Lincoln Electric Torchmate 4400 User Manual
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Lincoln Electric Torchmate 4400 User Manual

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USER GUIDE
December 12, 2019
Copyright 2019
Lincoln Electric Cutting Systems

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Summary of Contents for Lincoln Electric Torchmate 4400

  • Page 1 USER GUIDE December 12, 2019 Copyright 2019 Lincoln Electric Cutting Systems...
  • Page 2 Torchmate 4400/4800 Page ii...
  • Page 3 User Guide Page iii...

  • Page 4: Table Of Contents

    Using the Shape Library in VMD ..............23 Running a Job .....................25 Cut Quality ......................27 Build Your Own Cut Chart ................28 Nesting ........................29 Performing Your First Test Cut ...............32 Maintenance .......................33 Cut Quality ......................37 Basic Troubleshooting ..................40 Torchmate 4400/4800 Page iv...

  • Page 5: Unpacking Your New Machine

    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 and a cut metal sample can be found in the waterbed of the machine.

  • Page 6: Technical Support | On-Site Service

    Technical Support | On-Site Service Lincoln Electric Cutting Systems provides a number of technical support opportunities with the purchase of your new 4400 or 4800 Torchmate CNC cutting machine. The following is a brief outline of available options. Onsite visits are available at an additional cost, call 775-673-2200 for additional information.

  • Page 7: Statement Of Warranty

    Statement of Warranty 30 Day Guarantee If Buyer is not satisfied with the performance of the Goods within 30 days from the date the Goods were shipped from the Seller, Buyer may return the Goods in the original carton(s) for a full refund less Shipping, Handling, Damages and Freight Charges.

  • Page 8: Statement Of Warranty Cont

    C. The sale of Goods shall be governed by the laws of the State of Maryland. Seller agrees to comply with all applicable laws of the United States. D. The purchasers of products from Lincoln Electric Cutting Systems are responsible to dispose of consumables, fluids and machinery at the end of the life cycle in accordance with federal and local regulations.

  • Page 9: Safety Information

    Safety Information Torchmate and Lincoln Electric Cutting Systems equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation and thoughtful operation. WARNING: DO NOT INSTALL, OPERATE, OR REPAIR THIS EQUIPMENT WITHOUT READING THE SAFETY WARNINGS CONTAINED THROUGHOUT THIS MANUAL.
  • Page 10 Turn off 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. Torchmate 4400/4800 Page 2...
  • Page 11 Cutting flame and sparks can cause FIRE OR EXPLOSION: • Fire and explosion can be caused by hot slag, sparks, oxygen fueled cutting flame, or the plasma arc. • Have a fire extinguisher readily available. Provide a fire watch when working in an area where fire hazards may exist. •...
  • Page 12 Do not climb on machine. It is not intended as a ladder or to support anything but the intended use of metal cutting. By climbing onto the machine, could cause falling that can result in injury or death. Torchmate 4400/4800 Page 4...

  • Page 13: Site Preparation

    Site Preparation When installing a Lincoln Electric CNC Cutting System in your shop, there are many factors that will influence the potential productivity, ease of use of the machine and the safety of the operator. The main factors to prepare for include: the physical layout and placement of the machine in the shop, the availability of power, an EMI ground, compressed air and other gasses, and ventilation.

  • Page 14: Grounding Your Machine

    If the work piece is painted or dirty, it may be necessary to expose the bare metal to make a good electrical connection. Torchmate 4400/4800 Page 6...

  • Page 15: Power/Air/Water Requirements

    Please refer to the FlexCut operators manual for complete installation and operation guidelines. Only a qualified electrician should connect the input leads to the Torchmate 4400/4800 CNC unit and FlexCut 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.

