Torchmate 2 Bolt Together Assembly Instructions

Torchmate 2
Bolt-together Kit
Assembly Instructions
Revised July 23, 2013
Torchmate Inc. 2012-2013
TECHNICAL SUPPORT
Toll Free: 1-866-571-1066 x3
International: 775-673-2200 x3
Fax: 775-673-2206
Email: support@torchmate.com
Torchmate 2 Bolt-together Kit Assembly Instructions
Published by:
Lincoln Electric Cutting Systems
Torchmate Distribution Center
1170 Trademark Drive, #101
Reno, NV 89521
www.torchmate.com
Copyright 2011-2013 by Torchmate Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission
of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to
any party for any loss or damage caused by any error or omission in this
manual, whether such error results from negligence, accident, or any other
cause.
Publication Date: July 23, 2013
ii
Contents
Step 21: Add gantry arm to gantry support . . . . . . . . . . . . . . . . . . . .31

Step 22: Attach motor to mount plate . . . . . . . . . . . . . . . . . . . . . . . 32
Step 23: Add gear, pulleys, and belt to motor assembly . . . . . . . . . . . . 33
Step 24: Assemble inside corner brackets . . . . . . . . . . . . . . . . . . . . . 34
Step 25: Install motor assembly on gantry . . . . . . . . . . . . . . . . . . . . .35
Step 26: Add drive-shaft support bracket to gantry . . . . . . . . . . . . . . .36
Step 27: Install drive-shaft on gantry . . . . . . . . . . . . . . . . . . . . . . . . 37
Step 28: Assemble slide and cassette . . . . . . . . . . . . . . . . . . . . . . . .38
Step 29: Add slide and cassette to gantry . . . . . . . . . . . . . . . . . . . . . 39
Step 30: Add cam-follower support-bracket to gantry . . . . . . . . . . . . . 40
Step 31: Install cam-follower on gantry end . . . . . . . . . . . . . . . . . . . .41
Step 32: Install motor on mount plate . . . . . . . . . . . . . . . . . . . . . . . .42
Step 33: Add gear, pulleys, and belt to motor assembly . . . . . . . . . . . . 43
Step 34: Attach L-bracket and mounting plate to gantry cassette . . . . . .44
Step 35: Attach motor assembly to gantry L-bracket . . . . . . . . . . . . . . 45
Step 36: Attach cable-carrier brackets to gantry . . . . . . . . . . . . . . . . .46
Step 37: Install cable-carrier end caps and links on gantry . . . . . . . . . . .47
Step 38: Attach cable-carrier brackets to side and gantry support . . . . . .48
Step 39: Install cable-carrier end caps and links on side . . . . . . . . . . . . 49
Building a water table (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Basic water table dimensions: . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Water table design considerations . . . . . . . . . . . . . . . . . . . . . . . . 52
Water table support structure . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Water pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Water table slat support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Incorporation of the water table: . . . . . . . . . . . . . . . . . . . . . . . . . 56
Welcome Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Quick Link Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Torchmate 2 Supplied Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Gantry Supplied Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Table Frame Supplied Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Gear Rack Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv
Slat Support Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
Cable Carrier Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xviii
Other Included Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Step 1: Assemble 8-hole corner gusset . . . . . . . . . . . . . . . . . . . . . . .11
Step 2: Assemble slat support mounting brackets . . . . . . . . . . . . . . . .12
Step 3: Add leveling feet to legs . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Step 4: Add gussets to central legs . . . . . . . . . . . . . . . . . . . . . . . . . .14
Step 5: Add gussets to corner legs . . . . . . . . . . . . . . . . . . . . . . . . . .15
Step 6: Add legs to side extrusions . . . . . . . . . . . . . . . . . . . . . . . . . .16
Step 7: Add slat-support holder-brackets . . . . . . . . . . . . . . . . . . . . . 17
Step 8: Attach slat-support brackets to sides . . . . . . . . . . . . . . . . . . . 18
Step 9: Assemble gear racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Step 10: Assemble guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Step 11: Install gear racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Step 12: Install guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Step 13: Join sides with cross-members . . . . . . . . . . . . . . . . . . . . . . 23
Step 14: Install the (customer-provided) slats . . . . . . . . . . . . . . . . . . .24
Step 15: Assemble the joining plate . . . . . . . . . . . . . . . . . . . . . . . . .25
Step 16: Assemble the inside-corner brackets . . . . . . . . . . . . . . . . . . 26
Step 17: Add joining plate and brackets to gantry support . . . . . . . . . . 27
Step 18: Assemble the top rail cam-follower brackets . . . . . . . . . . . . . .28
Step 19: Assemble the side rail cam-follower brackets . . . . . . . . . . . . . 29
Step 20: Add cam-follower assemblies to gantry support . . . . . . . . . . . 30
Tool Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Attaching an Arc Voltage Height Control (AVHC) . . . . . . . . . . . . . . . . .58
Adjust the AVHC height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Attaching a plate marker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Adjusting a plate marker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Attaching an oxy-fuel torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Attaching a Z-axis for routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Router backlash-compensation adjustment . . . . . . . . . . . . . . . . . . . .64
Attaching a Laser Crosshair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Adjusting a laser crosshair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
iii
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Basic Driver Software Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Motion Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Testing Output Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Test Cutting - Manual Height Control Plasma . . . . . . . . . . . . . . . . . 100
Test Cutting - Manual Height Control Plasma . . . . . . . . . . . . . . . . . 101
Test Cutting - Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Setup & Test Cutting - Plasma with Automatic Height Control . . . . . . 104
Setup & Test Cutting - Line Speed Test . . . . . . . . . . . . . . . . . . . . . 108
Setup & Test Cutting - Voltage Test . . . . . . . . . . . . . . . . . . . . . . . 109
Test Cutting Checklist for Plasma with AVHC . . . . . . . . . . . . . . . . . 111
Importing Files & Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Pierce Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Plasma with Manual Height Control . . . . . . . . . . . . . . . . . . . . . . . . .68

Plasma with Automatic Voltage Height Control . . . . . . . . . . . . . . . . . 69
Plasma with Automatic Voltage Height Control & Plate Marker . . . . . . . .70
Plasma with Automatic Voltage Height Control & Oxy / Fuel Torch . . . . . 71
Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Raw Arc Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 74

Raw Arc Voltage Points for AVHC . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Thermal Dynamics: Cutmaster 51, Cutmaster 81, Cutmaster 101,
Cutmaster 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Thermal Dynamics: Cutmaster 52, Cutmaster 82, Cutmaster 102,
Cutmaster 152, Cutmaster A40, Cutmaster A60, Cutmaster A80,
Cutmaster A120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Hypertherm: Powermax 1000, Powermax 1100, Powermax 1250,
Powermax 1650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Hypertherm: Powermax 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Hypertherm: Powermax 65 & 85 . . . . . . . . . . . . . . . . . . . . . . . . . .80
Hypertherm: Powermax 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Lincoln Electric: Tomahawk 1000 . . . . . . . . . . . . . . . . . . . . . . . . . 82
Maintenance and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

General Maintenance Procedures & Suggested Replacement Parts List . 116
Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

Gear Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Loose Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Bevel Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
How Torch Position Affects Bevel . . . . . . . . . . . . . . . . . . . . . . . . 123
What Causes Bad Cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Driver Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Installing the Driver Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Manually Installing the Device Drivers (if necessary) . . . . . . . . . . . . . . 86
Driver Software Setup & Basic Overview . . . . . . . . . . . . . . . . . . . . . .88
Software Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Coordinates or DRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Connection Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
G-code Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Viewports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Output Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
iv
Welcome Letter
To the newest member of our Torchmate Family:
Thank You! Thank you for putting your faith and trust in Torchmate. When you purchased
your Torchmate CNC Cutting System, you purchased more than just a machine. You
purchased a team. The Torchmate team was built with the goal in mind of helping you get
the most value out of your automation investment.
For some, this Torchmate CNC Cutting System purchase is their first endeavor into the world
of automation. Others may consider themselves seasoned automation experts. No matter
which category you fall into it is important that you realize that investing in a Torchmate is
unlike any other machinery purchase you have made. We consider your success our success
as well as your challenges our challenges.
The Torchmate product line is designed to be simple, reliable and accurate. While there is no
Easy button on your new system, I can promise that you will get out of it what you put in.
Operating any machinery is a skill and does have a learning curve.
This manual is written to make assembly of

the Torchmate 2 CNC machine as easy as
possible. Each step in the assembly process
outlines the components needed for the
step and describes in text and pictures how
the step should be completed. On each step
there will be a small button that will link to a
video online of the step animated to further
clarify the process.
Click here to see
this step animated.
To view this video internet access is required.

If any questions arise while building or
operating the Torchmate CNC cutting system
please contact Torchmate technical support.
The first and perhaps most important item I want to give you today is the Torchmate
Technical Support Hotline: (866) 571-1066, ext 3. This number is toll free for those within
the United States. For those outside the United States, use the following number (775)
673-2200, ext 3. There is a dedicated professional support staff available Monday
Friday from 7:30am to 4pm to assist you in any way that they can. We pride ourselves on
offering free unlimited telephone support for your machine and all we expect in return is
communication, understanding and patience. We are here for you as long as you need us.
Please dont be a stranger. If you have questions or problems, call us. No matter how trivial
your issue may seem it is not trivial if it cuts into your productivity. Call, Call, Call! We are
here for you! Thank you again for putting your trust in us. We will do our best to not let you
down.
TECHNICAL SUPPORT
Toll Free: 1-866-571-1066 x3
Fax: 775-673-2206
Sincerely,
Bill Kunz, CEO

Torchmate CNC Cutting Systems
Click on a section link below
Quick Link Contents

Section 1:
Section 4:
Section 5:
START
OK TO MOVE
CORNER
PIERCE
FAULT
VOLTS
TORCH
Wiring Diagrams
for Different Configurations
Wires 12 & 14
on the CNC
Interface Cable
Section 2:
Raw arc voltage

connection on
plasma cutter
Software Setup and Operation
Wires 3 & 4
on the CNC
Interface Cable
Table and Gantry Assembly
Maintenance and
Replacement Parts
Motor Connection
To Plate Marker
To Oxy Solenoid
MOTOR LINES
Plasma Relay
10 Input Cable lines 1 & 2 are

used, 3, 4, & 5 are unused.
To Motors
CUTMASTER 52 & 82 VOLTAGE POINTS

USB
OUTPUT
How torch position affects bevel
INPUT
Section 3:
Correct torch height

Torch angled to material
Torch square to material
Section 6:
Raw Arc Voltage Connection

Points
Basic Troubleshooting
Incorrect torch height

Torch too high

Torch too low
Position of torch
while cutting
Bevel of finished part

Equal bevel on all sides
Unequal bevel
Excesive bevel
Reversed bevel
Minimal bevel angle
One side may be straight

another excesively beveled
Cut may not go all

the way through
Torch may contact

material and short out
or damage tip
Optimal consumable life
vi
Can be caused by a worn tip
Torchmate 2 Supplied Parts List

The following parts list outlines the basic parts used
for a 4x8 cutting area table.
The Torchmate 2 CNC cutting table is available in various sizes.
The provided aluminum extrusions and other parts will vary depending on the table size.
The parts list is organized in groups based on where the parts are
used in the table. You will find it helpful to organize the parts into
these groups before starting assembly. This will not only ensure
that you have all the required parts, but will make assembly
easier and faster.
When a different size of part would be used for a different size
table the specifications are listed in red based on the cutting
length or width. Torchmate part numbers are shown in green.
vii
Gantry Supplied Parts List

The gantry of a Torchmate 2 spans the table frame and supports
the tools being used. The gantry structure consists of an extruded aluminum cross member and t-section. The gantry supports
both drive motors, the drive shaft, and linear slide on which the
tool mounts.
X1
X1
X7
611/2x 3x 3
Aluminum Extrusion
X3
Table cutting width +131/2
Top Cam-follower
Support Bracket
AR05
12x 3x 3 Aluminum
Extrusion
X2
Same size for all table sizes.
Side Cam-follower
Support Bracket
AR06
1 Cam Follower
X1
08-0001-002
viii
Y-Axis L-Bracket
08-0010-003
X1
1/2 Mounting Plate

08-0003-001
X3
5/16 Shaft Collar
X1
X-Axis Motor Mount

Plate
X3
Spur Gear Pressed on

5/16 Shaft
Y-Axis Motor Mount

Plate
X2
Timing Belt
Drive Shaft Support

Plate
X2
48 Tooth Large Pulley
AR19
X1
09-0001-87986204
08-0011-002
08-0006-001
AR03
X1
Timing Pulley (Large)
AR20
ix
X2
14 Tooth Small Pulley
X2
380 oz in. Stepper

Motor
/16 (0.4375)
(11.11mm)
Timing Pulley (Small)
/16 (0.4375)
(11.11 mm)
X7
X 28
/16-20 Hex Nut

09-0001-67473041
7
/16 SAE Flat Washer

09-0001-67746644
7
08-0004-380
/4 (0.75)
1.575
(19.05 mm)
(40 mm)
X4
M10x40
Hex Head Bolt
09-0001-67444802
0.3937
(10 mm)
#8-32x3/4 SHCS
X8
#8 SAE Flat Washer
09-0001-05507074
0.164
(4.1656 mm)
(10 mm)
0.3937
X8
X4
M10 Flat Washer
0.164
09-0001-67493080
(4.1656 mm)
09-0001-67746446

/8 (0.875)
(22.225 mm)
0.164
(4.1656 mm)
X8
#8-32 Hex Nut
/16 (0.3125)
09-0001-87921292
(7.9375 mm)
X6
5/16-18x7/8
Hex Head Bolt
09-0001-87914933
X1
12 Hole Tee Joining

Plate
/16 (0.3125)
X 12
5/16 SAE Flat Washer
/16 (0.3125)
X6
5/16-18 Hex Nut
X1
491/2 Drive Shaft
(7.9375 mm)
09-0001-67746560
4325
X2
4 Hole Inside Corner

Gusset
(7.9375 mm)
4303
X2

Bracket
4375
xi
09-0001-87920914
Used to drive the gantry.

