Lincoln Electric Torchmate 5100 Series User manual

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

Torchmate 5100 ii
Table of contents
Unpacking the machine iii
Technical Support | On-site Service xi
Statement of Warranty xii
Safety Information 1
Table Specications 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

iii User Guide
C
B
DETAIL C
DETAIL B
Unpacking your new machine
Qty. Description Part Number
1 Lincoln Electric TorchmateTM 5100 Water Table with FlexCutTM 125 Plasma Unit LECS-5100-125-W0
1 Lincoln Electric TorchmateTM 5100 Water Table with FlexCutTM 200 Plasma Unit LECS-5100-200-W0
1Lincoln Electric TorchmateTM 5100 Water Table with Spirit®II 275 Plasma Unit LECS-5100-275-W0
1Lincoln Electric TorchmateTM 5100 Water Table with Spirit®II 400 Plasma Unit LECS-5100-400-W0
1 Lincoln Electric TorchmateTM 5100 Down draft with FlexCutTM 125 Plasma Unit LECS-5100-125-D0
1 Lincoln Electric TorchmateTM 5100 Down draft with FlexCutTM 200 Plasma Unit LECS-5100-200-D0
1Lincoln Electric TorchmateTM 5100 Down draft with Spirit®II 275 Plasma Unit LECS-5100-275-D0
1Lincoln Electric TorchmateTM 5100 Down draft with Spirit®II 400 Plasma Unit LECS-5100-400-D0
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.
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.
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.
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.
Do Not Fork Lift From
Cable Carrier Side Of
Machine!
A
DETAIL A

Torchmate 5100 iv
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)
LEVELING FEET AND
ALTERNATIVE DRAIN VIEW
LEVELING FEET AND
ALTERNATIVE DRAIN VIEW

vUser Guide
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. Remove the bolt from behind the monitor and
two bolts on the swing bracket.
2. Lift the monitor up and secure with the re-
moved bolt.
3. Grab the arm and swivel it 180 degrees into
place.
4. Re-insert the bolts to secure the arm in place.
1. REMOVE BOLT
2. LIFT MONITOR
1. REMOVE BOLTS 2x,
ONE TOP AND ONE ON BOTTOM
2. REINSTALL BOLT
3. ROTATE ENTIRE MONITOR
ARM 180 DEGREES
4. REINSERT BOLTS
AND SECURE IN PLACE

Torchmate 5100 vi
Unpacking your new machine (Electrical Connections)
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 connec-
tions that are required by your specic power supply to interface with the machine.
All electrical, air, and interface connections
to the machine will be o of the BULKHEAD
5100 - Table Power and Air connections:
5100 - Pneumatic Connection:
Electrical Bulkhead
Attach the supplied 120v 15Aplug into a wall outlet. This will power the electronics and table functions.
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.
P1
PLASMA
INTERFACE
P2
PLASMA
ARC VOLATGE
P3
CAN
INTERFACE
P4
AUXILARY
I/O
POWER
ENTRY
ETH 1
FLEX NET
ETH 0
EXT. NETW ORK
Star Ground
Star Ground
1/4” QUICK
CONNECT
INPUT
1/4” QUICK
CONNECT
To Plasma
1/4” OD TUBING
PUSH
CONNECT
(for accessories)
FRONT
VIEW
BOTTOM
VIEW
120v Power Cord
15’, NEMA 5-15p

vii User Guide
Unpacking your new machine (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.
FlexCut 125:
P1
PLASMA
INTERFACE
P2
PLASMA
ARC VOLATGE
P3
CAN
INTERFACE
P4
AUXILARY
I/O
POWER
ENTRY
ETH 1
FLEX NET
ETH 0
EXT. NETW ORK
Star Ground
Star Ground
FRONT
VIEW
BOTTOM
VIEW
120v Connection
CNC Interface
Cable
3-ph
Main Power
Air or Gas Inlet (1/4”
Female Quick Connect)
from bulkhead:
Torch Lead
Main Power
Switch
Work (ground)
Connection to
Star
FlexCut 125
Front
FlexCut 125
Back
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
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 identied 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
specied is properly attached to the supply cord.

Torchmate 5100 viii
Unpacking your new machine (FlexCut™ 200/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.
FlexCut 200 and FlexCool 35:
Unpacking the FlexCool 35:
The packaging of the cooler is designed to withstand shipping abuse. If any
shipping damage has occurred, contact your certied Lincoln distributor
or service center. When unpacking the unit, avoid thrusting sharp objects
through the carton, which may damage the machine. Below is the recom-
mended 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.

