Lincoln Electric Torchmate 5100 Series User manual

April 10, 2019
Copyright 2019
Lincoln Electric®Cutting Systems
QUICK START GUIDE
FLEXCUT®

Torchmate 5100 ii
Table of Contents
Page: Contents
i Title Page
ii Table of Contents
1 Machine Overview, Torchmate 5100, Front
2 Machine Overview, Torchmate 5100, Side
3 Machine Overview, Torchmate 5100, Rear
4 Overview, FlexCut 125
5 Overview, FlexCut 200
6 Powering up the Torchmate 5100
7 Running a Job
8 Running a Job, continued
9 Overview, Plasma Console
10 Performing your rst Test Cut, Non Bevel
11 Performing your rst Test Cut, Bevel
12 Customer Assistance Policy

Quick Start Guide, FlexCut
1
Machine Overview, Torchmate 5100, Front
Front:
1. Emergency Stop button
2. Lifter Station
3. Tool Mounting Plate
4. Gantry
5. Drive Enable button
6. Emergency Stop button
7. USB Port
8. Touchscreen/Human Machine Interface (H.M.I.)
9. Monitor Arm
10. Machine Bed
11. Leveling Foot
This section will provide a brief overview of the components of your Torchmate 5100 machine
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11

Torchmate 5100 2
Machine Overview, Torchmate 5100, Side
Cable Carrier Side:
1. Touchscreen/Human Machine Interface (H.M.I.)
2. Z Axis Motor
3. Remote Arc Start control box (FlexCut 200 and Spirit®II systems only)
4. Material Support Slats
5. Cable Carrier (Y Axis)
6. Linear Rail (Y axis)
7. Helical Gear Rack
8. Electrical Bulkhead
9. Pneumatic Manifold
10. Pneumatic Pressure Regulator for Collision sensor (FlexCut 200 or Spirit II models only)
11. Star Ground
12. Fork Pockets
13. Tie Down Hooks
14. Downdraft Zone Door Access Panel (downdraft models only)
This section will provide a brief overview of the components of your Torchmate 5100 machine
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Quick Start Guide, FlexCut
3
Machine Overview, Torchmate 5100, Rear
Rear:
1. Touchscreen/Human Machine Interface (H.M.I.)
2. Linear Rail/Helical Gear Rack (X axis)
3. X axis servo motor
4. Cable Carrier (X axis)
5. Emergency Stop button
6. Machine Serial Number Placard
7. Power On/O
8. QuickCAM/Nest Serial Number
9. Electrical Panel Access door
10. 14” ducting ange (downdraft model only)
11. Remote Arc Start control box (FlexCut 200 and Spirit II systems only)
This section will provide a brief overview of the components of your Torchmate 5100 machine
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5
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Torchmate 5100 4
FlexCut 125 Plasma Overview
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7
FRONT
1. LCD DISPLAY
2. PRIMARY AIR, GAS PRESSURE GAUGE
AND REGULATOR KNOB
3. HOME BUTTON
4. ONOFF SWITCH
5. TORCH CONNECTION
6. WORK LEAD CONNECTION
7. MENU CONTROL KNOBBUTTON
8. PURGE
BACK
9. AIR OR GAS INLET 14”IN. NPT QUICK
CONNECT
10. RECONNECT PANEL ACCESS
11. INPUT CORD STRAIN RELIEF
12. 14PIN CNC INTERFACE
13. FAN
Controls »
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 will execute. During this test, the control panel will light up.

Quick Start Guide, FlexCut
5
FlexCut 200 Plasma Overview
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FRONT
1. LCD DISPLAY
2. HOME BUTTON
3. MENU CONTROL KNOBBUTTON
4. ONOFF SWITCH
5. SHIELD GAS OUTLET
6. NOZZLE LEAD CONNECTION
7. WORK LEAD CONNECTION
8. ELECTRODE LEAD CONNECTION
9. ARCLINK CONNECTOR 5PIN
10. PLASMA GAS OUTLET
11. PURGE
12. SHIELD GAS REGULATOR
13. PLASMA GAS REGULATOR
BACK
14. AIR OR GAS INLET 14”IN. NPT QUICK
CONNECT
15. 115V15A AUXILIARY POWER RECEPTACLE
16. 15 AMP CIRCUIT BREAKER
1 7. ETHERNET CONNECTOR
18. 10 AMP CIRCUIT BREAKER
19. FLEXCOOL CONNECTOR
20. INPUT CORD STRAIN RELIEF
21. CNC INTERFACE CONNECTOR
22. FAN
Controls »
Please refer to the complete operation and user manual for your FlexCut 200 located with the plasma unit. When the
machine is turned on, an auto-test will execute. During this test, the control panel will light up.
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Torchmate 5100 6
Powering up the Torchmate 5100
1. Power up the machine by using the ON/O 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 Flex-
Cut manual. Verify air pressure is correct per manual.
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.
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5
Back
Left
Corner
4 3