X 48
5/16-18x5/8 T-bolt
X1
09-0001-65366833
571/2 Slide with

Cassette
11/2
/16 (0.3125)
(38.1 mm)
(7.9375 mm)
X 48
5/16 T-nut
X 16
T-nut
5/16-18x11/2 Socket
Head Cap Screw
09-0001-60667169
/16 (0.3125)
(7.9375 mm)
The total number of T-nuts and T-bolts provided will be much

more than the quantity listed here. The amount listed here
corresponds to the number used with the gantry. The number
of T-nuts will vary based on the width of the table; the number
of T-bolts used on the gantry is the same for all widths.
X 18
Special Fabricated
Washer 0.1 Thick
Special Fabricated Washer
Table Cutting Width

4
5
6
7'
5/16 T-nuts Needed

48
52
56
60
The total number of 5/16-18x11/2 Socket Head Cap Screws and Special
Washers corresponds to the number of holes on the slide listed below.
Note the 5/16-18x11/2 Socket Head Cap Screws will be used in other parts of assembly
and this quantity is just for use with the slide.
Table Cutting Width

4
5
6
7
xii
Screws and Washers Needed

18
22
26
30
Table Frame Supplied Parts List

The frame of a Torchmate 2 supports the gantry, provides structure and stability for the motion control components, and may
hold the material being cut. The frame is made from extruded
aluminum, upon which the precision ground guide rails rest.
X2
114x3x3
Aluminum Extrusion
X6
Leveling Foot
X2
56x3x3
Aluminum Extrusion
X6
Base Plate
X 24
/16-18x1 Socket
Head Cap Screw
Used for the length of the table.

Table cutting length +18
Used for the width of the table.

Table cutting width +8
X6
32x3x3
Aluminum Extrusion
09-0001-40610172
One used per leg.
2140
One used per leg.
(25.4 mm)
Used for legs.

The 4 and 5 cutting length tables
have four legs. Tables with 6 to
12 cutting lengths have six legs.
Tables with cutting length greater
than 14 will use eight legs.
xiii
/16 (0.3125)
(7.9375 mm)
3122
Four used on each leg.
Table Frame Supplied Parts List

120 Cold Rolled
Precision Ground Rails
X2
Used along the length of the table.

Table cutting length + 24
Tables with a cutting area longer
than 12 have multiple sections of
rail per side.
X 108
5/16-18x5/8 T-bolt
X 108
5/16 T-nut
09-0001-65366833
/16 (0.3125)
X 12
(7.9375 mm)

Bracket
T-nut
4338
Two used on each leg.
The total number of T-nuts and T-bolts provided will be many

more than the quantity listed here, which are just for the table
frame. The number of T-nuts and T-bolts will also vary based on
the cutting length of the table.
Table Cutting Length 5/16 T-bolts & T- Nuts Needed
4 76
5 76
6 108
8 108
10 108
12 116
14 148
16 148
18 180
20 180
xiv
Gear Rack Parts List

The gear rack is used to convert the rotational motion of the
motors to the linear motion of the machine. The quantity
and length of gear rack will vary based on the cutting length
and width of the table. Torchmate uses three lengths of gear
rack 24, 49, and 61. A combination of these lengths will be
used for each machine.
Provided Gear Rack and Hardware for 4 x 8 Table
Mounting hardware is included for each rack. A 24 section

of gear rack has three mounting holes, and the 49 and 61
sections of gear rack have five mounting holes. For each
gear rack mounting hole, one 5/16-18x7/8 hex head bolt, one
5/16 flat washer, and one 5/16 T-nut are provided.
X5
49 Gear Rack
X 20
5/16-18x7/8
Hex Head Bolt
/8 (0.875)
(22.225 mm)
Use the tables below to determine the length of gear rack

provided for the size of table ordered.
/16 (0.3125)
(7.9375 mm)
Table Cutting Width Gear Rack Provided

4
5
6
7
09-0001-87914933
1x49
1x61
1x49, 1x24
1x61, 1x24
Table Cutting Length Gear Rack Provided

4
5
6
8
10
12
14
16
18
20
03-0013-005
/16 (0.3125)
2x49
2x61
2x49, 2x24
4x49
4x61
6x49
4x61, 2x49
8x49
4x61, 4x49
8x61
(7.9375 mm)
X 20
X 20
5/16 T-nut
09-0001-67746560
/16 (0.3125)
(7.9375 mm)
xv
T-nut
Slat Support Parts List

Torchmates slat support system is designed to mount to the
table frame and support the material being cut. The system uses
a long slat support bracket to hold individual slats that hold the
material. This bracket is held to the table using a holder.
X8
Slat Support Bracket

Holder
/16 (0.3125)
(7.9375 mm)
X 32
X 16
5/16 ID Spacer
X 16
5/16-18x11/2 Socket
Head Cap Screw
09-0001-67746560
08-0012-001
X4
Slat Support Bracket

03-0011-048
09-0000-0000
11/2
(38.1 mm)
/16 (0.3125)
(7.9375 mm)
X 16
5/16-18 Hex Nut

09-0001-87920914
/16 (0.3125)
09-0001-60667169
(7.9375 mm)
xvi
Slat Support Parts List

The number and length of slat support brackets provided will
vary based on the length of table purchased. Torchmate machines use two lengths of slat support brackets: 2 and 4. Each
length uses two slat support bracket holders and four sets of
hardware.
Table Cutting Length
4
5
6
8
10
12
14
16
18
20
Slat Support Brackets Provided

2x4
2x4, 2x2
2x4, 2x2
4x4
4x4, 2x2
6x4
6x4, 2x2
8x4
8x4, 2x2
10x4
X 16
5/16-18x5/8 T-bolt
X 16
5/16 T-nut
09-0001-65366833
/16 (0.3125)
(7.9375 mm)
T-nut
The total number of T-nuts and T-bolts provided will be many more
than the quantity listed here. The number listed here corresponds to
the number used only with the slat support brackets. The number of
T-nuts and T-bolts will vary based on the cutting length of the table.
Table Cutting Length
4
5
6
8
10
12
14
16
18
20
xvii
/16 T-bolts & T- Nuts Needed

8
16
16
16
24
24
32
32
40
40
Cable Carrier Parts List

The Torchmate cable carrier system is designed to keep control
cables and tool cables clear of the CNC machines moving parts. This
extends the life of the cables and helps prevent damage.
The cable carrier system is optional but is generally purchased with a
Torchmate 2 table.
X1
Bracket A
X2
Bracket D
X2
Bracket B
X1
Bracket E
X1
Bracket C
X1
Bracket F
CC Bracket A
CC Bracket B
CC Bracket C
xviii
CC Bracket D
CC Bracket E
CC Bracket F
Cable Carrier Parts List

/4
(19.05 mm)
X8
#10-32 x 3/4
Socket Head Counter
Sunk Cap Screw
X 14
5/16-18x5/8 T-bolt
X 14
5/16 T-nut
X 72
Cable Carrier Link
09-0001-65366833
09-0001-60504198
/16 (0.3125)
(7.9375 mm)
/16 (0.3125)
(7.9375 mm)
X8
X8
#10-32 Hex Nut

09-0001-87921326
#10 Flat Washer

090001-67746487
(X 58)
Male Cable Carrier

End Cap
X2
T-nut
03-0016-200
(Optional Heavy-duty
Cable Carrier Link)
03-0016-301
(sold per foot [5-links])
Female Cable Carrier

End Cap
03-0016-201
(Male & Female Set)
X2
Male Cable Carrier
End Cap)
03-0016-300
(Male & Female Set)
03-0016-201
(Male & Female Set)
Female Cable Carrier
End Cap)
03-0016-300
(Male & Female Set)
xix
Other Included Parts
X1
3 Axis Micro Stepping

Drive Box
X1
USB Cable
USB Cable
3 Axis Drive Box
X2
25 Motor Cable
08-0005-025
xx
Safety
Torchmate 2 Bolt-together Kit Safety
Safety First
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 on your part.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
WARNING
KEEP CHILDREN AWAY. ALLOW NOBODY YOUNGER THAN 14 NEAR THIS EQUIPMENT.
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 purchase a
copy of 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 IS DONE ONLY BY QUALIFIED PEOPLE.
DO NOT INSTALL,
OPERATE, OR REPAIR
THIS EQUIPMENT WITHOUT READING THE
SAFETY WARNINGS CONTAINED THROUGHOUT
THIS MANUAL.
Think before you act
and be careful.
Electric Shock
1.
ELECTRIC SHOCK can kill.

1.1
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.
1.2
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.
1.3
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.
1.4
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.
1.5
Ground the work or metal to be cut or gouged to a good electrical (earth) ground.
1.6
Maintain the plasma torch, cable and work clamp in good, safe operating condition. Repair or replace all worn or damaged
parts. Replace damaged insulation.
1.7
Never dip the torch in water for cooling or plasma cut or gouge in or under water.
1.8
When working above floor level, protect yourself from a fall should you get a shock.
1.9
Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety clothing.
1.10 Also see Items 4.3 and 6.
Safety First (continued)

Arc Rays
2.
ARC RAYS can burn.

2.1
Plasma Arc Rays can injure your eyes and 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.
2.2
Use safety glasses and a shield with the proper filter 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 filter lens should conform to
ANSI Z87. I standards.
Arc Current
Less than 20A
20A-40A
40A-60A
60A-300A
300A-400A
400A-800A
Minimum
Shade No.
4
5
6
8
9
10
Suggested
Shade No.
4
5
6
9
12
14
2.3
Use suitable clothing including gloves made from durable flame-resistant material to protect your skin and that of your
helpers from the arc rays.
2.4
Protect other nearby personnel with suitable non-flammable screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

Fumes, Gases
and Dust
3.
FUMES AND GASES can be dangerous.

3.1
Plasma cutting or gouging may produce fumes and gases hazardous to 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.
3.2
Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
3.3
When plasma cutting or gouging on lead or cadmium plated steel and other metals or coatings which produce highly
toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or
mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required.
3.4
Additional precautions are also required when cutting (zinc) galvanized steel or materials containing or coated with any of
the following:
Antimony
Arsenic
Barium
Beryllium
Cadmium
Chromium
Cobalt
Copper
Lead
Manganese
Mercury
Nickel
Selenium
Silver
Vanadium
3.5
The operation of plasma cutting or gouging fume control equipment is affected by various factors including proper use
and positioning of the equipment, maintenance of the equipment, and the specific procedure and application involved.
Worker exposure levels should be checked upon installation and periodically thereafter to be certain levels are within
applicable OSHA PEL and ACGIH TLV limits. For information on how to test for fumes and gases in your work place, refer to
publications section of this manual.
3.6
Do not use plasma cutting or gouging equipment in locations near chlorinated hydrocarbon vapors coming from
degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene,
a highly toxic gas, and other irritating products. Remove all sources of these vapors.
3.7
Gases used for plasma cutting and gouging can displace air and cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.8
Read and understand the manufacturers instructions for this equipment and follow your employers safety practices.
3.9
This product, when used for cutting, produces fumes or gases which contain chemicals known to the State of California to
cause birth defects.

3.10 Some 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. Allowing dust to get into your mouth, eyes, or lay on the skin may promote
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).
3.11 Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these
chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are
specially designed to filter out microscopic particles.
Fire or Explosion
4.
Cutting flame and sparks can cause FIRE OR EXPLOSION.

4.1
Fire and explosion can be caused by hot slag, sparks, oxygen fueled cutting flame, or the plasma arc.
4.2
Have a fire extinguisher readily available. Provide a fire watch when working in an area where fire hazards may exist.
4.3
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 fire hazard.
4.4
Be sure there are no combustible or flammable materials in the workplace. Any material that cannot be removed must be
protected.
4.5
4.4.1
Sparks and hot materials from cutting or gouging can easily go through small cracks and openings to adjacent areas.
4.4.2
Avoid cutting or gouging near hydraulic lines.
4.4.3
Do not cut or gouge tanks, drums or containers until the proper steps have been taken to insure that such
procedures will not cause flammable 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).
4.4.4
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.
Cylinder
Explosion
Electrical
Power
5.
6.
4.6
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 fire hazards or overheat lifting chains
or cables until they fail.
4.7
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.
4.8
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.
CYLINDER may EXPLODE if damaged.

