Vision 50P CNC and Interface Box

m3 G2 Plasma System

Operator's Manual (EN)

0558008526 02/2012
 Be sure this information reaches the operator.
You can get extra copies through your supplier.

caution
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions be-
fore installing or operating this equipment.

USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-
vice facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

 table of contents

Section / Title Page

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.0 Vision 50P CNC with Interface Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Vision 50P CNC (0558008253) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Vision 50P CNC Interface Box (0558008250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Plasma Process Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Vision 50P CNC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.5 Operation without Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.6 Sequence of Operation without Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.7 Operation with Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.8 Sequence of Operation with Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.9 Cutting Holes With Plasma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
table of contents

4
section 1 safety precautions
1.0 Safety Precautions
WARNING: These Safety Precautions are
for your protection. They summarize pre-
cautionary information from the references
listed in Additional Safety Information sec-
tion. Before performing any installation or operating
procedures, be sure to read and follow the safety precau-
tions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield fitted with the correct filter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating
or observing operations. Warn bystanders not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-
sleeve shirt, cuffless trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A flameproof apron may also be desirable as protec-
tion against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-flammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety
glasses.
5
1.1 Safety - English
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot
slag or sparks can also cause fires and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protec-
tive non-flammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hid-
den smoldering fire or fires on the floor below. Make
certain that such openings are protected from hot
sparks and metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might
produce flammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable fire extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For ex-
ample, overloaded welding cable can overheat and
create a fire hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later fire. Use fire watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA
02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is confined, or if there is
danger of falling.
section 1 safety precautions
1. Be sure the power source frame (chassis) is con-
nected to the ground system of the input power.
2. Connect the workpiece to a good electrical
ground.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specific grounding recommenda-
tions. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur-
rent flowing through any conduc-
tor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health effects which
are unknown.
6
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the workpiece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stain-
less steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat ir-
ritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discom-
fort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
section 1 safety precautions
5. WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
§25249.5 et seq.)
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and vio-
lently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and fittings in good
condition. Follow manufacturer's operating instruc-
tions for mounting regulator to a compressed gas
cylinder.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar-
riages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures where they may
become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
7
1. Always have qualified personnel perform the instal-
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualified to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equip-
ment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
section 1 safety precautions

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held
Hazardous Substances."

Meaning of symbols - As used

throughout this manual: Means Atten-
tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-
mediate, serious personal injury
or loss of life.

Means potential hazards which

could result in personal injury or
loss of life.

Means hazards which could result

in minor personal injury.

8
secCION 1 sEGURIDAD
1.2 Safety - Spanish
ADVERTENCIA: Estas Precauciones de Se-
guridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas en la sección "Información Adi-
cional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.
PROTEJASE USTED Y A LOS DEMAS--
Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco,
como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden dañar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados
siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.
2. Use una careta que tenga el filtro correcto y lente
para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las per-
sonas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.
4. Chispas y partículas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chis-
pas calientes con una cortina adecuada no-flamable
como división.
6. Use careta protectora además de sus gafas de segu-
ridad cuando esté removiendo escoria o puliendo.
9
La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de
las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases flamables, solventes,
pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo esté to-
talmente limpia y libre de substancias que puedan
producir gases inflamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inflamables.
4. Tenga siempre a la mano equipo extintor de fu-
ego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.
5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspec-
cione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas
y tierra puede causar daño severo o
muerte. NO use soldadura de corri-
ente alterna (AC) en áreas húmedas,
de movimiento confinado en lugares estrechos o
si hay posibilidad de caer al suelo.
secCion 1 sEGURIDAD
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condi-
ciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mien-
tras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones específicas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETI-
COS - Son peligrosos. La corriente
eléctrica fluye através de cualquier
conductor causando a nivel local
Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.
2. Exponerse a campos electromagnéticos (EMF) puede
causar otros efectos de salud aún desconocidos.
10
3. Los soldadores deberán usar los siguientes proced-
imientos para minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo
lo más cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo
o gases. El gas de protección puede
causar falta de oxígeno.
Por lo tanto:
1. Siempre provea ventilación adecuada en el área
de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cad-
mio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique sub-
stancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de
ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico per-
siste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomen-
daciones específicas en la ventilación.
secCion 1 sEGURIDAD
5. ADVERTENCIA-- Este producto cuando se uti-
liza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos menos que usted esté cualificado para hacer el
conocidos por el Estado de Cali-
fornia de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romp-
erse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adapta-
dores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablil-
leros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.
3. Cuando el cilindro no está en uso, mantenga la
válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
11
1. Siempre tenga personal cualificado para efec-
tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.
6. Use el equipo sólo para el propósito que fue
diseñado. No modifique el equipo en ninguna
manera.
INFORMACION ADICIONAL DE SEGURI-
DAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
secCion 1 sEGURIDAD

SIGNIFICADO DE LOS sImbolOs

-- Según usted avanza en la lectura
de este folleto: Los Símbolos Sig-
nifican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.

