINGS
CONTAINED THROUGHOUT THIS MANUAL.
Think before you act—
and be careful.
While Operating the machine.
• WEAR CORRECT EYE, EAR & BODY PROTECTION
• PROTECT your eyes and face with welding helmet properly tted and with proper hade rating of lter plate (See
ANSI Z49.1).
• PROTECT your body from welding spatter and arc ash with protective clothing including woolen clothing, ameproof apron and gloves, leather leggings, and high boots.
• PROTECT others from splatter, ash, and glare with protective screens or barriers.
• WHEN OPERATING THIS EQUIPMENT, wear hearing protection.
• BE SURE protective equipment is in good condition.
• Provide adequate lighting to the area around the machine appriopriate for all the tasks being completed.
• Wear safety glasses in work area AT ALL TIMES.
• Do not climb on machine. It is not intended as a ladder or to support anything but the intended use of metal cutting. Climbing onto the machine could result in a fall that can result in injury or death.
KEEP CHILDREN AWAY.
IF YOU WEAR A PACEMAKER, YOU SHOULD CONSULT WITH YOUR
DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information it
is strongly recommended that you acquire a copy of “Lincoln Electric E205 ‘Arc Welding
Safety’”as well as “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American
Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR
PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS
ELECTRIC SHOCK can kill.
• The electrode and work (or ground) circuits are electrically “hot” when the power source is on. Do not touch these
“hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
• Disconnect the power source before performing any service or repairs. When the power source is operating,
voltages in excess of 250 volts are produced. This creates the potential for serious electrical shock - possibly even
fatal.
• Insulate yourself from work and ground using dry insulation. Wear dry gloves and clothing. Take extra care when
the work place is moist or damp.
• Always be sure the work cable makes a good electrical connection with the metal being cut or gouged. The
connection should be as close as possible to the area being cut or gouged.
• Ground the work or metal to be cut or gouged to a good electrical (earth) ground.
• Maintain the plasma torch, cable and work clamp in good, safe operating condition. Repair or replace all worn or
damaged parts. Replace damaged insulation.
• Never dip the torch in water for cooling or plasma cut or gouge in or under water.
• When working above oor level, protect yourself from a fall should you get a shock.
• Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety
clothing.
1
User Guide
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.
• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
• When plasma cutting or gouging on lead or cadmium plated steel and other metals or coatings which produce toxic
fumes, keep exposure as low as possible and within applicable limits such as the OSHA PEL and ACGIH TLV limits,
using local exhaust or mechanical ventilation. In conned spaces or in some circumstances a respirator will be
required.
• Additional precautions are also required when cutting (zinc) galvanized steel or materials containing or coated with
any of the following:
Antimony Beryllium Cobalt Manganese Selenium
Arsenic Cadmium Copper Mercury Silver
Barium Chromium Lead Nickel Vanadium
• The operation of plasma cutting or gouging fume control equipment is aected by various factors including proper
use and positioning of the equipment, maintenance of the equipment, and the specic procedure and application
involved. Worker exposure levels should be assessed by a qualied individual, such as an industrial hygienist, upon
installation and periodically thereafter to be certain levels are within applicable exposure limits, such as the OSHA
PEL and ACGIH TLV. For information on how to test for fumes and gases in your work place, refer to publications
section of this manual.
• Do not use plasma cutting or gouging equipment in locations near chlorinated hydrocarbon vapors coming from
degreasing, cleaning or spraying operations. The ultraviolet rays from the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products. Remove all sources of these vapors.
• Materials containing chromium may release hexavalent chromium compounds during plasma cutting and other hot
work.
• Hexavalent chromium compounds are on the IARC list as posing a lung cancer risk to humans. Use adequate ventilation to avoid overexposures.
• Gases used for plasma cutting and gouging can displace air and cause injury or death. Always use enough
ventilation, especially in conned areas, to insure breathing air is safe.