5.1
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, fittings, etc. should be suitable for the application and maintained in
good condition.
5.2
Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
5.3
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 flame.
5.4
Never allow any part of the electrode, torch or any other electrically hot parts to touch a cylinder.
5.5
Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
5.6
Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
5.7
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
Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY powered equipment.

6.1
Turn off input power using the disconnect switch at the fuse box before working on the equipment.
6.2
Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturers
recommendations.
6.3
Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturers recommendations.

Plasma Arc
Electric and
Magnetic Fields
7.
8.
PLASMA ARC can injure.

7.1
Keep your body away from nozzle and plasma arc.
7.2
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

8.1
Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Cutting or gouging
current creates EMF fields around torch cables and cutting machines.
8.2
EMF fields may interfere with some pacemakers, so operators having a pacemaker should consult their physician before
cutting or gouging.
8.3
Exposure to EMF fields during cutting or gouging may have other health effects which are now not known.
8.4
All operators should use the following procedures in order to minimize exposure to EMF fields from the cutting or gouging
circuit:
8.4.1
Route the torch and work cables together - Secure them with tape when possible.
8.4.2
Never coil the torch cable around your body.
8.4.3
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.
8.4.4
Connect the work cable to the workpiece as close as possible to the area being cut or gouged.
8.4.5
Do not work next to cutting power source.

Automatic
Operation
Noise
9.
10.
AUTOMATIC OPERATION
9.1
Any CNC machine may begin to operate automatically without warning. Only a trained individual familiar with the
software, machine, and computer system should operate this equipment.
9.2
Keep the immediate area around the CNC machine clear of materials that may cause interference. Keep area clear of
bystanders.
9.3
All untrained persons should not work on or near a CNC machine. Do not leave the CNC machine unattended while power
is on to any electronics.
NOISE
10.1 Noise can cause permanent hearing loss. CNC operation, plasma arc cutting, plate marking, routing, and drilling can cause
noise levels that exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.
10.1.1 To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.
10.1.2 Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
10.2 For information on how to test for noise refer to the publications section of this manual.
Heavy Parts
11.
HEAVY PARTS
11.1 Parts of CNC machines are heavy. Also, material you are cutting may be heavy. Use caution when lifting or moving
them. To avoid injury, get someone to help you, or use a mechanical lifter. When using a mechanical lifter, follow all the
manufacturers safety guidelines.
11.2 Review the Occupational Safety & Health Administration (OSHA) technical manual Sect. 7, Ch 1.5. See the publications
section for additional information.

Flying Debris
12.
FLYING DEBRIS
12.1 Metal cutting and marking operations create waste that can fragment and fly. Make sure you have proper eye
protection and that everyone close to the CNC operations has proper eye protection, too.
12.2 Review the ANSI Z87.1 requirements. See the publications section for additional information.
Pinch and Crush

Points
13.
PINCH AND CRUSH POINTS

13.1 Pinch and crush points are those normally moving parts of machinery, like CNC machines, that can pinch, capture,
crush, or sever parts of your body. Be aware of hazardous pinch and crush points.
13.2 Do not repair or adjust the machine with the controls on.
13.3 When the end of a CNC machines travel creates a hard stop, it creates a crush point. Keep fingers and hands away
from this.
13.4 Do not stack or store any additional items in contact with the machine. These could create additional pinch or crush
points, or could create a falling hazard.
13.5 Smaller limbs, hands, and fingers can fit into places that create additional pinch or crush points. Do not allow anyone
younger than 14 years old to operate this equipment or reach into it when its power is connected.
Rotary Tools
14.
SHARP ROTARY TOOLS

14.1 Routing and drilling use high-speed rotating bits and cutters with sharp edges. Keep clear of bits when in use.
14.2 Turn the router, spindle, or drill off when changing bits. Be careful of the sharp edges.

Hot Materials
15.
HOT MATERIALS
15.1 Plasma cutting uses an electric arc that can reach temperatures of 45,000F (25,000C). Oxygen-fuel cutting flames can be
up to 6,330F (3,500C). Any parts and scrap will be very hot after cutting. Use extreme care.
15.2 Use tongs and wear protective gloves when handling recently cut material. Also, consider other devices for safe hot
material handling.
15.3 It is safest to let material cool completely before handling.
Mechanical
Drives
16.
MECHANICAL DRIVES
16.1 High-speed mechanical drives made of gears, belts, and or drive screws are used by CNC machines. Keep clear of them
during operation.
16.2 Do not attempt to service, adjust, or otherwise touch these components while the machine is on.
16.3 Secure loose clothing and cables to prevent entanglement.
Pressurized
Air Lines
17.
AIR LINES UNDER PRESSURE

17.1 Some tools use compressed air or gases. Often flexible tubing (lines) bring the high-pressure air or gas to the machine.
Inspect these lines periodically. Repair or replace damaged lines.
17.2 Hot sparks, flying debris, other objects, or vehicles can melt, burn, or puncture these lines. Check them for punctures,
burns, or other damage or defects that could cause failure.
17.3 Check the routing of the lines to keep them away from traffic and from underfoot.
Table Assembly
10
Torchmate 2 Bolt-together Kit Table Assembly
Step 1: Assemble 8-hole corner gusset

x12
8 Hole Inside
Corner Gusset
On each of the 12 eight hole corner

gussets, pass a 5/16 T-bolt through
each hole.
Fasten a 5/16 T-nut to each T-bolt.
Leave the nut loose on the bolt.
The T-nuts should be positioned so

that the flanges face away from the
gusset.
x96
x96
5/16 T-bolt
5/16 T-nut
Click here to see

this step animated.
11
Step 2: Assemble slat support mounting brackets

x8
Slat Support Mounting

Bracket (6-Hole)
On each of the eight slat support

mounting brackets, pass a 5/16 T-bolt
through the set of holes, spaced 11/4
from the center holes..
Fasten a 5/16 T-nut to each T-bolt.
Leave the nut loose on the bolt.
The T-nuts should be positioned so

that the flanges face away from the
bracket .
x16
x16
5/16 T-nut
5/16 T-bolt
11/4
O. C.
Click here to see

this step animated.
12
Step 3: Add leveling feet to legs

x6
32x3x3
Aluminum Extrusion
For each of the 32 aluminum

extrusions, place a base plate on the
end of the extrusion that has been
tapped.
Attach the base plate with four

5/16x18x1 cap screws.
Attach a leveling foot through each

base plate.
x24
5/16x18 x1
SHCS
x6
Leveling
Foot
x6
Base
Plate
Click here to see

this step animated.
13
Step 4: Add gussets to central legs

x4
Completed Component
from Step 1
Using two legs completed from step

3, slide two eight-hole corner gussets
onto each leg.
Adjust the gussets so that the top of

the gusset is flush with the end of the
extrusion.
Position the gussets like this for only

two of the competed legs.
Tighten the T-bolts down so that the

gussets cannot move.
x2
Completed Component
from Step 3
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this step animated.
14
Step 5: Add gussets to corner legs

x8
Completed Component
from Step 1
x4
Completed Component
from Step 3
Using the remaining four legs

completed from step 3, slide two
eight-hole corner gussets onto each
leg.
Adjust the gussets so that the top of

one gusset is flush with the end of
the extrusion.
The second gusset should be 3 from

the top of the extrusion.
Tighten the T-bolts down so that the

gussets cannot move.
Click here to see

this step animated.
15
Step 6: Add legs to side extrusions

x2
114x3x3
Aluminum
Extrusion
Using the 114 aluminum extrusions,

slide the leg completed in step 4
onto the extrusion.
Position this leg in the center of the

long extrusion.
Position a leg completed in step 5 on

each end of the 114 extrusion.
Ensure that the lower gusset faces

the same direction on both end legs.
Once positioned fully, tighten the

legs.
x2
Completed
Component
from Step 4
x4
Completed
Component
from Step 5
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this step animated.
16
Step 7: Add slat-support holder-brackets

x2
Completed Component
from Step 6
For each side completed in

step 6, slide four slat-support
holder-brackets from step 2
onto the extrusion.
Place the holders-brackets

on the same side as the
protruding gussets.
Slide the T-nuts into the

lower slot of the extrusion.
Do not fully tighten the slatsupport bracket-holders yet.

They will be adjusted later.
Repeat for both sides.
x8
Completed Component
from Step 2
Click here to see

this step animated.
17
Step 8: Attach slat-support brackets to sides

x2
x4
Completed Component
from Step 7
x16
5/16x18x11/2
Socket Head
Cap Screw

On each of the side components,

attach two slat-support brackets.
Use the four slat-support bracket
holders on each side, two holders
per bracket.
Insert a 5/16x18x11/2 cap screw

through the lower holes of the slatsupport-bracket holder, followed
by the 5/16 spacer, then the slatsupport bracket, two 5/16 washers,
and finally a 5/16x18 nut.
Position the slat-support brackets

so that they are centered on each
side.
Slat-Support
Bracket
x16
5/16 ID
Spacer
x32
5/16 SAE
Washer
x16
5/16x18 Nut
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this step animated.
18
Step 9: Assemble gear racks

x5
49 Gear
Rack
For each piece of gear rack, for each

hole, insert one 5/16 hex bolt with one
5/16 washer, and retain with one 5/16
T-nut. Leave the T-nuts loose.
Repeat this for every supplied piece

of gear rack.
x20
x16
5/16x18x7/8 Hex
Bolt
5/16 T-nut
x20
5/16 SAE Washer
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this step animated.
19
Step 10: Assemble guide rails

x2
120 PrecisionGround Rail
On each of the 120 precision-ground

rails, insert a 5/16 T-bolt through each
hole.
Fasten a 5/16 T-nut to each T-bolt,

leaving the nut loose.
Ensure all T-nuts flanges face away

from the rail.
x12
x12
5/16 T-nut
5/16 T-bolt
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this step animated.
20
Step 11: Install gear racks

x2
Completed
Component
from Step 8
x4
Completed
Component
from Step 9
On each side completed in step 8, slide two pieces of gear rack assembled in
step 9 onto the top slot of the extrusion. The teeth of the gear rack should face
up.
Position one gear rack 15" from the end of the extrusion. Choose the end that
will be on the torch side of the gantry to set this spacing.
Align the remaining rack(s) with the first rack, using the illustrated spacing
method (with the supplied small section of gear rack as an alignment tool).
Once the gear racks are correctly positioned, fully tighten their hex bolts.
15
Engage the teeth of the provided

small section of gear rack in both
installed sections of gear rack to get
the proper spacing.
Click here to see

this step animated.
21
Step 12: Install guide rails

x2
x2
Completed Component
from Step 11
Slide the precision ground rails from

step 10 onto the long extrusions of
the Torchmate 2 frame.
Overhang the rail on the outside on

each side of the frame.
Center the rails so that they extend

by 3 on each end of the extrusion.
Fully tighten the precision ground

rails.
Completed Component
from Step 10
Click here to see

this step animated.
22
Step 13: Join sides with cross-members

x2
Completed Component
from Step 12
Join the two completed sides from step 12. Slide

the two 56 extrusion cross members onto the
protruding gussets.
Level all horizontal members.
Ensure table is square.
Measure the outside edges of the guide rails along

the table length. This measurement must be equal
within 1/32" overall.
Once squarely assembled, tighten the T-bolts.
x2
56x3x3
Aluminum Extrusion
cross-members
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this step animated.
23
Step 14: Install the (customer-provided) slats

x2
Completed
Component
from Step
12
x32
551/4x3x3/16
Support Slat
Customer Provided
Place each of the (customer-provided)

slats into the slat-support brackets.
Slat Specifications
Table Width
4
5
6
7
Table Length
4
5
8
10
12
14
16
18
20
Slat Length
551/4
671/4
791/4
911/4
Number of Slats
16
20
32
40
48
56
64
72
80
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this step animated.
24
Step 15: Assemble the joining plate

x1
12-Hole
Joiinng Plate
On the 12-hole joining plate, insert a

5/16 T-bolt through each hole.
Loosely fasten a 5/16 T-nut to each

T-bolt, with the flanges facing away
from the plate.
x12
5/16 T-nut
x12
5/16 T-bolt
Click here to see

this step animated.
25
Step 16: Assemble the inside-corner brackets

x2
6-Hole InsideCorner Bracket
On the two 6-hole corner brackets,

insert a 5/16 T-bolt through each hole.