Quick Start Guide, FlexCut
7
Running a Job
For your rst machine cut, we highly recommend cutting the Factory provided test cut program, and comparing it to the
sample that was cut in the factory. This will help verify that the machine is operating to factory specications.
When you rst turn on the machine, it will already be congured and
ready to run. A screen displays PLEASE SWITCH DRIVES ON. Press HIDE
and then in the lower left corner press DATUM. The Torch will travel to the
limits of the machine and establish the MACHINE ZERO.
Datum:
Pressing one of the arrows on the screen will move the torch-
body in the direction you are pressing. When released, the
head will stop.
The distance from your nger press to the base of the arrow
will determine the speed at which the machine moves. While
you are jogging, sliding your nger in the direction of the
arrow will increase or decrease your speed.
Continuous Jog:

Torchmate 5100 8
This establishes the Lower Left corner of the program, centerline
of the torch body. This will be where the job will start from for any
part or nest programmed for the Torchmate 5100 .
Establish the plates position by pressing SET PROGRAM ZERO.
This will move the torch body back to the established PROGRAM
ZERO, at the highest possible torch position to avoid torch collisions.
Set Program Zero:
Go To Program Zero:
Follow the steps below to Jog the tool around the table
Running a job (continued)
Pressing one of the arrows on the screen will move the torch-
body in the direction you are pressing, the amount of distance
specied in the “Increment Distance” setting.
By using the slider, you can set increments between .000 -
.100”. You can directly enter any number into the dialog.
Incremental Jog:

Quick Start Guide, FlexCut
9
Plasma Console in Visual Machine Designer software: (FlexCut 200)
The FlexCut 200 allows you or the G-Code program to set variables for the plasma cutter to operate with.
Plasma Cutter Conguration
With the machine set into the correct position over the material, nalize the plasma cutter settings. See the details
below on conguring the FlexCut 125 and FlexCut 200 for your First Cut.
• Material - Choose the appropriate material type
• Gas Combination - Based on input gases and material selection
• Thickness - material thickness
• Current - 50, 100, 150, or 200 depending on material thickness and consumables
• Plasma/Shield Pressure, Set Point - Based on material type, gas type, thickness, and amperage, the correct pressures
are displayed for that combination for the operator to set
• Plasma/Shield Pressure, Actual - These should be set after clicking the “Begin Purge” button by adjusting the pressure
regulators on the front panel of the FlexCut 200. These values are also displayed on the FlexCut 200 LCD display
• VMD in Control - Either the settings can be controlled via the VMD software on the HMI (default ON) or only at the
FlexCut 200 power supply
• Purge - Begins purging the Plasma and Shield gases allowing the operator to set the pressures
• Selected Process - Plate cutting, Arc Marking, Expanded Metal cutting, and Arc Gouging modes. See FlexCut 200
manual for details.
• Status - Information regarding the status of the plasma cutter, see FlexCut 200 manual for details.
FlexCut 125 main panel:
On the front panel of the FlexCut 125, turn the main dial to display 65
Press and hold the Purge button, and adjust the regulated air pressure to be 70PSI.