• Read and understand the manufacturer’s instructions for this equipment and follow your employer’s safety
practices.
• This product, when used for cutting, produces fumes or gases which contain chemicals known to the State of
California to cause birth defects
• Fumes and gases from hot work and dust created by routing, sawing, grinding, drilling, and other construction
activities contains chemicals known to cause cancer, birth defects or other reproductive harm. Avoid prolonged contact with this dust. Wear protective clothing and wash exposed areas with soap and water. Avoid dust to get into
your mouth, eyes, or lay on the skin as this may promote or result in the absorption of harmful chemicals.
Some examples of these chemicals are:
• Lead from lead-based paint.
• Crystalline silica from bricks and cement and other masonry products.
• Arsenic and chromium from chemically-treated lumber (CCA).
Your risk from these exposures varies, depending on the nature and frequency of this type of work. To revent your exposure to these chemicals: Use local exhaust ventilation and/or work in a well ventilated area, and work with approved
safety equipment, including respiratory protection that is properly selected in accordance with the contaminants, and
their concentrations present in the work environment.
Torchmate 5100
2
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.
• Use safety glasses and a shield with the proper lter and cover plates to protect your eyes from sparks and the rays
of the arc when performing or observing plasma arc cutting or gouging. Glasses, head-shield, and lter lens should
conform to ANSI Z87. I standards.
Use suitable clothing including gloves made from durable ame-resistant material to protect your skin and that of
your helpers from the arc rays.
• Protect other nearby personnel with suitable non-ammable screening and warn them about the hazards of the
activity taking place, and the precautions they must take.
• According to IARC, ultraviolet radiation from
welding causes ocular melanoma. IARC identies
gouging, brazing, carbon arc or plasma arc cutting, and
soldering as processes closely related to welding
Cutting ame and sparks can cause FIRE OR EXPLOSION.
Arc Current Minimum
Shade No.
Less than 20A 4 4
20A-40A 5 5
40A-60A 6 6
60A-300A 8 9
300A-400A 9 12
400A-800A 10 14
Suggested
Shade No.
• Read and follow NFPA 51B “ Standard for Prevention During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.
• Fire and explosion can be caused by hot slag, sparks, oxygen fueled cutting ame, or the plasma arc.
• Have a re extinguisher readily available. Provide a re watch when working in an area where re hazards may
exist.
• When not cutting or gouging, make certain no part of the electrode circuit is touching the work or ground.
Accidental contact can cause overheating and create a re hazard.
• Be sure there are no combustible or ammable materials in the workplace. Any material that cannot be removed
must be adequately protected as to avoid any potential for contact with ames, sparks or spatter.
• Sparks and hot materials from cutting or gouging can easily go through small cracks and openings to adjacent
areas.
• Avoid cutting or gouging near hydraulic lines.
• Do not cut or gouge tanks, drums or containers until the proper steps have been taken to insure that such
procedures will not cause ammable or toxic vapors from substances inside. They can cause an explosion even
though they have been “cleaned.” For information purchase “Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American
Welding Society (see address above).
• Vent hollow castings or containers before heating, cutting or gouging. They may explode.
• Do not add fuel to engine driven equipment near an area where plasma cutting or gouging is being done.
• Connect the work cable to the work as close to the cutting or gouging area as practical. Work cables connected
to the building framework or other locations away from the cutting or gouging area increase the possibility of
the current passing through lifting chains, crane cables or other alternate circuits. This can create re hazards or
overheat lifting chains or cables until they fail.
• Hydrogen gas may be formed and trapped under aluminum work pieces when they are cut underwater or while
using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be
eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.
3
User Guide
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, ttings, etc. should be suitable for the application and
maintained in good condition.
• Always keep cylinders in an upright position securely chained to an undercarriage or xed support.
• Cylinders should be located: • Away from areas where they may be struck or subjected to physical damage. • A safe
distance from plasma cutting or gouging, arc welding operations and any other source of heat, sparks, or ame.