Significa riesgo inmediato que,

de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.

Significa el riesgo de un peligro

potencial que puede resultar en
serio daño personal o la muerte.

Significa el posible riesgo que

puede resultar en menores daños
a la persona.

12
section 1 sÉCURITÉ
1.3 Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution
provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurez-
vous de lire et de suivre les précautions de sécurité ci-
dessous, dans les manuels, les fiches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans la-
téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.
2. Portez un écran facial muni de verres filtrants et de
plaques protectrices appropriées afin de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas re-
garder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise
épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes afin de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé
de porter un tablier ininflammable afin de vous proté-
ger des étincelles et de la chaleur par rayonnement.
4. Les étincelles et les projections de métal incandescent
risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recom-
mandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des
étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininflammable.
6. Portez des lunettes étanches par dessus vos lunettes
de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
Les personnes se trouvant à proximité doivent égale-
ment porter des lunettes étanches par dessus leur
lunettes de sécurité.
13
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des flammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
1. Éloignez suffisamment tous les matériaux combus-
tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les
matériaux combustibles incluent le bois, les vête-
ments, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.
2. Les étincelles et les projections de métal incan-
descent peuvent tomber dans les fissures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.
3. N'exécutez pas de soudure, de coupe ou autre tra-
vail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inflammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.
4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.
5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauffer et provoquer un in-
cendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projec-
tion de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-
telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
section 1 sÉCURITÉ
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de
terre électrique.
3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion afin d'éviter le risque
de choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endom-
magés. côté de votre corps.
5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porte-
électrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.
7. Si vous devez effectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directe-
ment sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spécifiques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉ-
TIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conduc-
teur produit des champs électriques
et magnétiques localisés. Le soudage et le cou-
rant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour cer-
tains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magné-
tiques peut avoir des effets néfastes inconnus pour
la santé.
14
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A. Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
D. Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne re-
spirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventila-
tion naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation efficaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'effectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lor-
sque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ven-
tilation n'est pas adéquate. Cessez votre travail afin
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spécifiques
concernant la ventilation.
section 1 sÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe-

dans une opération de soudage ou de ment entretenu de façon défectueuse ou
coupage, dégage des vapeurs ou des inadéquate peut causer des blessures
gaz contenant des chimiques consid- graves ou mortelles. Par conséquent :
éres par l'état de la Californie comme
1. Efforcez-vous de toujours confier les tâches
étant une cause des malformations
d'installation, de dépannage et d'entretien à un
congénitales et dans certains cas, du
personnel qualifié. N'effectuez aucune réparation
cancer. (California Health & Safety
électrique à moins d'être qualifié à cet effet.
Code §25249.5 et seq.)
2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
MANIPULATION DES CYLINDRES --
l'alimentation électrique.
La manipulation d'un cylindre, sans
3. Maintenez les câbles, les fils de mise à la terre,
observer les précautions nécessaires,
les branchements, le cordon d'alimentation et la
peut produire des fissures et un
source d'alimentation en bon état. N'utilisez ja-
échappement dangereux des gaz.
mais un équipement s'il présente une défectuosité
Une brisure soudaine du cylindre, de la soupape ou
quelconque.
du dispositif de surpression peut causer des bles-
4. N'utilisez pas l'équipement de façon abusive. Gardez
sures graves ou mortelles. Par conséquent :
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des flaques
1. Utilisez toujours le gaz prévu pour une opération
d'eau, de l'huile ou de la graisse, des atmosphères
et le détendeur approprié conçu pour utilisation
corrosives et des intempéries.
sur les cylindres de gaz comprimé. N'utilisez jamais
5. Laissez en place tous les dispositifs de sécurité et
d'adaptateur. Maintenez en bon état les tuyaux et
tous les panneaux de la console et maintenez-les
les raccords. Observez les instructions d'opération
en bon état.
du fabricant pour assembler le détendeur sur un
6. Utilisez l'équipement conformément à son usage
cylindre de gaz comprimé.
prévu et n'effectuez aucune modification.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
INFORMATIONS SUPPLÉMENTAIRES RELA-
une colonne ou un support convenable. Ne fixez
TIVES À LA SÉCURITÉ -- Pour obtenir de
jamais un cylindre à un poste de travail ou toute autre
l'information supplémentaire sur les règles
dispositif faisant partie d'un circuit électrique.
de sécurité à observer pour l'équipement
3. Lorsque les cylindres ne servent pas, gardez les
de soudage à l'arc électrique et le coupage,
soupapes fermées. Si le détendeur n'est pas bran-
demandez un exemplaire du livret "Precau-
ché, assurez-vous que le bouchon de protection de
tions and Safe Practices for Arc Welding,
la soupape est bien en place. Fixez et déplacez les
Cutting and Gouging", Form 52-529.
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée
Les publications suivantes sont également recomman-
de toute source de chaleur, des étincelles et des
dées et mises à votre disposition par l'American Welding
flammes. Ne jamais amorcer l'arc sur un cylindre.
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
5. Pour de l'information supplémentaire, consultez
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
CGA Standard P-1, "Precautions for Safe Handling
2. AWS C5.1 - "Recommended Practices for Plasma Arc
of Compressed Gases in Cylinders", mis à votre dis-
Welding"
position par le Compressed Gas Association, 1235
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Jefferson Davis Highway, Arlington, VA 22202.
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