T-bolt, with the flanges facing away
from the bracket.
x12
x12
5/16 T-nut
5/16 T-bolt
Click here to see

this step animated.
26
Step 17: Add joining plate and brackets to gantry support

x1
12x3x3
Aluminum Extrusion
Slide the 12-hole joining plate onto the bottom of the

extrusion, engaging the 8 T-nuts in both extrusion slots.
On the same side of the extrusion that has the protruding

part of the 12-hole joining plate, slide each of two-hole sides
of the 6-hole inside-corner brackets onto the extrusion.
Have the four-hole sides of the brackets face each other.
Do not fully tighten the T-bolts.
x1
Completed Component
from Step 15
x2
Completed Component
from Step 16
Click here to see

this step animated.
27
Step 18: Assemble the top rail cam-follower brackets

x2
Top Rail
Cam-follower
Support
Bracket
x8
5/16 T-nut
x8
5/16 T-bolt
x2
1 Cam
Follower
x8
/16 SAE
Washer
x2
/16x18 Nut
Orient the two top rail cam-follower support brackets as right and left-handed, to
mirror each other.
On each bracket, insert a 5/16 T-bolt through each of the the four
small holes. Loosely fasten a 5/16 T-nut to each T-bolt, with the
T-nuts flanges facing away from the brackets.
For each bracket, insert a 1

cam-follower through two
7
/16 washers, then through
the bracket. Add two more
washers, and finally add a 7/16
hex nut.
As with all cam-followers,

add or subtract washers from
either side of the bracket
to best position the camfollower on the rail.
Note: If you are installing a Router kit,

an additional 3/4" cam follower (with
washers and nut) will be installed in each
bracket in the slot below the 1" cam
follower. This step will be done after the
gantry is positioned on the table.
Click here to see

this step animated.
28
Step 19: Assemble the side rail cam-follower brackets

x2
Side Rail Cam-Follower

Support Bracket
x8
x8
5/16 T-nut
5/16 T-bolt
x4
1 Cam
Follower
x16
7/16 SAE
Washer
x4
7/16x18 Nut
Orient the two side rail cam-follower

support brackets as right and lefthanded, to mirror each other.
On each bracket, insert a 5/16 T-bolt

through each of the four small holes.
T-bolt, with the T-nuts flanges facing
away from the brackets.
For each bracket, insert a 1 camfollower through two 7/16 washers,

then through bracket. Add two more
washers, and finally add a 7/16 hex
nut.
As with all cam-followers, add or

subtract washers from either side of
the bracket to best position the camfollower on the rail.
Click here to see

this step animated.
29
Step 20: Add cam-follower assemblies to gantry support

x1
Completed
Component
from Step 17
On each side of the T-section

assembled in step 17, slide one siderail cam-follower support bracket and
one top-rail cam-follower support
bracket onto the extrusion.
Slide the two plates on

simultaneously.
Position the side-rail cam-follower

support bracket to be in contact
with the 12-hole joining plate.
Repeat at the other end of the

T-section.
Tighten the T-bolts.
x1
Completed
Components
from Step 18
x1
Completed
Components
from Step 19
Click here to see

this step animated.
30
Step 21: Add gantry arm to gantry support

x1
x1
Completed Component
from Step 20
611/2x3x3
Aluminum Extrusion
Tapped
End
Slide the gantry T-section assembled

in step 20 onto the 611/2 aluminum
extrusion.
One end of the extrusion is tapped.

Ensure that this end is not covered
by the T-section.
Once positioned, fully tighten all

T-bolts.
Click here to see

this step animated.
31
Step 22: Attach motor to mount plate

x1
X-Axis MotorMount Plate
Attach a 380 oz.-in. motor to the

x-axis motor-mount plate so that
the motor presses onto the plate.
Insert four #8 cap screws through

the motor and then through the
plate.
Add a #8 washers and a #8 hex

nuts to each cap screw.
Do not fully tighten the nuts at

this time.
x1
x4
380 oz.-in. Motor
#8-32x3/4
Socket Head
Cap Screw
x4
#8 SAE Flat
Washer
x4
#8x32 Nut
Click here to see

this step animated.
32
Step 23: Add gear, pulleys, and belt to motor assembly

x1
Completed
Component
from Step 22
x1
Spur Gear
Pressed on
5/16 Shaft
x1
Timing
Belt
x1
14 Tooth
Small
Timing-Pulley
Attach the small timing-pulley to the spindle on the 380 oz.-in. motor. The set
screws should be towards the motor.
Insert the spur gear through the center of the large timing-pulley. The large timingpulleys set screws should be towards the spur gear.
Insert the end of the spur gear through the motor mount plate and then through a
shaft collar.
Tighten all the set screws.
Once assembled, route a timing belt around the large and small timing-pulleys.
Slide the motor on the x-axis

motor-mount plate, to tighten the
belt.
Fully tighten the motor cap screws

and nuts.
x1
48 Tooth
Large
Timing-Pulley
x1
Shaft
Collar
Click here to see

this step animated.
33
Step 24: Assemble inside corner brackets

x2
4-Hole InsideCorner Bracket
On the two 4-hole inside-corner

brackets, insert two 5/16 T-bolt
through one pair of holes.

T-bolt, with the T-nut flanges facing
away from the bracket.
x4
5/16 T-nut
x4
5/16 T-bolt
Click here to see

this step animated.
34
Step 25: Install motor assembly on gantry

x1
x1
Completed Component
from Step 23
x2
5/16x18x7/8 Hex Bolt
Attach the assembled motor

plate to the 4-hole insidecorner bracket with two 5/16"
hex bolts and 5/16" nuts. Use a
5/16" washer on both sides.
Fully tighten the hex bolts.
From the far end, slide the

motor assembly onto the
left side of the T-section
and gantry extrusion, as
illustrated.
Leave a 1/2 space between

the end of the T-sections
6-hole inside-corner bracket
and the x-axis motor-mount
plate.
Fully tighten the T-bolts.
Completed Component
from Step 24
x4
5/16 SAE Washer
x1
Completed Component
from Step 21
x2
5/16 Nut
1/2
Click here to see

this step animated.
35
Step 26: Add drive-shaft support bracket to gantry

x1
x1
Drive-Shaft
Support-Bracket
x2
5/16x18x7/8
Hex Bolt
x1
Completed Component
from Step 24
x4
5/16
SAE Washer
Completed Component
from Step 25
x2
5/16 Nut
Attach the two brackets. Insert a 5/16" Hex Bolt, with a 5/16" washer, through
the drive-shaft support-bracket and then through the 4-hole inside-corner
bracket. Add a 5/16" washer and hex nut, and securely tighten.
Slide the assembly onto the gantry extrusion, leaving the T-bolts loose.
Place the support about 65/16 from the end of the extrusion. The distance will
be adjusted when the gantry is placed on the table.
65/16
Click here to see

this step animated.
36
Step 27: Install drive-shaft on gantry

x1
Completed Component
from Step 26
The drive shaft is drilled on both ends and each

end has a set screw.
Slide one end of the drive shaft over the motor

plates spur gear shaft.
Place a shaft collar over the additional spur

gear's shaft, and then insert the spur gear's shaft
through the drive shaft support and into the drive
shaft.
Tighten all the set screws and T-bolts.
x1
/4 Diameter
Drive Shaft
3
x1
Spur Gear Pressed

on 5/16 Shaft
x1
Shaft
Collar
Click here to see

this step animated.
37
Step 28: Assemble slide and cassette

x1
Slide and Cassette
For all holes in the slide, insert one

special washer with one 5/16x18x11/2
cap screw.
On the side opposite the cassette,

loosely attach one T-nut onto each
screw.
Do not fully tighten the T-nuts.
x18
5/16x18x11/2 Socket
Head Cap Screw
x18
5/16 Special
Washer
x18
5/16 T-nut
Click here to see

this step animated.
38
Step 29: Add slide and cassette to gantry

x1
Completed Component
from Step 27
On the assembled gantry, insert the slide and

cassette in the top slot on the side opposite
the drive shaft.
Position the slide to just make contact with

the 6-hole inside-corner bracket on the
T-section.
Insert the gear rack on the top of the gantry,

into the slot closest to the slide and cassette,
with the teeth facing toward the drive shaft.
Align the center of the gear rack with the

center of the slide.
Tighten the hex T-bolts.
x1
Completed Component
from Step 28
x1
Completed Component
from Step 9
Click here to see

this step animated.
39
Step 30: Add cam-follower support-bracket to gantry

x1
Completed Component
from Step 29
Slide three T-nuts into both slots on the

bottom assembled gantry. These will be used
to attach the cable carrier brackets at a later
step.
At the base of the gantry T-section, orient the

cam-follower support bracket's protrusion in
the same direction as the cassetteand away
from the gear rack.
Insert four T-bolts into the small holes of the

top-rail cam-follower support bracket, and on
into the end of the gantry.
Tighten the T-bolts into the tapped holes in

the extrusion.
x6
5/16 T-nut
x1
Top-Rail
Cam-follower
Support
Bracket
x4
5/16 T-bolt
Click here to see

this step animated.
40
Step 31: Install cam-follower on gantry end

x1
Completed Component
from Step 30
On the top hole of the cam-follower

support plate, install a 1 cam-follower,
with four washers (install two washers on
each side of the support plate to begin
with), and secure with a 7/16 nut.
As with all cam-followers, add or subtract

washers from either side of the bracket
to best position the cam-follower on the
rail.
x1
1 Cam
Follower
x4
7/16 SAE
Washer
x1
7/16x18 Nut
Note: If you are installing a Router kit, an

additional 3/4" cam follower (with washers and nut) will be installed in the slot
below the 1" cam follower. This step will
be done after the gantry is positioned on
the table.
Click here to see
this step animated.
41
Step 32: Install motor on mount plate

x1
Y-Axis Motor
Mount Plate
Attach a 380 oz.-in. motor to the

y-axis motor plate. Insert four #8 cap
screws through the motor, and then
through the mount plate.
Secure each screw with a #8 washer

and a #8 hex nut.
Do not yet fully tighten the nuts.
x1
x4
380 oz.-in. Motor
#8-32x3/4 Socket
Head Cap Screw
x4
#8 SAE Flat
Washer
x4
#8x32 Nut
Click here to see

this step animated.
42
Step 33: Add gear, pulleys, and belt to motor assembly

x1
Completed Component
from Step 32
Slide the small timing-pulley onto the

shaft of the 380 oz.-in. motor, with
the set screws toward the motor.
Tighten the set screws.
Insert the shaft of the spur gear

through a shaft collar, then through
the motor-mount plate bushing, and
through the large timing-pulley, with
the set screws on the large pulley
facing away from the motor-mount
plate.
Once assembled, attach a timing belt

around the large and small pulley.
Align timing-pulleys so that the belt
runs straight.
Slide the motor to tighen the belt,

and then fully tighten the motor to
the mounting plate.
Check the tighness of all set screws.
x1
Spur Gear
Pressed on
5/16 Shaft
x1
x1
Timing
Belt
14 Tooth
Small
Timing-Pulley
x1
48 Tooth
Large
Timing-Pulley
x1
Shaft
Collar
Click here to see

this step animated.
43
Step 34: Attach L-bracket and mounting plate to gantry cassette

x1
Completed Component
from Step 31
Attach the Y-axis L-bracket

and the half inch mounting
plate to the cassette on the
slide. Use four M10 washers
and bolts.
If installing a plate marker,

place the mounting plate
for the plate marker
between the 1/2" mounting
plate and the Y-axis L
bracket.
x1
x1
Y-Axis
L-Bracket
1/2 Mounting
Plate
x4
M10
Hex Bolt
x4
M10
Washer
For Plate Marker
Click here to see

this step animated.
44
Step 35: Attach motor assembly to gantry L-bracket

x1
x1
Completed Component
from Step 34
x4
/16 SAE
Washer
x2
5/16x18x7/8
Hex Bolt
Attach the assembled motor plate to the Y-axis

L-bracket with two 5/16 hex bolts using a 5/16 washer
on both sides of the assembly.
Ensure that the gear engages fully in the gear-rack

before tightening.
Completed Component
from Step 33
x2
/16 Nut
Click here to see

this step animated.
45
Step 36: Attach cable-carrier brackets to gantry

x1
Completed
Component
from Step 35
x8
/16 T-bolt
x1
CableCarrier
C-Bracket
x2
Attach the D-Brackets and the E- bracket to the underside of the

gantry using a pair of T-bolts for each bracket (the T-nuts have
been pre-installed in Step 30). Put the E-bracket closest to the
T-section of the gantry.
Insert two T-nuts and T-bolts into the C-bracket and slide it to
the center of the top of the T section of the gantry. Tighten the
T-bolts.
Attach the F-bracket to the back of the 1/2" mounting-plate. At

the same time, attach the primary tool to the front of the 1/2"
mounting-plate.
Use the hardware provided with the tool to hold both the tool
and the F-bracket to the 1/2" mounting-plate.
(This illustration
shows an AVHC being
attached with the
1/4-20 x 11/2 bolts
included with the
AVHC system.)
CableCarrier
D-Bracket
x2
5/16 T-nut
x2
CableCarrier
F-Bracket
CableCarrier
E-Bracket
1/4x 20 x 11/2 SHCS