• Never allow any part of the electrode, torch or any other electrically “hot” parts to touch a cylinder.
• Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
• Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for
use.
• Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in Cylinders,”available from the Compressed Gas Association
1235 Jeerson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY powered equipment.
• Turn o input power using the disconnect switch at the fuse box before working on the equipment.
• Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
• Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s
recommendations.
PLASMA ARC can injure.
• Keep your body away from nozzle and plasma arc.
• Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety
clothing.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
• Electric current owing through any conductor causes localized Electric and Magnetic Fields (EMF). Cutting or gouging current creates EMF elds around torch cables and cutting machines.
• EMF elds may interfere with some pacemakers or other medical implant devices, so operators who have such a
device should consult their physician and the device manufacturor before cutting or gouging.
• Exposure to EMF elds during cutting or gouging may have other health eects which are now not known.
• All operators should use the following procedures in order to minimize exposure to EMF elds from the cutting or
gouging circuit:
• Route the torch and work cables together - Secure them with tape when possible.
• Never coil the torch cable around your body.
• Do not place your body between the torch and work cables. If the torch cable is on your right side, the work
cable should also be on your right side.
• 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
Torchmate 5100
http://torchmate.com/white-papers/EMI-Reduction
4
Table Specications
Input Power
• 120V / 1Ph / 15A / 60Hz (table and computer)
• 380-600V / 3Ph / 50-60Hz (Plasma Power Supply specic)
Machine Size
• 60˝ x 120” (1524mm x 3048mm) Cutting Area
• 113.5˝ x 167” (2895.6mm x 4241.8mm) Footprint
Traverse Speed
• 1,500 ipm (0.635 mps)
Cut Speed
• Up to 1500 ipm
Plate Capacity
• Holds Up To 4” (102mm) 5’x10’ (1524mm x 3048mm) Mild Steel
Weight
• 6,600 lbs (
Operating Temperature
• 32-104° Farenheit (0-40° Celcius)
Motors
• Servo Motors Fitted with Rotary Glass Encoders
Drive System
• Helical Gear Rack and Hardened Pinion with Lubrication
System
Linear Guidance
• Prole Linear Rail
Height Control
• Ohmic Sensing
• Automatic Torch Height Control
• 6.75” Z-axis Travel
Bevel Capabilities
• +/-45° Rotation (dependent on material thickness and power
supply conguration)
Software
• Easy-To-Use Lincoln Electric User Interface
• CAM with Irregular Part Nesting
• Popular Shape Library
Fume Extraction (Optional Accessory)
• 61,801 ft3/hr or 1,750 m3/hr minimum
• Automatic Filter Cleaning, Pressure Controlled
Downdraft Conguration
• Multiple Zones Controlled By Motion Controller
Safety
• Dual-Channel Safety System Supporting Emergency Stop
Switch
• Safety System Extended To External Peripherals
• External Drive Power On Switch
Machine Construction
• Fabricated Steel Frame with Powder Coated Finish
Acceleration Rate
• 0.08g (0.06g Bevel)
Warranty
• *1 Year Warranty
Deceleration Rate
• 0.08g (0.06g Bevel)
TORCHMATE 5100 CNC PLASMA SYSTEMS FC 125 FC 200 SP 275 SP 400
PRODUCTION CUTTING CAPACITY
Mild Steel 1” (25mm) 1.25” 1.5” (38mm) 2” (50mm)
Stainless Steel 3/4”(20mm) 3/4”(20mm) 1” (25mm) 1.5” (38mm)
Aluminum 5/8”(16mm) 3/4”(20mm) 3/4” (20mm) 1.5” (38mm)
CUTTING SPEED @ RATED OUTPUT CURRENT
1/4” MS 210 ipm @125A 200 ipm @200A 230 ipm @200A 230 ipm @ 200A