15
section 1 sÉCURITÉ

SIGNIFICATION DES SYMBOLES

Ce symbole, utilisé partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.

DANGER

Signifie un danger immédiat. La situation peut

entraîner des blessures graves ou mortelles.

AVERTISSEMENT
Signifie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.

ATTENTION
Signifie un danger qui peut entraîner des blessures
corporelles mineures.

16
section 2 VISION 50P cnc WITH interface BOX

2.0 Vision 50P CNC with Interface Box

The m3-CAN Plasma System consists of several components: Vision 50P, Interface Box (or CAN Hub), Shield Gas
Box, Plasma Gas Box, Remote Arc Starter (RAS), Power Supply, Coolant Circulator, Torch, Lifter (optional), and
customer CNC.

External CNC Component Locator Designation

( Digital I/O ) (See following pages for component illustrations)

Remote
Arc
Starter
CAN (RAS)
J

B AHC/Lift Power Cable

I AHC / Lift
Vision 50P H CAN ( Optional )
Control
Interface Gas Controls Power Cable
G Shield Gas
C CAN
F Control
E
D

CAN CAN Plasma

Gas Control
K
Vision 50P
CNC

External Power
120V / 3A without AHC
230V / 3A with AHC

Vision 50P CNC and Interface Box Component Locator Designations

17
section 2 VISION 50P cnc WITH interface BOX

2.1 Vision 50P CNC (0558008253)

Vision 50P is a touch-screen based CNC used to control plasma cutting and marking process, gas control, cur-
rent control and sequence control. However it has no function related to machine movement. Vision 50P is a
PC-based operating panel for controlling peripheral components with ACON protocol. Vision 50P has a 8,4” VGA
TFT-Display with touch control and a incremental potentiometer with push button for navigation and acknowl-
edgement and a key switch for authorization management. The CAN-Bus and power supply is connected via
a 8 pin CAN connector. Vision 50P provides an additional Ethernet and USB interface for communication and
maintenance.

9.25”
(235.0 mm)

Weight:
10 lbs. (4.5 kg)
Vision 50P case is 4.62” (117.5 mm) wide. It is
12.75” 5.12” (130.2 mm) wide if you include knob on
(323.9 mm) the front panel

Vision 50P can run under two different modes: Operation Mode or Service Mode. The default mode is Operation
Mode and allows the operator to conduct all necessary operations. Service Mode is needed for service, such as
update station constant, diagnosis, etc. Some process parameters are displayed only under Service Mode. Ser-
vice Mode can be activated if a USB keyboard is plugged in or the key is turned to ‘0’ position.

In the front panel, there is a incremental potentiometer. If the operator does not have a keyboard, the two input
devices for Vision 50P are the incremental potentiometer and the touch screen. With this incremental poten-
tiometer, the operator can scroll down/up to another parameter. While pressing it down, the operator can also
change the value of that parameter.