(Supplied with
AVHC ONLY)
46
x1
x1
x2
1/4 Washer
(Supplied with
AVHC ONLY)
Step 37: Install cable-carrier end caps and links on gantry

x1
Completed Component
from Step 37
x4
x4
#10-32x3/4 Socket-Head
Counter-Sunk Screw
#10
Washer
x4
#10-32
Hex Nut
On the D-bracket, installed in the previous step,

attach the female cable-carrier end-bracket with
a counter-sunk screw, and on the reverse side, a
washer and hex nut.
On the F-bracket, installed in the previous step,

similarly attach the male cable-carrier end-bracket.
Connect the length of 36 cable carrier links to both

end brackets (26, if heavy-duty links are being
used).
The links open to allow cables to be placed inside.
For tools with large

diameter cables, it
may be best to delay
attaching the cablecarrier links to the end
brackets until after the
cable has been run
through the links.
x1
x1
x36
(optional
(optional
(optional
x1
x1
x26
Female Cable
Carrier EndBracket
Heavy-Duty
Female Cable
Carrier EndBracket
47
Male Cable
Carrier EndBracket
Heavy-Duty
Male Cable
Carrier EndBracket
Cable
Carrier Link
Heavy-Duty Cable
Carrier Link)
Step 38: Attach cable-carrier brackets to side and gantry support

x1
Completed Component
from Step 37
Attach the A-bracket and the two

B-brackets to the side of the table using a
pair of T-nuts and T-bolts to hold each on.
Place the brackets on the same side as

the T-section of the gantry.
Center the A-bracket on the table.
x1
x2
Cable
Carrier
A-Bracket
Cable
Carrier
B-Bracket
x6
/16 T-bolt
x6
/16 T-nut
Click here to see

this step animated.
48
Step 39: Install cable-carrier end caps and links on side

x1
x4
Completed
Component
from Step 39
x4
#10-32x3/4
Socket-Head
Counter-Sunk
Screw
#10-32
Hex Nut
x4
#10
Washer
On the A-bracket, installed in the

previous step, attach the female
cable-carrier end-bracket with a
counter-sunk screw, and on the
reverse side, a washer and hex nut.
On the C-bracket, installed in step

36, similarly attach the male cablecarrier end-bracket.
Connect the length of 36 cablecarrier links to both end-brackets

(26, if heavy-duty links are being
used).
The links open to allow cables to be

placed inside.
For tools with large diameter

cables, it may be best to delay
attaching the cable-carrier links
to the end-brackets until after the
cable has been run through the
links.
x1
x1
x36
(optional
(optional
(optional
x1
x1
x26
Female Cable
Carrier End
Bracket
Heavy-Duty
Female Cable
Carrier EndBracket
Male Cable
Carrier End
Bracket
Heavy-Duty
Male Cable
Carrier EndBracket
Cable
Carrier Link
HeavyDuty Cable
Carrier Link)
Click here to see

this step animated.
49
Building a water table (optional)

This and the following pages describe the construction of a simple water table that you can build with your own skil and materials. Several
design considerations to keep in mind when building a water table are also incuded.

A water table is not required for a

Torchmate 2. However, using one
can significantly reduce the amount
of airborne contaminants created
during plasma cutting.
Cutting on water can be done with

most metals without concern.
WARNING:
Aluminum should not be cut in
contact with water by a plasma
cutter! Aluminum can react
chemically with the oxygen in
the water molecules, releasing
flammable (explosive) hydrogen
gas!

For thicker, heavier material or

other applications, additional cross
bracing or reinforcement may be
necessary.
For any questions, please contact

Torchmate Technical Support:
Toll Free: 1-866-571-1066 x3

Fax: 775-673-2206
50
Basic water table dimensions:

Cutting Area Width
4 (1219.2mm)
5 (1524mm)
6 (1828.8mm)
7 (2133.6mm)
Cutting Area Length

4 (1219.2mm)
5 (1524mm)
6 (1828.8mm)
8 (2133.6mm)
10 (2438.4mm)
12 (2743.2mm)
14 (3048mm)
16 (2438.4mm)
18 (2743.2mm)
20 (3048mm)
56(1422.4mm)
68 (1727.2mm)
80 (2032mm)
92 (2336.8mm)
60(1524mm)
72 (1828.8mm)
84 (2133.6mm)
108 (2743.2mm)
132(3352.8mm)
156 (3962.4mm)
180 (4572mm)
204(5181.6mm)
228 (5791.2mm)
252 (6400.8mm)
Water pan should

be at least 4
(101.6mm) deep
34 (863.6mm)
51
Water table design considerations
This water table design holds

the material at the correct
height, with the material in
contact with the water during
cutting.
The table shown here is built

with 3x3 square tube. However,
any building material with
sufficient strength to hold the
weight of water and the metal
being cut could be used.
Commonly, legs are spaced 3040 (762mm-1016mm) apart.
The frame needs to support the

bed of the water pan, to keep it
from sagging.
Use the slat support brackets

(provided with the bolt together
table). Weld them onto the
bed of the pan, so that the
slats rest in the pan and can be
completely submerged in the
water.
52
Water table support structure
This design guide provides basic,

usable dimensions for the water
table, but there may be a need
to customize the design.
To achieve an overall height

of 34", and to accommodate
a 4 (101.6mm) water pan the
top of the support structure
should be 30 (762mm) from the
ground. This can include leveling
feet, or a means of permanent
attachment to the floor of the
shop.
The structure must be sturdy

and able to support the weight
of water, the pan and slats, and
the metal being cut.
Water weights 0.036 pounds

per cubic inch. For example, a
water pan for a 4x8 table would
contain almost 875 pounds (400
kg) of water.
For wider tables center legs or

cross bracing (or both) should be
used.
53
Water pan
The water pan may be constructed

from multiple pieces of metal,
welded together,or from a single
piece of metal, bent, then welded.
The critical part of the design is the

pan's depth.
Consider adding a drain to your

water table design, to make it easier
to empty the water.
Other water table designs,

incorporating a two chamber
system, allow the water to be raised
and lowered, without having to refill
the table each time.
These design details are left to you

so that you can fit the water table to
the unique situation of your shop .
After satisfying the basic constraint

of having the ability to hold your
material and 4 (101.6 mm) of water,
you can customize the water pan to
fit any need you may have.
54
Water table slat support
You can remove the slatsupport brackets that come

with the Torchmate 2 bolt
together table from the
aluminum extrusions and weld
them into the water pan.
Position the brackets 3 6

(76.2mm 152.4mm) from the
inside of the pans edges.
Center the brackets lengthwise to allow even support of

the material.
55
Incorporation of the water table:
To place the water table inside the

aluminum frame, remove a cross
member from one end. Slide the
water table inside of the aluminum
frame.
It is best to independently level

the water table and the aluminum
frame, ensuring that they are level
to each other.
If you have removed the gantry, it

can now be replaced on the table.
Add water to the table and you are

ready for cutting.
56
Tool Attachment
57
Torchmate 2 Bolt-together Kit Tool Attachment
Attaching an Arc Voltage Height Control (AVHC)
58
Adjust the AVHC height
Breakaway Magnet
Torch Height Adjustment
Assembly Height Adjustment
59
Attaching a plate marker
60
Adjusting a plate marker
Pen Height Adjustment
61
Assembly Height Adjustment
Attaching an oxy-fuel torch
62
Attaching a Z-axis for routing
Note: Your Router Kit will include additional

cam-follower bearings (3 x 3/4 ) with nuts and
washers that will be mounted under the side
rails after the gantry is positioned on the table.
See Table Assembly Steps 18 and 31.
63
Router backlash-compensation adjustment
64
Attaching a Laser Crosshair
65
Adjusting a laser crosshair
Attachment Set Screw
Crosshair Alignment Adjustment
Emitter Aim Adjustment
66
Wiring Diagrams
67
Torchmate 2 Bolt-together Kit Wiring Diagrams
Plasma with Manual Height Control

Wires 3 & 4 on the Plasma Torch
CNC Interface Cable, or
the Green and Black Pair
To Table
Motors
RELAY
115
AXIS 1
AXIS 2
AXIS 3
AXIS 4
PUSH
PUSH
PUSH
PUSH
MOTOR SIGNALS
OUTPUTS 1-8
INPUTS 1-8
To magnetic
breakaway
sensor
68
Plasma with Automatic Voltage Height Control
RELAY
115
AXIS 1
AXIS 2
AXIS 3
AXIS 4
PUSH
PUSH
PUSH
PUSH
To Table Motors
Pro-Series CNC
Controller
MOTOR SIGNALS
OUTPUTS 1-8
INPUTS 1-8
Input Cable: Magnetic

Breakaway Sensor(3)
[other lines reserved for

optional limit switches]
10 Input Cable: Pierce(1) and Fault(2)
Wires 12 & 14 on the Plasma Torch CNC

Interface Cable, or
the Red and Black Pair
AVHC Motor
(top connector)

Raw Arc Voltage

on the Plasma Torch
(See Section 3)
AVHC Controller
69
Plasma with Automatic Voltage Height Control & Plate Marker
RELAY
115
AXIS 1
AXIS 2
AXIS 3
AXIS 4
PUSH
PUSH
PUSH
PUSH
To Table Motors
Pro-Series CNC
Controller
MOTOR SIGNALS
OUTPUTS 1-8
INPUTS 1-8

Breakaway Sensor(3)
Universal Relay Interface
To Plate Marker


Interface Cable, or
AVHC Motor
(top connector)

Raw Arc Voltage

on the Plasma Torch
(See Section 3)
AVHC Controller
70
Plasma with Automatic Voltage Height Control & Oxy / Fuel Torch
RELAY
115
AXIS 1
AXIS 2
AXIS 3
AXIS 4
PUSH
PUSH
PUSH
PUSH
To Table Motors
Pro-Series CNC
Controller
MOTOR SIGNALS
OUTPUTS 1-8
INPUTS 1-8

Breakaway Sensor(3)
To Oxy / Fuel
Solenoid


Interface Cable, or
AVHC Motor
(top connector)

Raw Arc Voltage

on the Plasma Torch
(See Section 3)
AVHC Controller
71
Plasma with Automatic Voltage Height Control, Oxy Torch, & Plate Marker
RELAY
115
AXIS 1
AXIS 2
AXIS 3
AXIS 4
PUSH
PUSH
PUSH
PUSH
To Table Motors
Pro-Series CNC
Controller
MOTOR SIGNALS
OUTPUTS 1-8
INPUTS 1-8

Breakaway Sensor(3)
To Plate Marker
1
To Oxy / Fuel Solenoid


Interface Cable, or
AVHC Motor
(top connector)

Raw Arc Voltage

on the Plasma Torch
(See Section 3)
AVHC Controller
72
Router
RELAY
115
AXIS 1
AXIS 2
AXIS 3
AXIS 4
PUSH
PUSH
PUSH
PUSH
To Table Motors
Pro-Series CNC
Controller
MOTOR SIGNALS
OUTPUTS 1-8
INPUTS 1-8
To Router
73
Raw Arc Voltage Connections
74
Torchmate 2 Bolt-together Kit Raw Arc Voltage Connections
Raw Arc Voltage Points for AVHC

Use the raw arc voltage points on your plasma cutter unit to control the Arc Voltage Height Control (AVHC) unit.
The 25 Raw Arc Voltage Wire comes with the Arc Voltage Height Control unit. It is packaged with the 10 start wire, as pictured below. It is a
pair of shielded 16 to 18 gauge wire rated for up to 300 volts DC. Connectors for the plasma cutter are not provided, as they can vary greatly
between models.
The following pages contain photos and diagrams that will help to locate the connection points (on most common makes and models of
Plasma Cutters).
Please find the picture for your model Plasma Cutter below, and refer to it, as well as to the wiring diagram from the Section 2 above, to
connect the AVHC unit. If your model is not listed, contact the Torchmate Support Department: phone 866-571-1066 x3 or email
support@torchmate.com.
75
Thermal Dynamics: Cutmaster 51, Cutmaster 81, Cutmaster 101, Cutmaster 151
76
CUTMASTER 52 & 82 VOLTAGE POINTS

Thermal Dynamics: Cutmaster 52, Cutmaster 82, Cutmaster 102, Cutmaster 152,
Cutmaster A40, Cutmaster A60, Cutmaster A80, Cutmaster A120
Location may vary between models, but the points will be labeled as shown.
WORK
(+)
ELECTRODE
(-)
77
Hypertherm: Powermax 1000, Powermax 1100, Powermax 1250, & Powermax 1650
Red
Black
78
Hypertherm: Powermax 45
J19 or J18
(white wire)
(-)
J21
(work lead)
(+)
79
Hypertherm: Powermax 65 & 85
this
80
Hypertherm: Powermax 105
81
Lincoln Electric: Tomahawk 1000
82
Driver Software
Wear eye protection of the shade recommended by your

plasma torch manual while watching the plasma arc.
Full information about each option and configuration setting can be found in the
Torchmate 4 Users Guide, which can be found in the menu under Help u Users Guide.
83
Torchmate 2 Bolt-together Kit Driver Software
Installing the Driver Software

The Torchmate driver software to be installed is either on the

Driver Software CD or the USB Flash Drive in a folder called
Driver Software.
To install the software click on the Torchmate4LiveSetup

icon.
The installer wizard will start. Windows may ask permission to

continue installation. Proceed with the installer program by
selecting Next.
84
Under Customer Information, enter both a User Name and a

Company Name. Click Next to continue.
For the Destination Location, the default install location is

often best. Click Next to continue.
Review the installation setup information. Use Back to

correct any errors. Click Next to begin the installation.
If you receive an Unsigned Driver warning, select Continue