  • Page 16: Flexcut 80 Plasma Controls & Settings

    THERMAL YELLOW LED GAS PRESSURE YELLOW LED PARTS-IN-PLACE (PIP) YELLOW LED OUTPUT CURRENT KNOB CNC INTERFACE WORK GROUND BACK INPUT CORD - 10 ft. (3.0 M) POWER SWITCH AIR OR GAS INLET (1/4 in. NPT QUICK CONNECT) Torchmate 4400/4800 Page 8...

  • Page 17: Flexcut 80 Plasma Controls & Settings

    FlexCut 80 Plasma Controls & Settings Please refer to the FlexCut operators manual for complete installation and operation guidelines. Do not overtighten the consumables. Only tighten until the parts are seated properly. Rated Output: Product Product Input Power Current/ Input Current @ Output Gas Pressure Gas Flow...

  • Page 18: Flexcut 125 Plasma Controls & Settings

    PRIMARY AIR, GAS PRESSURE GAUGE AND REGULATOR KNOB HOME BUTTON ON/OFF SWITCH TORCH CONNECTION WORK LEAD CONNECTION MENU CONTROL KNOB/BUTTON PURGE BACK AIR OR GAS INLET (1/4”IN. NPT QUICK CONNECT) RECONNECT PANEL ACCESS INPUT CORD STRAIN RELIEF 14-PIN CNC INTERFACE Torchmate 4400/4800 Page 10...

  • Page 19: Flexcut 125 Plasma Controls & Settings

    FlexCut 125 Plasma Controls & Settings Please refer to the FlexCut operators manual for complete installation and operation guidelines. Do not overtighten the consumables. Only tighten until the parts are seated properly. Rated Output: Product Product Input Power Current/ Input Current @ Output Gas Pressure Gas Flow...

  • Page 20: Powering Up The Torchmate 4X00

    Powering Up the Torchmate 4x00 To power up the Torchmate 4400/4800 CNC machine, please follow the instructions below. The complete user guide is available as an embedded file in the VMD. Use the button with the question mark to access this file.

  • Page 21: Overview Of The Visual Machine Designer

    Overview of the Visual Machine Designer Visual Machine Designer (VMD) is the driver software to all ACCUMOVE controllers. This design allows ® CNC the operator to access a majority of the table's controls from the main screen, while hosting other features that aid in creating and manipulating files.

  • Page 22: Job Group

    PLATE ALIGNMENT: Used to have the controller ‘angle’ the job to the skewed material on the table. SET PLATE ORIGIN: This establishes the PLATE ORIGIN. GO TO PLATE ORIGIN: Moves the head back to the PLATE ORIGIN. Torchmate 4400/4800 Page 14...
  • Page 23 Process Stations: PROCESS STATIONS configure and control the tool outputs on the machine. KERF and DWELL times can be added along with programming the offset to the plate marker accessory. Log On: LOG ON switches users of the VMD software. ADMIN opens the MACHINE SETTINGS (password protected).

  • Page 24: View Screen

    Arc Voltage is the voltage feedback comparison value. If using SAMPLE VOLTAGE this will adjust during cutting. • Feedrate displays/sets to the OPTIMAL FEEDRATE in the cut charts for the thickness of material and amperage set. Torchmate 4400/4800 Page 16...
  • Page 25 Graphics View: The MACHINE LIMITS are displayed in blue. The head is represented with white crossed lines. Plasma assigned tool paths are displayed in red. Plate Marker assigned tool paths are displayed in green. Rapid travels will be a dashed grey line. Zoom to Machine will zoom to the programmed ma- chine limits.

  • Page 26: Datum & Program Zero Group

    ACTIVE RUN: This will activate your torch to fire when you RUN a job. • DRY RUN: This deactivates your torch from operation. If in DRY RUN, the torch will simulate all movements without firing the torch. Torchmate 4400/4800 Page 18...

  • Page 27: Jogging

    Jogging Jogging allows the user to move the head by pressing on the direction. The JOGGING group is tabbed, allowing it to move the head to the proper location anywhere on the table. Jog: The JOG keys are laid out in the manner the table moves. By pressing more towards the center of the arrow, the torch body will move slower.