18
 relate
centra
section 2 VISION 50P cnc WITH interface BOXignitio

2.1 Vision 50P CNC (0558008253) (con’t.)

The A
Vision 50 has three ports on the back panel: CAN+Power, USB and Internet Port. CAN is always used for com-
move
munication and also 24VDC power to 50P. USB is used for keyboard, USB stick, etc. Internet Port is used only for
service.
the fu
CAN-Bus and Power Supply
Pin #
1 (White)
Name
Not Used
The S
LAN 2 (Brown) Not Used as a g
K
3 (Pink)
4 (Yellow)
CAN GND
CAN-H Out
third
USB 5 (Grey) CAN-L Out pin st
6 (Green) CAN GND
7 (Blue) +24VDC
POWER +
CAN 8 (Red) DC COM
Unit
Each device contains two address switches. The combination of these switches identify the station and substa-
tions on the CAN Bus. Switch 1 designates the station number. Switch 2 designates the substations.
ACON
switch
a unit
rotary
statio

m3 CAN Plasma System

S1 S2 Device
1 - 12 0 MCU – B4 / A6 Lift Assembly
1 - 12 1 Shield Gas Box Fun
1 - 12 2 Plasma Gas Box
1 - 12
1 - 12
3
4
Remote Arc Starter (RAS) Box
Interface Box
Stat
1 - 12 5 Water Injection Box

19
Stat
section 2 VISION 50P cnc WITH interface BOX

2.1 Vision 50P CNC (0558008253) (con’t.)

Operating Conditions:

Operating Temperature: 5 - 50°C

Max. Humidity: 95%
Enclosure Degree of Protection: IP54
Power Supply: 24V +/- 20%

CAUTION
Hole in mounting plate allows proper 3.74”
cooling air circulation through Vision (95mm)
50P. Do not block opening or heat relat-
ed damage may occur. 1.87”
(47.5mm)

0.274”
(6.96mm)

Replacement Parts
It is recommended that customers contact Technical
Support before attempting repairs on these units.
Item 1.69”
Description ESAB PN (43mm)
No.
Complete control with all 0.79”
1 components excluding 0558008728 (20mm)
cabinet
2 Potentiometer 0558008729 1.57”
(40mm)

Vision 50P CNC Mounting Hole Locations

(Bottom View)

20
section 2 VISION 50P cnc WITH interface BOX

2.2 Vision 50P CNC Interface Box (0558008250)

I G Power
Switch PIN Function
A Fault
B Motion Enable
C CNC COM
D Mark Mode
E Cycle Start
F Corner / IHS
G ENC_0 / ARC_1
H Station On
J +24 VDC
K Station Down
L Station Up
D H F E J CAN Cable M Digital Out 9
( P1 ) N Digital Out 11
( One Plasma Station with AHC shown )
P 24 DC COM
R Gas Error
S AHC Error
B ( J3 )
Weight: 19-Pin T Up Limit SW
ID Switch
10.1 lbs. (4.6 kg) U Down Limit SW
J5
Interface Box case is 6.00” (152.4 mm) wide. It is V Digital Out 8
8.50” (215.9 mm) wide if you include the fittings on 14-Pin
front and back

7.50”
C (190.5 mm)

Note:
Chassis must be
connected to the
machine ground.
10.75”
GND (273.1 mm) 12.75”
(323.9 mm)

21
section 2 VISION 50P cnc WITH interface BOX

2.2 Vision 50P CNC Interface Box Mounting Holes

11.50”
(292.1 mm)

3.00”
(76.2 mm)

 0.281”
(7.14 mm)

22
section 2 VISION 50P cnc WITH interface BOX

2.2 Vision 50P CNC Interface Box (0558008250) (con’t.)

One Plasma with AHC One Plasma no AHC

CAN # Function CAN # Function
1 Not used 1 Not used
2 Plasma Control Unit 2 Not used
3 * AHC / Lift 3 Plasma Control Unit
4 * Shield Gas Control 4 * Shield Gas Control
5 * Plasma Gas Control 5 * Plasma Gas Control
6 * Arc Starter 6 * Arc Starter
7 * Interface 7 * Interface

Two Plasma with AHC Two Plasma no AHC

CAN # Function CAN # Function
1 Plasma Control Unit 1 Not used
2 * AHC / Lift 2 Plasma Control Unit
3 * Shield Gas Control 3 * Shield Gas Control
4 * Plasma Gas Control 4 * Plasma Gas Control
5 * Arc Starter 5 * Arc Starter
6 * Interface 6 * Interface
7 Crossover 7 Crossover

Two Plasma with AHC Two Plasma no AHC

CAN # Function CAN # Function
1 Not used 1 Not used
2 Crossover 2 Not used
3 * AHC / Lift #2 3 Crossover
4 * Shield Gas Control #2 4 * Shield Gas Control #2
5 * Plasma Gas Control #2 5 * Plasma Gas Control #2
6 * Arc Starter #2 6 * Arc Starter #2
7 * Interface #2 7 * Interface #2

* These components can be connected in any order. Refer to enclosed diagrams.