Anyway.
Click Finish to complete the wizard.
Once the software is installed, it is recommended that you

restart the computer.
The software installs all the necessary components, including

any necessary drivers. Click Install to install the signal
generator drivers, as prompted.
85
Configure the computers power saving feature

Finally, to prevent your computer from going to sleep during cutting
or marking operations, set the Control Panel > Power Options to Never
turn off the display and Never go to sleep.
Select Change when the

computer sleeps
Set both to Never
86
Manually Installing the Device Drivers (if necessary)

If for some reason, the device drivers for the Torchmate

controller may not have been installed, you can install them
manually.
Look under either Universal Serial Bus Controllers, or Other

Devices. Click the [+] to expand the listings of devices.
When the controller is plugged in, the USB cable is

connected, and the controller is turned on, then the
computer will automatically check for the necessary device
drivers.
Select the USB Signal Generator 501A.
Right-click on this and select Update driver. This will begin

the driver install process.
If a warning is displayed saying that device drivers need to be

installed, then they will need to be installed manually.
Go to the Start menu and right-click on Computer or My

Computer. Then select Manage.
In the Computer Management screen, select the Device

Manager from the left menu.
Select Install from list or specific location, then click Next.
87
Select Search for the best driver in these locations.
Check Include this location in the search.
Select Browse.
If you receive a warning about Windows testing, select

Continue Anyway.
The Device Manager will confirm that the driver has

successfully installed.
Click Finish to close the installer.
On the C:\ drive, navigate to

C:\Program Files\Torchmate 4\Drivers\USB
Note: for 64-bit driver software, browse your
distribution USB Flash Drive (or CD) for the 64 Bit
Drivers folder.
Click Next.
88
Driver Software Setup & Basic Overview

Launch the Torchmate 4 software from the Start menu or by

double-clicking the Torchmate 4 icon:
The Torchmate driver software includes pre-configured setup

files for different table configurations. To use a configuration
file, go to File u New Setup....
A selection box appears. Make the appropriate selection

(refer to the box below), then click Open.
Torchmate1.stp is for Torchmate 1 (also called Torchmate

Standard CNC systems).
Torchmate2.stp is for Torchmate 2 bolt together and kit
tables.
Torchmate3.stp is for Torchmate 3 bolt together and kit
tables.
TorchmateX.stp is for Torchmate X turn key and kit systems.
Routermate.stp is for Routermate kits and bolt together
tables.
Torchmate2x2Plasma.stp, Torchmate2x4Plasma.stp, and

Torchmate4.4Plasma.stp are for plasma setups on a Torchmate Growth Series table. These setup files contains presets
for pierce delays and for importing files with two dimensions
of movement. Select the file that corresponds to your Growth
Series size.
An information box appears.
Torchmate2x2Router.stp, Torchmate2x4Router.stp, and

Torchmate4x4Router.stp are for router configurations on
a Torchmate Growth Series table. They contain settings to
enable z-axis for routing and for importing files with three
dimensions of movement. Select the file that corresponds to
your Growth Series size.
Click OK to continue.
Torchmate2x2Other.stp, Torchmate2x4Other.stp, and

Torchmate4x4Other are used for other tools on a Torchmate
Growth Series table. They will require additional setup to run,
depending on the type of tool. Select the file that corresponds
to your Growth Series size.
89
Software Overview

After you open a setup file, the main Torchmate screen

appears, containing all information needed to run the
Torchmate table.
The information is organized into seven sections:
CONNECTION STATUS
Viewport
Shows a graphical representation of what is being cut.

VIEWPORT
Can be configured to display different views for routing

applications.
G-code
Displays the machine code for the file loaded.
OUTPUT
BOX
Control Panel Selection

Allows different control panels to be selected.
Current Control Panel
Displays the selected control screen.
CURRENT CONTROL
PANEL
Output Box
A user-defined screen that shows different parameters for
tools, delays, and outputs.
Coordinates or DROs
Displays where the machine is based on a zero location.
Also referred to as DROs, or Digital Readouts.
Connection Status
Indicates whether the software is connected to the
Torchmate electronics unit or not.
COORDINATES
CONTROL PANEL
SELECTION
90
G-code
Control Panels
There are eight different control panels that the Torchmate driver
software uses. Each panel is accessed by the Control Panel Selection
buttons to the left of the panels. In most setups not all panels will
be used.
Across all panels, the color of a button indicates its general function.
Green Buttons adjust settings or perform some action that does

not move or pause the machine.
Yellow Buttons will cause the machine to move.
Red Buttons will pause the machines motion.
White Fields indicate a setting that can be changed.
G-code
This panel starts, pauses, and
resets the current program, also
called a G-code file.
The panel also allows a jump to
a specific line of code, a change
to the feed rate by a percentage,
and shows the progress of the
program being run.
Point
Similar to the jog panel,
the point panel moves the
machine for positioning. Type a
coordinate and pressing move
to have the machine travel that
distance.
A list of reference points allows
quick movement.
The feed rate for the motion can
also be set.
Jog
Jog allows the machine to be
moved, but for positioning only.
Jog cannot be used while a tool
is operating.
The left pull down is how far
the machine will move when a
direction is clicked.
The right pull down is how fast
the machine will move.
Home
The home panel is used only
if optional limit switches are
installed on the machine.
Limit switches allow the
machine to run until a switch
is tripped and then reposition
itself based on this setting.
Most Torchmate tables do not
use limit switches.
91
Aux
The Aux or Auxiliary panel is
used for testing output lines
that are enabled in the software.
This panel is only used when not
running a G-code program and
should only be used for testing,
or activating a passive tool such
as a laser cross hair.
Pressing any button listed here
will activate the output line that
is associated with it.
Probe
The probe panel is used when a
touch probe sensor is installed
on the machine.
The probe will create a three
dimensional map of an object in
the machines motion envelope.
MDI
The Manual Data Input or MDI
panel allows the execution or
testing of G-code entered in the
field.
The G-code in the MDI field
overrides the currently loaded
G-code file.
Start will start the code entered
here, reset will jump back to the
beginning, and hold will pause
the code.
Cycles
The cycles panel creates G-code
files without the use of a CAD
software.
The cycles represent simple
programs for routing and
drilling. Each cycle will open
a configuration screen with
options to write the program.
92
Coordinates or DRO

The coordinates section--also called DRO (Digital Read Out)-indicates the machines current position.
The main coordinates are referred to as the Program

coordinates, which show where the machine currently is
relative to the program zero.

When a file is imported to the driver software, the

reference coordinates for all motion is the program zero.
By default this point is the lower left of a drawing, but it
can be relocated. The machine starts its motion from the
program zero.
To set a program zero, move the machine to the position

of the desired zero point, and select the Set pull down.
Select Zero All. The machine will now use this

reference point when running the G-code program.
Each axis can also be zeroed individually by selecting

either Zero X or Zero Y.
Any non-zero coordinates can be set for the current

position using the Set uEnter... function.
The Machine coordinates define a machine envelope that

can not be exceeded by jogging or by a program. Once
specified, they are represented by a light blue rectangle on
the Viewport.

After you set the machine coordinates, clear them by

selecting Clear from the Set menu.
Machine coordinates are used primarily when a machine

has limit switches installed.
93
Connection Status

To run the machine, the software must connect with the

controller (electronics) unit (also referred to as the signal
generator).
On the main screen, the software indicates whether it is

connected or not through the connection status.
Not Connected indicates that there are no signals being

sent from the software to the electronics. This mode can be
used to simulate how a program will run without having the
machine move.

The driver software in a Not Connected mode can also

be used on a computer other than the one connected to
the cutting tableto simulate cut paths and ensure that a
G-code file is working before being brought to the cutting
machine.
Connected indicates that the machine is being controlled by

the software. Any commands from the driver software will
be executed on the machine.
Note: It is strongly advised that before connecting, any
operator should achieve a basic understanding of the entire
software package.

If a connection to the electronics unit cannot be achieved or

maintained, ensure that the power connection and the USB
connection are secure. Refer to the Troubleshooting section
for more steps regarding problems with connecting.
94
G-code Panel

G-code is the machine code that actually runs the machine.
Any file brought into the Torchmate driver software is

converted to G-code. The G-code panel displays the G-code
currently loaded.
The G-code panel highlights the line of code that the

machine is currently running.
The G-code that is loaded can be viewed in its entirety and

edited by double-clicking on the G-code panel.
It is not normally necessary to be able to read, write, or

understand G-code to operate the machine. However, a
familiarity with G-code and its purpose can be helpful in
understanding and correcting problems.
Additional information about different G-codes, their

function, and how to write and edit G-code can be found in
the G-code Overview section of this manual.
95
Viewports

A viewport is a visual representation of a loaded G-code file.

The window can be configured to display multiple views of
the G-code.
In the viewport, every motion command is displayed.

Where a tool will be actively cutting (referred to as Feed

rate movement), its path is shown as a solid line.
Where the tool will be moved between cuts (referred to

as Rapid travel), its path is displayed as a dotted line.
As the program is executed, the red lines get replaced by

blue lines--indicating that the machine has completed those
moves. Similarly, when the machine is moved using the jog
control panel, the motion is indicated with a blue line.
A viewport can be zoomed in and out using a mouse with

a scroll wheel. It can be panned by holding down a rightmouse-click while moving the mouse.
Additional zoom options are available by right clicking on

the screen and releasing. Zoom Toolpath Extents will fit
the zoom to show the entire coded path. Zoom Machine
Extents will zoom to the machine envelope if Machine
Coordinates are used. Hide will remove the selected
viewport from the main screen.
96
Output Box
The Output Box displays settings and information. It displays

different parameters, depending on the selection of tools
and their setups.
When multiple tools are used on the machine, the active tool
for a particular file is dispayed in the Output Box while the file
is being run.
All tools can be selected and configured to display in this

area, whether they are active or not.
Values called user-defined variables are edited in the

Output Box. These can be used for a variety of functions,
from counting pierces to setting preheat delays.
To edit any of the values in the set of user-defined

variables, select Edit.
Once a change has been made select Accept to keep the

changes or Cancel to undo the changes and revert to the
previous settings.
When editing the user-defined variables, all other functions

of the software are locked out until either Accept or Cancel is
selected.
97
Basic Driver Software Operation

With the software open, and the appropriate setup file

loaded, the Torchmate driver software is ready to control a
machine.
If the software is indicating that it is not connected to

the electronics go to Controller u Connect to establish
communication.
The main screen of the driver software will vary depending

on the setup file loaded. All setup files will have G-code, Jog,
Point, and Aux control panels.
When the software opens for the first time, it will have the
Program Coordinates set to zero regardless of the machines
position in its motion.
Before running a program, it is necessary to verify that the

machine is moving correctly and that any attached tools can
be activated.
If the machine must be stoppedat any timewhen

in motion, press any key on the keyboard to pause the
program.

98
Motion Testing

Proper motion of the machine is essential to its smooth and

consistent operation. The Jog control allows you to test for
proper motion and to manually position the tool anywhere
on the table.
Access the Jog control panel on the main screen of the

driver software. Use the X-, X+, Y+, and Y- buttons to Move
the table in all directions and ensure that the motion is not
obstructed or binding anywhere on the machine.
The direction that the machine moves when one of these

buttons is pressed can be changed in Configuration u
System u Motor Signals.
This menu selection shows how the motor signals are set up.
Each motor is plugged into a corresponding numbered port
on the back of the electronics unit. Set the axis and direction.

Set the axes and directions so that, from the operators viewpoint, the machine moves the same as it does on the screen.

For example, if you see the machine move left or right (instead of closer or away from you) when you press the the Y+ button, then
switch each Axis Letter from X to Y and Y to X.
Similarly, if you see the machine move away from you when you press the Y- button, this is the correct axis but the wrong direction.
Reverse the Motor Direction polarity (Negative or Positive) for ports with the Y-axis.
In the same way, reverse the direction for ports using the X-axis if the machine goes to the right when you press the X- buton.
99
Testing Output Lines

By default, the selected setup file for the Torchmate driver

software configures either a plasma or router set up. This is
generally sufficient to run the CNC table when initially set up.
To test the (default) tool: Turn the tool on. Then, activate the
tool either in the Aux menu or in the Output Box. If the tool
is connected to the controller (electronics) unit, the tool will
activate.
To turn the tool off, click the activation button again to deactivate it, then turn the tool off.
Any output line with a Description will appear in the Aux

menu, where it can be tested. Begin by assigning each line a
Description, such as the number corresponding to the line.
Test each line to see if it activates the tool.
Once youve identified the corresponding lines and tools,

change the Description of the output lines to reflect the
setup.
If additional tools are set up, the activation and operation of

these tools will also need to be setup and tested. To perform
this, you must identify which output line is associated with
each tool. Go to Configuration u I/O u Output Lines.
100
Test Cutting - Manual Height Control Plasma

The optimal cut speed for plasma can vary depending on

location and other factors.
To find the ideal cutting speed, use the supplied line speed
test file that will cut 13 different lines, each at a different
speed. This allows the ideal cut speed to be found.
To load the line speed test, go to File u Open G-code. The

default installation puts the line speed test in the folder:
C:\Torchmate Data\G-Code.
There are two line speed tests, Line Speed 130-10 and Thick
Line Speed. The thick line speed test should be used when
working with materials 3/8 or thicker.
Once the file is opened, jog the machine so that the torch is
at the lower-left corner of your test area. Select Set u Zero
All in the Program coordinates (DRO). The machine will
position of the torch at the lower left corner of the part. The
part is 21/2 wide and 31/2 tall.
Set the amperage on the plasma cutter appropriately for the

material being cut. Consult the plasma cutters manual for
recommendations.
Select Start from the G-code panel. The machine will cut the
13 lines and then cut around all of the lines.

program.