1/2” MS 88 ipm @125A 110 ipm @200A 125 ipm @ 275A 160 ipm @ 400A
1” MS 32 ipm @125A 40 ipm @200A 65 ipm @275A 85 ipm @ 400A
PROCESS AMPS 20A - 125A 15A - 200A 30A - 275A 30A - 400A
CUTTING GAS
Mild Steel Air / Air Air / Air Oxygen / Air Oxygen / Air Oxygen / Oxygen
Stainless Steel Air / Air Nitrogen Air / Air Nitrogen Air / Air - Nitrogen H17 / Nitrogen Nitrogen / Air
Aluminum Air / Air Air / Air Air / Nitrogen Nitrogen Air
INPUT VOLTAGE 380/400/415V3Ph50/60Hz 380/460/575V3Ph50/60Hz 380V 3Ph 50/60Hz | 400V 3Ph 50/60 Hz
460V 3Ph 50/60Hz 400V3Ph 50Hz (CE) 415V 3Ph 50/60Hz | 440V 3Ph 50/60Hz
575V 3Ph 50/60Hz 480V 3Ph 50/60Hz | 600V 3Ph 50/60 Hz
5
User Guide
Site Preparation
When installing a Lincoln Electric CNC Cutting System in your shop, there are many factors that will inuence the
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.
• When preparing to install the Lincoln Electric CNC Cutting System, provide sucient space. Three feet of work
space should be maintained at the front of machine
• Forklift load material opposite the cable carrier only. Utilize the back of the machine to park the gantry while
loading material.
• A dedicated earth ground must be provided and should be installed in a manner to reduce trip hazard.
po-
5100
5100
113.25”
15’ Power Cord, NEMA 5-15P
Air Supply
Earth Ground
Provided by Other
FlexCut 125/200
Plasma
Machine
within 10’ of cable
carrier
167”
Load From
This Side
Torchmate 5100
Operator
Console
MAINTAIN WORK AREA
6
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
167”
Load From
This Side
113.25”
15’ Power Cord, NEMA 5-15P
Air Supply
Earth Ground
Provided by Other
Gases
30.0
Burny
Spirit 2
Power
Supply
Locate power supply
within 6’ of table cable
chain. Automatic Gas
43.0
Console should be kept
within 2’ of power
supply.
3-phase
Power Supply
Air Supply
Provided by Customer
MAINTAIN WORK AREA
Operator
Console
7
User Guide
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 eective 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. A ground rod must be installed.
Consult with a qualied electrical technician to verify your system grounding.
Use 6 AWG Stranded Wire to connect the Star Ground on the table to the customer supplied dedicated earth ground.
For proper operation of your CNC cutting tables you are required to run a 6 AWG cable from the “star” ground to a
dedicated earth-ground rod
Ground rod installations are covered by NEC Section 250.
Place the plasma unit on the appropriate location.
Re-install the power lead and the table ground into
the plasma power supply.
The FlexCut plasma unit is shipped with a factory
ground attached to the star ground. In addition, a
work ground is attached to the star ground to connect
to your material to be cut. If the work piece is painted
or dirty it may be necessary to expose the bare metal
to make a good electrical connection.
Earth Ground Rod is not included with machine
A
STAR GROUND
DETAIL A
GROUND ROD
Torchmate 5100
8
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 qualied electrician should connect the input leads to the Torchmate 5100 CNC unit and FlexCut/Spirit II Plasma unit. Connections should be made in accordance with all local and national electrical codes. Failure to do so may result in bodily
injury or death.
The FlexCut 125/200 is rated for 380 VAC through 575 VAC input voltage, three phase only and 50 or 60 Hz. Before
connecting the machine to power, be sure the input supply voltage, phase and frequency all match those listed on the
machine rating plate.
The Burny Kaliburn Spirit II plasma cutters are manufactured to the customer’s power availability.