23
section 2 VISION 50P cnc WITH interface BOX

2.2 Vision 50P CNC Interface Box (0558008250) (con’t.)

One Plasma Station with AHC

ID Switch: S1 = 1, S2 = 4
INTERFACE BOX

Two Plasma Stations with AHC

ID Switch: S1 = 1, S2 = 4 ID Switch: S1 = 2, S2 = 4
INTERFACE BOX INTERFACE BOX

CROSS-OVER CABLE

NOTE:
This cable is only used with
a Vision 50P to connect the
second Interface Box.

24
section 2 VISION 50P cnc WITH interface BOX

2.2 Vision 50P CNC Interface Box (0558008250) (con’t.)

One Plasma Station without AHC

ID Switch: S1 = 1, S2 = 4
INTERFACE BOX

Two Plasma Stations without AHC

ID Switch: S1 = 1, S2 = 4 ID Switch: S1 = 2, S2 = 4
INTERFACE BOX INTERFACE BOX

CROSS-OVER CABLE

NOTE:
This cable is only used with
a Vision 50P to connect the
second Interface Box.

25
section 2 VISION 50P cnc WITH interface BOX

Connector J3 on Interface Box (0558008250)

PIN (Wire# ) Signal Function

1. Signal output from Interface Box.
2. Errors, such as gas error, power supply error, and coolant error, will
A Fault activate (high) this Fault signal.
(# 1) (PCUA X63-2) 3. Once Fault signal is high, Vision 50P will stop the plasma, and re-
move ‘Motion Enable’, then the customer CNC needs to remove
‘Cycle Start’ signal.
1. Signal output from Interface Box to Customer CNC.
2. This signal is selectable among “Motion Enable”, “Arc On”, or “Arc
On After Piercing Delay” depending on the station constant # 214
in SPS.KON.
3. “Motion Enable” becomes activated after the piercing delay. Cus-
B Motion Allowed
tomer CNC can move the torch when ‘Motion Enable’ is TRUE af-
(# 2) (PCUA X62-2)
ter the cycle starts. Be sure to check this signal during cutting and
marking. Once it turns FALSE, “Cycle Start” must be removed.
4. “Arc On": becomes activated immediately after the main arc is ON.
5. “Arc On After Piercing Delay” become activated after the piercing
delay is done and the arc must be ON.
1. Provided by customer CNC. This will affect the signal level of “Fault”
C CNC COM and “Motion Enable”.
(# 3) (PCUA X63-1 and X62-1) 2. Depending on the signal level of Customer CNC, it can be AC or DC.
Max 130VAC/3A or 30VDC/3A.
D Mark Mode 1. Selects marking (1) or cutting (0) mode.
(# 4) (PCUA X61-4) 2. Signal level is 24VDC.
1. Activates the plasma system.
2. Remove ‘Cycle Start’ signal at the end of geometric motion during
E normal marking/cutting.
Cycle Start (PCUA X61-1)
(# 5) 3. During hole-cutting, CNC should remove ‘Cycle Start’ before the
end of geometry in order to improve the roundness and overall
quality.
1. During cutting this signal acts as "corner" signal; before cutting it
acts as "IHS".
2. Corner prevents torch from diving down when the machine slows
down in the geometry corner or at the start/end of line if arc volt-
age mode is selected.
3. A False Corner signal (0) means CNC is moving at a constant cutting
speed. A True Corner Signal (1) means CNC is approaching corner,
F Corner / IHS and AHC will be blocked.
(# 6) (PCUA X60-4) 4. When a constant speed is reached, remove the ‘Corner’ signal to
activate automatic height control. At corner or anytime the ma-
chine slows down, the ‘Corner’ signal must be ON to prevent
torch from diving inside corners.
5. Customer CNC must provide this signal if AHC function from Vision
50P is used.
6. "IHS" signal will turn on / off gas pre-flow if AHC from Vision 50P
is not used.
1. Selects height control mode: Encoder (FALSE) or Arc Voltage
G ENC_0 / VOLT_1
(True).
(# 7) (PCUA X60-1)
2. Encoder height control is useful during hole-cutting.