101
Test Cutting - Manual Height Control Plasma

The line speed test has 13 lines. The first line is cut at 130
inches/minute, and each subsequent line is 10 in/min slower,
ending with the last line, which is cut at 10 inches/minute.
After cutting the part, it will be very hot. Carefully handle it

with gloves or pliers, or allow to cool.
Examine the cuts. Typically, the first few lines will be cut too
fast and not be fully cut through, or will have cut through but
melted back together after cutting.
As the cut speed slows down to the ideal cutting speed, the
lines improve.
When the speed is too slow, the line will show an excessive
build up of hard slag on the underside of the cut.
Determine which line has the best cut, looking for the least
amount of slag build up and a generally clean cut.
On all cuts, the initial pierce area is a bit wider than the cut.
This is to be expected and is the reason lead ins are used
on tool paths. If the pierce point stretches into the line more
than about 1/8 of an inch, then the pierce delay is most likely
set too low. This can be increased in the Output Box. Ideally
the torch will fire, pierce completely through the metal, and
then begin to move.
10 in/min
20 in/min
30 in/min
40 in/min
50 in/min
60 in/min
70 in/min
80 in/min
90 in/min
100 in/min
110 in/min
120 in/min
130 in/min
Thick Excessive
Slag
Cleanest Cut
Not Cut Through
Underside of Cut
102
Test Cutting - Router

Routing speeds can vary for a number of reasons. The depth

of each pass, type of bit, and type of material all affect the
overall cut.
In most cases there will be a maximum speed that the router

can move through a material with a given bit and depth of
cut. However, there is generally no lower limit. This means
that, in general, finding an ideal speed for routing means
starting slower and gradually increasing test speeds until a
good speed is found.
The Driver Software CD or USB Flash Drive contains a test file

called RouterTest.DXF. This file has a small number of lines
that can be be used to test different parameters.
To open the file, go to File u Import DXF and select

RouterTest.DXF. When prompted, save the G-code. This
saves the settings for the test, and displays an import
configuration screen, with parameters for how the router
makes passes.
Main Routing Parameters

Tool Up
Incremental Depth of Cut
Final Tool Down (Milling)
XY Feedrate
Plunge Feedrate
How far the router will raise above the material when moving between plunges.
How much material will be removed each pass (Positive Number)
How much material will be removed each pass (Positive Number)
How fast the router will move once it has plunged to depth.
How fast the router will dive into the material to reach the depth of each pass
103
Test Cutting - Router (continued)

Pre-set numbers for speed and depth cannot be specified

for routing a given type of material, because the speed for a
good cut will vary significantly, depending on bit type, cut
depth, and other factors. Because of this, a good speed and
depth must be found by testing.
With the RouterTest.DXF file loaded, jog the machine to

where you want to set the lower-left corner for the test.
Jog the router down so that the bit is just in contact with the
surface of the material.
Select Set u Zero All next to the program coordinates. The

machine will now use this bit position as the lower left corner
of the part and as the surface of the material.
The test cut is a square about 2 X 2. The size will vary based
on the bit used.
Select Start from the G-code panel to begin routing the test
part.
After the test is complete, examine the piece for quality of

cut.
When testing, begin slower than expected and increase the

speed on subsequent tests. Moving too fast or going too
deep can melt plastics, burn wood, and break or dull bits
quickly in metalsand it puts unnecessary wear on the
machines drive components.

program.
104
Setup & Test Cutting - Plasma with Automatic Height Control

The Torchmate 4 software is pre-configured to use Automatic

Voltage Height Control (AVHC).
Select Edit from the Output Box. In the field labelled AVHC
(T/F), select True. This enables all settings for the AVHC.
When the AVHC is enabled, the Pierce Delay field is NOT

used in the software. All settings for the AVHC are made in
the AVHC electronics unit. This setup is explained next.
105
Setup & Test Cutting - Plasma with Automatic Height Control

Use the configuration menu on the AVHC electronics unit.

Turn on the AVHC and use the up and down arrow buttons to
navigate the menus. When you see the desired menu item,
press OK.
Navigate to Set Pierce Height.
For material up through about 3/8 thick, use a Pierce Height

of 0.18. For thicker material, increase the number to 0.20 or
even 0.22 to help avoid increased splash back.
To change the number, press OK. Use the up and down

arrows to change the value. Press OK to set the value.
106
In Auto mode, the AVHC automatically controls the

height, after starting at the Initial Cut Height.
In Manual mode, the height remains at the Initial Cut

Height.
Next is the Jog Slide screen. Press OK at this prompt to

enable using the arrow keys for manual up and down
toggling of the torch over the full range of travel.
Jog Slide is useful for positioning the torch, but is not used
during actual cutting. The torch will NOT fire when Jog Slide
is enabled.
Avoid hard-bottoming the torch (or the bottom of the AVHC

lifter station) into the material.
Once finished press OK again to exit the menu. Be sure to

exit the Jog Slide screen before cutting.
The Select Auto/Manual screen toggles the height control

between its two modes of operation.
Initially cut all materials in Manual mode until the AVHC is

calibrated for the material.
Scroll down to the next menu: Set Initial Cut Height. This
specifies the torch height to use after completing a pierce.
This number will usually be lower than the Pierce Height,
and about 1/8 from the material.
Note: to account for any vertical play in the lifter station,
try adding up to .04 more to the Pierce and Init Cut
Height settings.
The Auto/Manual mode setting influences the Set Initial Cut

Height setting.
Setup & Test Cutting - Plasma with Automatic Height Control (continued)
The next screen is the Setup Menu.
If OK is pressed, the AVHC displays the Setup Menu, which has

additional configuration settings.
OK to Move
Disabled
Disabled
Enabled

The Pierce Delay specifies the transition time between

various modes. Refer to the table below to determine the
setting to use.
Pierce Complete
Disabled
Enabled
Enabled
Pierce Delay
2.5 + sec.
0.8-1.5 sec.
0.1-0.3 sec.
The ranges in the Pierce Delay are based on the thickness of

material: thicker materials need a slightly longer Pierce Delay.
The first option in the Setup Menu is OK to Move. This will

only be enabled if the connected plasma cutter has an OK to
move signal. Consult the plasma cutter manual to verify the
availabilty of this signal.
Sensing Delay specifies the time after completion of the

Pierce Delay before the AVHC begins to adjust for voltage.

The next option is Pierce Complete. This option enables the

signal that is sent from the AVHC to the signal generator.
Ensure that it is Enabled.
107
This setting only affects operation in Automatic mode, and

is generally left at 0.5 seconds. This Sensing Delay allows
the torch to travel away from the pierce area to get a cleaner
sample of cutting arc voltage before adjustments are made.
Setup & Test Cutting - Plasma with Automatic Height Control (continued)
The last setting in the Setup Menu is Touch Torque.
The Touch Torque is an amperage setting indicating the

power the motor puts out when the material is contacted.
In normal operation, when beginning a cut, the AVHC
lowers the torch to sense the material. The amperage briefly
increases after contact. The AVHC then retracts the torch back
to the Pierce Height.
For normal operation, set Touch Torque in the 15-18 range.
Note: Under no circumstances should the Touch Torque be

set higher than 35.
Note: A setting higher than 18 over a long period will
damage the AVHCs motor.
Note: If the Touch Torque is set too low, then the AVHC will
falsely sense resistance before reaching the material. This can
cause an attempt to fire the torch in the air.
108
Setup & Test Cutting - Line Speed Test

For plasma cutting, there are generally three main

components of a quality cut: amperage, speed, and height.
To find the best cut settings, find the amperage first, then
speed, then height.

Changing an amperage setting will require a change to

each of the subsequent settings to get the best cut.
Changing a speed setting (at a given amperage) requires

a height change.
Amperage is set on the plasma cutter. Use consumables that

match the amperage 10%.
Speed is set in the driver software. Its number is found using
a cut file called Line Speed Test.
Height is controlled by changing the Set Voltage for AVHC.

For each thickness and type of material, the settings will be

different.
The line speed test files are located with the other installed
G-code files (G-code files are typically found in the folder:
C:\Torchmate Data\G-Code).
There are two line speed tests, Line Speed 130-10 and Thick
Line Speed. Use the thick line speed test with 3/8 or thicker
materials.
Jog the machine so that the torch is at the lower-left corner

of the test area. Set this location as the cut path reference
point with Set u Zero All, next to the program coordinates.
The part is 2-1/2 wide and 3-1/2 tall.
Ensure the height control is set in Manual mode.
Select Start from the G-code panel. The machine will cut the
13 lines and then cut around all of the lines.
Inspect each cut to determine the best quality cut and its
speed.
Load the line speed test using File u Open G-code on the
menu.
If at any time the machine must be stopped, press any key on

the keyboard to pause the program.
109
Setup & Test Cutting - Voltage Test

Once the best Speed is found, the last step is to determine

the best Height.
Locate the VoltageTest.DXF file in the C:\Torchmate Data\

DXF folder. Import this file using the menu selection: File u
Import DXF.
When prompted, Save the G-code, which saves the specific

settings for this test.
At the import Configuration screen, enter the best Speed

(found using the line speed test) in the XY Feedrate section.
No other settings need to be changed.
The voltage test file cuts two six inch lines with one inch of
separation. Position the torch so that these two lines can be
cut on a single piece of material.
Zero the program coordinates and select Start from the

G-code menu. Run this program in AVHC Manual mode.

While the program is running, monitor the AVHC screen that

shows Current Voltage. The Current Voltage is related
directly to the height of the torch above the material.
As the VoltageTest path is cut, after the torch moves from

the pierce area, the Current Voltage will settle on an average
number. Note this number.
110
Setup & Test Cutting - Voltage Test (continued)

On the main screen of the AVHC, press the OK button, to

enter edit mode.
Change the Set Voltage to the average number you noted

being displayed under Current Voltage.

Jog the torch to a fresh area of metal, so that the two lines
can be cut again.

Change the AVHC mode from Manual to Automatic.
Zero the program coordinates and select Start from the

G-code menu.

Monitor this cut as it runs in Automatic mode with the

specified Set Voltage. Observe the height of the tip as it
travels.
Height is related directly to the Set Voltage value:

If the tip see-saws up and down, the voltage is too high.
Decrease downward in 5 to 10 volt increments.
Remember: To bring the torch tip closer to the
material, decrease the Set Voltage.
If the tip dives into the material, the voltage is too low.
Increase in 5 to 10 volt increments.
Remember: To raise the tip higher, increase the Set
Voltage.
Repeat the VoltageTest, as necessary, using different Set

Voltage values, to find a Set Voltage that gives the best cut
quality.
The height will commonly be about 1/8 from the material.
Once the Set Voltage is found, parts are ready to be cut for
this thickness, speed, and type of material.
111
Test Cutting Checklist for Plasma with AVHC

This list is a step-by-step, quick guide for finding optimal cut settings for a particular type and thickness of material.
Procedure
Goal
Set the amperage dial on the plasma cutter to the prescribed setting for the thickness of material.
Set the plasma cutters

amperage.
Manual
Set the Pierce Height and Cut Height in the AVHC for the thickness of material being cut.
Set the AVHCs Piece Height and

Cut Height.
Manual
Open the Line Speed Test G-code file. Position the torch at a suitable cut area and zero the Program Coordinates.
Prepare to cut the line speed test.
Manual
Cut the Line Speed Test file. Examine the cut to see which line
gives the best cut quality. The first line cut is 130 in/min and each
line after slows down by 10 in/min.
Determine the best cutting

speed.
Manual
Import the DXF file called Voltage Test. Set the XY Feedrate to the
best cutting speed found. Position the torch at a suitable cut area
and Set the Program Coordinates to zero.
Prepare to cut the Voltage Test

file.
Manual
Cut with the Voltage Test file. Watch the Current Voltage displayed on the AVHC to see the arc voltage when the torch cuts at
the Cut Height.
Determine the initial value for Set

Voltage.
Manual
Change the Set Voltage to the voltage found when running the
Voltage Test.
Setting the Set Voltage.
Manual
Reset the Voltage Test program. Position the torch at a suitable

cut area and Set the Program Coordinates to zero. Change the
AVHC mode to Automatic.
Preparing to cut the voltage test
Auto
Cut the Voltage Test. Inspect the cuts. Repeat as necessary, varying the Set Voltage until the best cut quality is found.
Fine tuning the Set Voltage.
Auto
Cut Parts as needed. It is a good practice to keep a notebook or

settings sheet is to record the settings found from the test cutting
procedure.
Cut parts.
Auto
112
AVHC Mode
Importing Files & Cutting