The power supply cord is supplied on the FlexCut 125 without an attachment plug to accommodate three phase installations of being hard wired to a disconnect or for a wall plug. FC200/Spirit II do not include SO cord for connection to
customers power and will need to have the appropriate cable connected per electrical requirements.
Warning:
The FlexCut on/o switch is not
intended as a service disconnect
for this equipment. Only a
qualied electrician should
connect the input leads to the
Torchmate 5100.
120v to Machine
To Plasma Power Supply
The Torchmate 5100 CNC machine requires a clean, dry, oil-free compressed air. A high pressure regulator MUST be used
with a compressor or high pressure cylinder.
Supply pressure must be between 87-110 psi (6-7.6 bar) with ow rated rates of at least 300 SCFH or 140 SLPM.
AIR SUPPLY PRESSURE SHOULD NEVER EXCEED 130 PSI OR DAMAGE TO THE MACHINE MAY OCCUR!
A standard nominal 5 micron in-line lter is recommended, but for optimal performance, select a pre-lter with
a 3 micron absolute rating. Air must be supplied to the plasma with 3/8” inside diameter tubing and 1/4 NPT quick
disconnect coupler. Air lines should be run as to not create a trip hazard.
Water should be installed in the table before operation. Operators are encouraged to use a readily available
anti-corrosive water additive designed for use in CNC plasma water tables.
Water Capacity: 428 gallons (1620 liters)
9
User Guide
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.
• Inside the table sit an array of 69.625” x 3” x 3/16” (4.7625mm) thickness slats that support the material
being cut. After repeated cutting, generally after a year or so of normal cutting time, you will need to
replace the slats. Perform the replacement when the slats can no longer support the material properly or
the build up is hindering the plate from being at.
• The center slat support is oset, to create an ARC of the slats. This makes the slats less prone to getting
damaged in straight cuts, along with keeping the material from moving during cutting.
• The slats can be used on one side and ipped over to increase usage time on one set of slats.
Torchmate 5100
10
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. The power switch for the plasma power supply
is located on the front of the unit. The complete user guide is available as an embedded le in the VMD. Use the button
with the question mark to access this le.
1. Power up the machine by using the toggle switch. (back left of the machine)
2. The VMD Application will auto start with the computer, wait for control panel to load (run.wap)
3. Verify the EMERGENCY STOP(s) are disengaged by turning the RED EMERGENCY STOP button clockwise. One on the
non-cable carrier side of the gantry and one above the monitor.
4. Press the GREEN BUTTON above the Operators Console. (This will power the motors)
5. Press DATUM. (Machine will seek back left corner)
6. Go to the plasma torch head to check and evaluate the consumables. Turn the plasma power supply on and set
the appropriate amperage for the consumables and the material you will be cutting. Cut charts are available in the FlexCut manual. Verify air pressure is correct per manual.
7. Jog the torch to the lower left corner of the material you are going to cut. Press SET PROGRAM ZERO.
8. Press GO TO PROGRAM ZERO. The head should return to the top of the lifter.
Back
Left
Corner
1
3, 4
To JOG machine press
and swipe your nger in
the direction you wish
to JOG.
2
5
7 8
11
User Guide
Water Table Operation
Table Drain
The 5100 in Water Table conguration, 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.
The water table is controlled by the HMI.
When you press RAISE WATER, compressed air is
FILL / DRAIN
pushed into the lower chamber.
This “pushes” the water up into the cutting table.
When you press LOWER WATER, the ball valve will
OPEN, releasing the compressed air from the bottom
chamber. This allows the upper chamber to drain the
water into the lower chamber.
• To completely DRAIN your table, use the 2”
QC ball valve in the FRONT LEFT of the table.
Table Drain
Torchmate 5100
12
Table Drain
Air IN
Water UP
WATER TABLE
LOWER CHAMBER
BALL VALVE
OVER FLOW DRAIN
(DRAINS TO FLOOR)
OVERFLOW TUBE
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