ix User Guide
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
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.
1. Connect the 115v from the FlexCool 35 to the 115v connec-
tion 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.
FLEXSTART box mounted to gantry on the
5100. Hoses and cables are run into the
cable carrier.
Connections between the FlexCut 200 and FlexCool 35:
Input Cord Strain Relief:
Route input cord through
relief and twist nut to tighten.
Ground Connection:
Connect Ground Lead per local
and national electrical codes
Power Connection Block:
Connect each phase of a three
phase connector here
ARCLINK
COOLANT RETURN
COOLANT SUPPLY
GROUND
FROM
POWER
SOURCE
FROM
COOLER
TO
STAR
GROUND
COOLANT SUPPLY
COOLANT RETURN
TO
FLEXSTART
115 V
AC**
ARC LINK

Torchmate 5100 x
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.
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.
NOZZLE
ARC LINK
ELECTRODE
WORK
PLASMA GAS
SHIELD GAS
FROM
CABLE CARRIER
FROM
CABLE CARRIER
TO
STAR GROUND
CNC INTERFACE
ETHERNET
TO
5100 BULKHEAD
Connections between the FlexCut 200 and 5100:
Unpacking your new machine (FlexCut™ 200/FlexCool™ 35)
P1
PLASMA
INTERFACE
P2
PLASMA
ARC VOLATGE
P3
CAN
INTERFACE
P4
AUXILARY
I/O
POWER
ENTRY
ETH 1
FLEX NET
ETH 0
EXT. NETW ORK
Star Ground
Star Ground

xi User Guide
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 eort 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, conguration, and quality
related issues. Operational or CAD training is not included in phone technical support.
• Email
Lincoln Electric will return emails to the [e-mail] 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
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.

Torchmate 5100 xii
If Buyer is not satised 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 modied 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
armation 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, modication (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.
Statement of Warranty
30 Day guarantee
Warranty

xiii User Guide
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 prot, 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 specically 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 aect 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
Statement of Warranty (cont.)

1User 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.
WARNING
DO NOT INSTALL,
OPERATE, OR REPAIR
THIS EQUIPMENT
WITHOUT READING
THE SAFETY WARNINGS
CONTAINED THROUGH-
OUT THIS MANUAL.
Think before you act—
and be careful.
THIS MACHINE CREATES ELECTRO-MAGNETIC FIELDS DURING OPERATION
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS 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.
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, ame-
proof 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 cut-
ting. Climbing onto the machine could result in a fall that can result in injury or death.

Torchmate 5100 2
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 conned 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 aected by various factors including proper
use and positioning of the equipment, maintenance of the equipment, and the specic procedure and application
involved. Worker exposure levels should be assessed by a qualied 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 venti-
lation to avoid overexposures.
• Gases used for plasma cutting and gouging can displace air and cause injury or death. Always use enough
ventilation, especially in conned 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 con-
tact 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 ex-
posure 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.

3User Guide
Cutting ame and sparks can cause FIRE OR EXPLOSION.
• 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.
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.
Arc Current Minimum
Shade No.
Suggested
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
• According to IARC, ultraviolet radiation from
welding causes ocular melanoma. IARC identies
gouging, brazing, carbon arc or plasma arc cutting, and
soldering as processes closely related to welding

Torchmate 5100 4
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 goug-
ing 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 eects 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.
http://torchmate.com/white-papers/EMI-Reduction
For more information on electromagnetic interference please visit
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 Jeerson 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 rec-
ommendations.
• Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s
recommendations.

5User Guide
Input Power
• 120V / 1Ph / 15A / 60Hz (table and computer)
• 380-600V / 3Ph / 50-60Hz (Plasma Power Supply specic)
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
• Prole Linear Rail
Acceleration Rate
• 0.08g (0.06g Bevel)
Deceleration Rate
• 0.08g (0.06g Bevel)
Height Control
• Ohmic Sensing
• Automatic Torch Height Control
• 6.75” Z-axis Travel
Bevel Capabilities
• +/-45° Rotation (dependent on material thickness and power
supply conguration)
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 Conguration
• 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
Warranty
• *1 Year Warranty
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
Table Specications

Torchmate 5100 6
Site Preparation
• When preparing to install the Lincoln Electric CNC Cutting System, provide sucient 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.
113.25”
167”
Load From
This Side
Operator
Console
15’ Power Cord, NEMA 5-15P
Air Supply
Earth Ground
Provided by Other
5100
MAINTAIN WORK AREA
When installing a Lincoln Electric CNC Cutting System in your shop, there are many factors that will inuence 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.
5100
FlexCut 125/200
Plasma
Machine
within 10’ of cable
carrier

7User Guide
Locate power supply
within 6’ of table cable
chain. Automatic Gas
Console should be kept
within 2’ of power
supply.
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.
Site Preparation (HD)
113.25”
167”
Load From
This Side
Operator
Console
15’ Power Cord, NEMA 5-15P
Air Supply
Earth Ground
Provided by Other
MAINTAIN WORK AREA
5100 HD
Gases
3-phase
Power Supply
Air Supply
Provided by Customer
43.0
30.0
Burny
Spirit 2
Power
Supply