  • Page 28: Avhc & Dashboard

    • Auto - The torch will maintain the distance entered in CUT HEIGHT and profile the material based on the SET VOLTAGE and the CURRENT VOLTAGE being read from the plasma power supply. Torchmate 4400/4800 Page 20...
  • Page 29 IHS (Initial Height Sense): This setting turns OHMIC DETECTION on or off. • ON: The head will detect material when the ohmic cap comes into contact with the grounded, conductive material on the table. Once detected the head will retract to the TRANSFER HEIGHT setting.

  • Page 30: Accessory Toggle

    Move the head and use the indicator for setting PLATE ORIGIN, setting plate alignment, dry run a job, or for visualizing a point on the plate. Once done using the laser, toggle the laser to OFF. Step 4: By changing to ACTIVE RUN, the laser will power off automatically. Torchmate 4400/4800 Page 22...

  • Page 31: Using The Shape Library In Vmd

    Using the Shape Library in VMD In the VMD, you can generate one of 36 standard shapes without needing to generate them in your CAD software. Access the Shape Library: To get to the Shape Library, press SHAPE LIBRARY located on the left hand side of the VMD screen, in the Job Group.
  • Page 32 NO and it will add the kerf based on the material thick- ness to the part. On VMDNest and TMCAD programmed jobs, SELECT YES. Once selected, press OK. The job will display in the GRAPHICS screen. Torchmate 4400/4800 Page 24...

  • Page 33: Running A Job

    Running a Job When you have a GM format file to run or shape generated in the VMD ready to cut, there is a simple process to follow to get the job produced through the VMD. This will go over the workflow of running the job.
  • Page 34 FEEDRATE OVERRIDE % slider bar. By default, the slider is set to 100%. To slow down based on percentage, move the slider to the left. To speed up the feedrate, slide past 100%. Torchmate 4400/4800 Page 26...

  • Page 35: Cut Quality

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

  • Page 36: Build Your Own Cut Chart

    Build Your Own Cut Chart Use this template to create your own custom cut charts using the line speed test. Material Thickness Amperage Cut Speed Pierce Delay Pierce Height Cut Height Type Torchmate 4400/4800 Page 28...

  • Page 37: Nesting

    Nesting VMDNesting is an irregular parts nesting program. This allows the operator to import DXF or DWG files without the need for an offline CAM software to generate the proper G-Code. The NESTING will apply the kerf correction along with the appropriate lead-ins to all features. Also, it will generate the tightest nest available for the size of material you enter in.
  • Page 38 Change this setting if you need particular lead-ins or kerf diameters. LAYER MAP separates the layers present in the job. Select the appropriate process for the layers to be PLASMA, PLASMA MARKING, IGNORE. Torchmate 4400/4800 Page 30...
  • Page 39 Make Nest: When all the parts have the proper quantity, go to the right button list and select NESTING. Press NEST and it will display a pop up asking for ALL or SELECTED parts. Make your selection and press OK. This will then arrange your parts into the material and display the layout in the Job screen.

  • Page 40: Performing Your First Test Cut

    Performing Your First Test Cut There are multiple test files pre-loaded on the computer of the Torchmate 4400/4800 models for testing and cut quality purposes. The Line Speed Test and Simple Test Cut are provided to help determine the proper feed rate in IPMs to cut the material thickness to the amperage you have set on the plasma power supply.

  • Page 41: Maintenance

    Maintenance As with all machinery, there is required maintenance. This will cover Daily, Monthly, and ‘ A s Needed’ tasks to keep your 4400/4800 running like new. Daily Maintenance: Plasma Power Supply: The plasma power supply and torch body will need to be evaluated between material thicknesses or prior to cutting. Remove and check if the consumables need to be changed.