The Torchmate 4 driver software will run G-code previously

created (such as that created in Torchmate CAD software), or
it will import any DXF file and convert this file to G-code.
DXF files can be created in most CAD design software. When

importing a DXF from Torchmate CAD, the cut order, tool
offset, and lead-ins are all created in the CAD software.
Using other design software is perfectly acceptable, but be

aware that some CAD software may not create cut order, tool
offsets, or lead-ins and these may need to be done manually.
To import a DXF file go to File u Import DXF and select the

file to import. When prompted, Save the G-code file created
from the DXF file. After the G-code is saved, the software will
open the import Configuration screen.
In the Import Configuration screen, changes can be made to

the file that affect how it will run. In most applications only
the XY Feedrate will need to be changed. The XY feedrate
specifies how fast the machine will cut a file.
In routing applications the Z-Axis Configuration will need to

be set for the incremental depth of cut, and final tool down
as explained in the routing test cut section.
Program Zero Location is generally left on Lower Left of

Toolpath. Other corners may be specified. X,Y of Import
File allows use of the coordinate system used in the CAD
Software that created the DXF as the program coordinate
system for the G-code.
113
Importing Files & Cutting

Once a DXF file is imported into the driver software, or

whenever a G-code file is opened, the machine is ready to
cut.
If test cutting has been done, the settings for the material are
in place.
The program coordinates only need to be zeroed at the lower

left of the parts, and then the file can be cut.
If at any time the machine must be stopped, press any key on

the keyboard to pause the program.
114
Pierce Counter

The Torchmate driver software can track the number of

pierces performed. When the plasma tool is selected, the
software records how many times the torch has been told to
fire.
You have to edit to a Macro file (a customizing set of

instructions is called a Macro), that way you are automatically
warned when the tip has exceeds 100 pierces.
Go to Configuration u Programming u M-Code Definitions

and select the Macro for Multi Tool Start. Add the line G161
in the following location. Click OK and OK again:
To change the life span of the tool, go to Configuration u

Tool u Tool Life Management on the menu. The warning
level may be set to any number depending on the kind of tip
used. The default is 100 pierces.
The Torchmate 4 Users Guide in the software provides

further information about each option and configuration
setting. This guide can be found by selecting Help u
Users Guide on the menu. It contains detailed technical
explanations of each option, and a full G-code reference
including the different types of G-codes accepted.
If you have any questions about the operation of the driver

software or about cut quality, or if you have any problems,
please contact Torchmate Technical Support.
IF #CURRTOOL = 0 THEN
M00 No Tool Selected
ELSEIF #CURRTOOL = 1 THEN
M50
M101 I1 No Pierce Signal From AVHC
G161

When you close the program later, youll be prompted to

save the .STP setup file. Be sure to save it to keep the Pierce
Counter enabled.
TECHNICAL SUPPORT
Toll Free: 1-866-571-1066 x3
Fax: 775-673-2206
If a tool or tip is changed, to reset the counter in the Output

Box, click the Replace button next to the counter.
115
Maintenance and Parts
115
Torchmate 2 Bolt-together Kit Maintenance and Parts
General Maintenance Procedures & Suggested Replacement Parts List

support@torchmate.com
Recommended Spare parts (For standard spare parts Kit, order
part number 03-0015-010A)
1. Spur Gears (400 hrs. estimated life on Long Axis, 800 hrs.
estimate life on Short Axis)
Part Number per Item: R/D - 24 Tooth Spur Gear
2. AVHC Spring Coupler/Lead Screw/Bronze Nut/Bearings (1000
hrs. estimated life with proper maintenance and oiling)
Part Number for Rebuild Kit: 03-0015-018A
3. Motor Cable(s). Replace as necessary due to cuts, pinches,
and burns. If Damage is found, specify number of cable
sections needed.
Part Number for single 25 section: 08-0005-025
4. Felt Wipers (replace as necessary due to drying out, being
broken off, or failing to clean the rails)
Part Number, quantity two per cassette, sold individually:
Origa Felt Wiper
5. Replacement Torch Mounting sleeve, or Torch head, in case
of damage. Part number depends on Torch model.
To purchase spare parts or consumables,

visit our website at:
Spare parts can be ordered by contacting the Torchmate

Support Department at 866-571-1066, x2
www.TorchmateStore.com
Consumable life & Plasma Cutter Maintenance

1. The life of consumable pieces depends on the type of Plasma
cutter, and the speed and height settings.
2. For Plasma Cutter maintenance guidelines and procedures,
consult the specific models user manual.
116
General Maintenance Procedures & Suggested Replacement Parts List (continued)

Cleaning & machine maintenance

5. Inspect the Cable Carrier system for any damage or strain on

the cables.
Once a day:
6. Re-check the square on the gantry and hard stops, to ensure

the gantry is still running true.
1. Blow off the machine, gears, and gear rack with compressed
air. Wipe off any water from the machine rails.
2. Check the gantry for square.
7. Check all CAM Followers to see that they are properly

supporting and guiding the gantry.
3. Check the pinion gear placement for proper engagement

with the gear rack. There should only be a small amount
of backlash (no more than 1/16) anywhere along the entire
length of the table.
8. Put a flat piece of material on the table, and square the torch
head to the material. If necessary, adjust the torch alignment in
both the X and Y dimensions to bring it back to perpendicular.
Once a week:
Grounding
1. Plasma Cutter to Material directly, or through solid metal
contact through the frame.
1. Lightly oil the machine rails with WD-40, 3-in-1, or a light

machine oil to keep them from rusting.
2. On High Frequency Plasma cutters, ground the table to a

dedicated earth ground. This ground needs to be checked
on occasion for quality. Please contact Torchmate Technical
Support for clarification on ground quality and testing
procedure.
2. Clean and then lightly oil the AVHC Lifter station lead screw
and bronze nut with 3-in-1 or a light machine oil only (do
NOT use WD-40 here).
3. Check the water level in table, and fill as necessary.

Once every other month:

1. Remove the cover from the Plasma cutter power supply, and
blow the power supply clean with compressed air.
2. Remove the cover from the Torchmate control box (with the
fan), and blow the control box clean with compressed air.
3. Remove the PC side cover, and blow the PC clean with
compressed air.
Torchmate Technical Support
4. Check the motor cable connections for any sign of wear,

or any pulling or snagging that may cause motor cable
connection failure.
866-571-1066 x3
support@torchmate.com
117
Basic Troubleshooting
118
Torchmate 2 Bolt-together Kit Basic Troubleshooting
Gear Spacing

Gear spacing is important to achieving the correct

movement of the machine.
If the gear is too far out of the gear rack, there will be
excessive backlash. This backlash will result in poor direction
changes, because the motors motion does not fully translate
into machine motion.
Set the gears so they fully engage the gear rack. Ordinally,
a papers thickness (0.004 in) between the gear and rack is
sufficient clearance.
When setting the gears on the drive shaft, ensure that they
are not supporting the weight of the gantry. All weight
should be supported by the cam followers.
Incorrect
Correct
119
Belt Tension

Improper belt tension can also cause poor motion and cuts.
If a belt is loose, then motion will not get transferred from the
small pulley to the large pulley.
Adjust the belt tension by loosening the four screws that

hold the motor to the mounting plate. The motor and small
pulley will now slide. With your hands, pull the motor as far
as you can. Hold it in this position as you tighten the four
screws again.
You should be unable to move one pulley without the other

one moving as well.
120
Loose Set Screws

If the table is going out of square, cuts are erratic, or motion

is not consistent, then there could be a loose set screw.
Set screws in the large pulley, small pulley, and drive shaft
ensure that motion from one component is efficiently
transferred to other components. If any of these become
loose, then the table may not operate correctly.
Set Screws
121
Bevel Basics

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. Because
of this, the arc has a direction of
rotation, which causes one side of
the cut to have more bevel than
the other side. To reduce the bevel
on the part, the proper direction of
travel must be used.
The direction of cuts are referred
to as conventional and climbing.
In a conventional cut, the torch will
go counter-clockwise on outside
cuts and clockwise on inside cuts.
A climbing cut is the opposite, and
the best bevel is achieved by using
a climbing cut.
Basically, the best bevel is to the
right of the direction of travel.
Conventional
Climbing
Corners can have more bevel than

a normal cut. This is caused when
the machine slows down for the
direction change. This can be
minimized by adjusting ramping
rates and start stop values. A
lower amperage, in some cases,
allows slower travel speeds and
reduces slowdown bevel through
corners.
Sharp corners can be achieved by

cutting a larger shape that puts
the slow down and acceleration of
the machine into a scrap area. This
cut is used more often on thicker
materials, where the corner bevel
is increased dramatically.
Replace consumables regularly

to reduce bevel. A worn tip
or one with slag buildup, can
redirect air flow causing random
bevel and varying cut quality.
Always check consumables when
troubleshooting bevel.
One of the easiest ways to reduce

bevel is by cutting at the proper
speed and height for the material
and amperage.
Air that is at constant pressure

and clean and dry also decreases
bevel.
122
How TorchCorrect
Position
Affects Bevel
torch height
Torch angled to material
Torch
square
material Torch angled to material
Correct
torchto
height
Torch square to material

Torch too
high
Incorrect
torch
height
Torch too high

Torchtorch
too low
Incorrect
height
Torch too low
Excessive bevel
Reversed bevel
Excesive bevel
Reversed bevel
Position of
ion of torch
torch while
ile cutting cutting
Bevel of
l of finished
part
finished
part

Minimal bevel
Unequal bevel
Unequal bevel
One side may be straight

One side may
be straight
the another
excessively
bevanother
excesively
beveled
Longest consumable life
eled
Minimal bevel angle
Optimal consumable life
Can be caused by a worn tip
Cut may not go all the

way
through
Cut
may not material
go all
the way through
Torch may contact mateTorch

may out
contact
rial and
short
or dammaterial
and
short
age tip out
or damage tip
Can be caused by worn tip
123
What Causes Bad Cuts

Instances where the metal was not fully cut indicate a few
different problems:
1) Ground clamp not properly attached to the material
2) Air pressure drop or surge
3) Moisture in the air line
4) Drop in power
5) Contact with the material by the torch
(Most plasma cutters go into a low power mode on contacting
the material, causing the cut to not fully penetrate the material).
When the machine begins to move before a pierce is completed,

the cut will not complete. In this case the dwell time or Pierce
Delay must be adjusted to allow for enough time to pierce the
material.
When a cuts the path does not return to the start point, there may
be mechanical slipping or binding. In some cases it will be clear
which axis is losing position. Examine the particular axis for build
up, or obstructions that can cause binding.
124

Torchmate 2 Bolt Together Assembly Instructions

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Torchmate 2

Torchmate Inc. 2012-2013

Torchmate 2 Bolt-together Kit Assembly Instructions

Step 21: Add gantry arm to gantry support . . . . . . . . . . . . . . . . . . . .31

Torchmate 2 Bolt-together Kit Assembly Instructions

Basic Driver Software Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Plasma with Manual Height Control . . . . . . . . . . . . . . . . . . . . . . . . .68

Raw Arc Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . 74

Maintenance and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

Torchmate 2 Bolt-together Kit Assembly Instructions

This manual is written to make assembly of

To view this video internet access is required.

Bill Kunz, CEO

Torchmate 2 Bolt-together Kit Assembly Instructions

Click on a section link below

Quick Link Contents

Raw arc voltage

Software Setup and Operation

Table and Gantry Assembly

10 Input Cable lines 1 & 2 are

CUTMASTER 52 & 82 VOLTAGE POINTS

How torch position affects bevel

Correct torch height

Raw Arc Voltage Connection

Incorrect torch height

Incorrect torch height

Bevel of finished part

Minimal bevel angle

One side may be straight

Cut may not go all

Torch may contact

Optimal consumable life

Can be caused by a worn tip

Torchmate 2 Bolt-together Kit Assembly Instructions

Torchmate 2 Supplied Parts List

Torchmate 2 Bolt-together Kit Assembly Instructions

Gantry Supplied Parts List

Table cutting width +131/2

Same size for all table sizes.

Torchmate 2 Bolt-together Kit Assembly Instructions

Gantry Supplied Parts List

1/2 Mounting Plate

5/16 Shaft Collar

X-Axis Motor Mount

Spur Gear Pressed on

Y-Axis Motor Mount

Drive Shaft Support

48 Tooth Large Pulley

Timing Pulley (Large)

Torchmate 2 Bolt-together Kit Assembly Instructions

Gantry Supplied Parts List

14 Tooth Small Pulley

380 oz in. Stepper

Timing Pulley (Small)

/16-20 Hex Nut

/16 SAE Flat Washer

#8 SAE Flat Washer

M10 Flat Washer

Torchmate 2 Bolt-together Kit Assembly Instructions

Gantry Supplied Parts List

#8-32 Hex Nut

12 Hole Tee Joining

5/16 SAE Flat Washer