Torchmate 5100 10
1. Press SELECT JOB
2. Locate FC125/200 (amperage of plasma) INLINE TEST CUT 65A/100A (plasma ma-
chine).gm and press OK
3. Verify that your amperage on your plasma power supply is set to 65 amp (FC125) or
100 amp (FC200)
4. Set AVHC Mode to AUTO
5. Set AVHC Sample Voltage to ON
6. Set IHS (ohmic detection) set to ON
7. Set IHS Mode to Always
8. Set the Machine to Active Run (If Dry Run is displayed, press once to toggle to
Active Run)
9. Verify that the FEED RATE OVERRIDE is set to 100% beneath the Continuous Jog
Buttons
10 PRESS RUN JOB (machine may throw sparks)
11. The cut will progress as follows:
Rapid travel to the rst inside feature
Z Axis moves toward the material, touching the top of the material
(IHS -ohmic detection)
Torch retracts to set PIERCE HEIGHT and will re
Dwells until the PIERCE DELAY is expired
Drops to set CUT HEIGHT and starts the program
Will cut all inside features rst, then move to the outside geometry
Once cut is complete, compare the cut to the provided sample and verify that they
match. This will provide verication that the machine is functioning properly.
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 IPM to cut the
material thickness to the amperage you have set on the plasma power supply. These have been included in your pre
loaded rst cut on the Torchmate 5100 models. The plasma torch body is pre-loaded with 65 amp consumables (FlexCut
125) or 100 amp (FlexCut 200) for a 3/16” material cut from the factory. We highly suggest your rst cut is our pre-load-
ed, *FC125/200 INLINE TEST CUT 65A/100A.gm to ensure your machine has transported in the same condition it has left
the factory. Please locate the factory test sample located in the waterbed and load a piece of 3/16” mild steel for the
comparison cut test.
If you need to stop the
machine at any time
please hit the stop button
on the touch screen.

Quick Start Guide, FlexCut
11
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 rst cut is our pre-loaded, *FC125/200 BEVEL
TEST CUT 105A/150A.gm* to verify your machine has arrived in the same condition it has left the factory. Please locate
the factory test sample located in the waterbed and load a piece of 1/2” mild steel for the comparison cut test.
If you need to stop the
machine at any time
please hit the stop button
on the touch screen.
1. Press SELECT JOB
2. Locate FC125/200 (amperage of plasma) BEVEL TEST CUT 105A/150A (plasma ma-
chine).gm and press OK
3. Verify that your amperage on your plasma power supply is set to 105 amp (FC125) or
150 amp (FC200)
4. Set AVHC Mode to AUTO
5. Set AVHC Sample Voltage to ON
6. Set IHS (ohmic detection) set to ON
7. Set IHS Mode to Always
8. Set the Machine to Active Run (If Dry Run is displayed, press once to toggle to
Active Run)
9. Verify that the FEED RATE OVERRIDE is set to 100% beneath the Continuous Jog
Buttons
10 PRESS RUN JOB (machine may throw sparks)
11. The cut will progress as follows:
Rapid travel to the rst inside feature
Z Axis moves toward the material, touching the top of the material
(IHS -ohmic detection)
Torch retracts to set PIERCE HEIGHT and will re
Dwells until the PIERCE DELAY is expired
Drops to set CUT HEIGHT and starts the program
Once cut is complete, compare the cut to the provided sample and verify that they
match. This will provide verication that the machine is functioning properly.

The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. Our challenge is to meet the needs of our customers and
to exceed their expectations. On occasion, purchasers may ask
Lincoln Electric Cutting Systems for advice or information about their
use of our products. We respond to our customers based on the best
information in our possession at that time. Lincoln Electric Cutting
Systems is not in a position to warrant or guarantee such advice, and
assumes no liability, with respect to such information or advice. We
expressly disclaim any warranty of any kind, including any warranty
of tness for any customer’s particular purpose, with respect to such
information or advice. As a matter of practical consideration, we also
cannot assume any responsibility for updating or correcting any such
information or advice once it has been given, nor does the provision
of information or advice create, expand or alter any warranty with
respect to the sale of our products.
Lincoln Electric Cutting Systems is a responsive manufacturer, but the
selection and use of specic products sold by Lincoln Electric Cutting
Systems is solely within the control of, and remains the sole respon-
sibility of the customer. Many variables beyond the control of Lincoln
Electric Cutting Systems aect the results obtained in applying these
types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our
knowledge at the time of printing. Please refer to
www.torchmate.com for any updated information.
Customer Assistance Policy
1170 Trademark Suite 101 • Reno, NV • 89521 • U.S.A
Phone: [phone]• www.torchmate.com
US70-041019-MA-01-03