  • Page 42: Daily Maintenance

    Shutdown the Accumove controller, and loosen the 1/8” Hex head bolts that hold the side cover in place two turns. DO NOT REMOVE THESE BOLTS. Slide the side cover so the bolts can fit through the keyholes and remove Step 3: the cover. Torchmate 4400/4800 Page 34...
  • Page 43 Step 4: With the cover removed, the zerk fittings will be visible, attach the grease gun and pump until the grease comes from the bottom of the cassette. Grease the front and back zerk fittings. Step 5: Attach the side cover to the table. PLEASE NOTE: Slide the cover so the bolts go back into their original position at the bottom of the keyhole, and torque the bolts to 17.8 in.
  • Page 44 Close the valve and refill the table with water. The 4400 holds 60 gallons (230 liters) and the 4800 holes 107 gallons (405 liters). Lincoln Electric Cutting Systems recommends GreenCut® by Lab Corp® is used as a water additive for rust prevention and anti-bacterial growth.

  • Page 45: Cut Quality

    Cut Quality Beveled edges are caused by the motion of the plasma gas as it is emitted from the nozzle. In plasma cutting, it is unavoidable. A high-definition plasma cutter produces less bevel than a standard cutter. Torch height, air pressure, air quality, cut direction, and consumable condition all influence bevel. In plasma arcs used for cutting, the gas forms into a vortex.
  • Page 46 One side may be straight the Cut may not go all the Torch may contact another excessively beveled material and short out way through material Longest consumable life or damage tip Can be caused by worn tip Torchmate 4400/4800 Page 38...
  • Page 47 What Causes Bad Cuts: Instances where the metal was not fully cut indicate a few problems: 1. Ground clamp is not properly attached to the material 2. Air pressure drop or surge 3. Moisture in the air line 4. Drop in power 5.

  • Page 48: Basic Troubleshooting

    Reset the Z axis. If a larger error is reported, the laser po- the centerline of the torch would be on the sition would be off. Enter the material thickness decimal material equivalant, and turn the laser off and back on again. Torchmate 4400/4800 Page 40...
  • Page 49 Software Faults: Problem Solution Check to make sure the Orange Ohmic Wire is con- nected to the ohmic clip. Validate the clip is contact- ing the shield. During an Initial Height Sensing routine, the Ohmic Light does not indicate a Yellow Detected status Check that the material surface is free of rust or when the torch contacts the material.
  • Page 50 Connected” screen for more than 30 seconds. Check the Red Ethernet cable is plugged into the computer and the Accumove controller. Also verify that the red Ethernet cable is plugged into the right or outermost port on Accumove 2 controllers Torchmate 4400/4800 Page 42...
  • Page 51 Software Faults (Cont.): Problem Solution To register the software, e-mail the support@torchmate. When VMD is opened, a Trial Period screen appears. com e-mail address with the 8 digit alpha numeric code that appears on the registration screen. Check that the breakaway capture leash and any debris on the magnet are not keeping the torch from sitting fully in position.
  • Page 52 Log in as an Admin (password 1234) and load the VMD screen displays a “Please update the firmware” error message. firmware under the Machine Settings - Advanced tab, follow the on-screen instructions After FIRMWARE is complete, go to BASIC tab and press FACTORY RESET. Torchmate 4400/4800 Page 44...
  • Page 53 Software Faults (Cont.): Problem Solution Power down the Accumove controller and verify all motor cable connections are fully seated on the back of the Accumove controller, as well as at each motor. Power up the Accumove controller and after 30 sec- One of the machine’s motors is not moving when attempting to Datum or Jog the machine onds open the VMD software.
  • Page 54 Lockout Mode for extended periods of time. Login as Admin, go to Machine Settings, and on the Basic tab change the Distance to Corner value to .250. Torchmate 4400/4800 Page 46...
  • Page 55 User Guide Page 47...
  • Page 56 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 fitness for any customer’s...

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