26
section 2 VISION 50P cnc WITH interface BOX

2.2 Vision 50P CNC Interface Box (0558008250) (con’t.)

Connector J3 on Interface Box (0558008250)

PIN (Wire# ) Signal Function

1. Turns ON/OFF the station.
2. Customer can also turn ON/OFF the station from Vision 50P. The
H Station Select
last action, either from Customer CNC or Vision 50P, will control
(# 8) (PCUA X48-1)
the status ON/OFF.
3. It is not time sensitive.
1. 24VDC supplied to Customer CNC.
J +24VDC
2. Customer CNC will use this signal to provide Digital Inputs for In-
(# 9) (PCUA X48-2)
terface Box.
K Station Down 1. Moves down the torch.
(# 10) (PCUA X48-4) 2. It is not time sensitive.
L Station Up 1. Moves up the torch.
(# 11) (PCUA X49-1) 2. It is not time sensitive.
M Digital Out 9
1. Digital Out 9
(# 12) (PCUA X66-2)
N Digital Out 11
1. Digital Out 11
(# 13) (PCUA X66-5)
P 24VDC COM 1. 24VDC COM.
(# 14) (PCUA X40-2) 2. For production testing only.
R Gas Error 1. Indicates fault in gas / water flow.
(# 15) (PCUA X62-5) 2. Fault (Pin A) must be high.
S AHC Error 1. Indicates fault from AHC.
(# 16) (PCUA X63-5) 2. Fault (Pin A) must be high.
T Up Limit SW
1. Lifter is in up limit position
(# 17) (PCUA X65-2)
U Down Limit SW
1. Lifter is in down limit position
(# 18) (PCUA X64-5)
V Digital Out 8
1. Digital Out 8
(# 19) (PCUA X65-5)

For underwater cutting without air curtain, customer can enable additional pre-flow by setting the station con-
stant #213 in SPS.KON.

27
section 2 VISION 50P cnc WITH interface BOX

2.3 Plasma Process Parameters

The following parameters are used in the m3 CAN plasma system. Some of them are displayed only in Service
Mode but hidden in Operation Mode.
Parameters Description Hidden
Specifies gas type for plasma start, cut, and shield gases. See table
Gas Selection No
below for details for gas selection.
Sets appropriate Pilot Arc Current. ONLY FOR EPP-201 AND EPP-
Pilot Arc Yes
360.
Specifies arc voltage used during plasma cutting and marking. This
Main Arc Voltage setting is important because it controls the torch height if there is no No
encoder height control.
Predicted measurement of material removed during cutting process.
Kerf It is the gap between production part and plate. Cutting speed, No
torch standoff (arc voltage), and cutting current will affect kerf.
Recommended travel speed for requested cutting condition. Usu-
Travel Speed No
ally reduced for small holes.
Plate Thickness Used in calculating the slowdown height. No
Ignition Height Distance from torch to plate during pilot start sequence. No
Distance from torch to plate during piercing sequence. Enough
piercing height to avoid torch contact with the molten spatter which
Piercing Height No
can damage the shield and/or nozzle which will in turn, diminish
hole quality.
Distance from torch to plate during cutting. Used during encoder
height control with ESAB lifts; otherwise, it is a reference height for
Cutting Height No
OEM lifters. Maintaining this height during the cutting cycle is very
important.
Time for the plasma torch to stay at piercing height. Optimized to
Piercing Time ensure the torch is at the correct height and the arc is stable before No
the lead in starts.
Time delay of height control activation to allow torch to enter part
Lead-in Time pattern. Optimized to ensure the torch is at the correct height and Yes
the arc is stable before the lead in starts.
THC Delay After Corner Time before the voltage height control reactivates after corner. Yes
Raise Torch When Finished Time before raising the torch after cutting finished. Yes
PG1 Start Pressure
Plasma Gas 1 Start pressure. Yes
(ARG, H35, N2/O2/AIR)
PG1 Cut Pressure
Plasma Gas 1 Cut pressure. Yes
(ARG, H35, N2/O2/AIR)
PG2 Start Pressure (O2/N2/AIR) Plasma Gas 2 Start pressure. Yes
PG2 Cut Pressure (O2/N2/AIR) Plasma Gas 2 Cut pressure. Yes
SG1 Start Flow (AIR/N2) Shield Gas 1 Start flow. Yes
SG1 Cut Flow (AIR/N2) Shield Gas 1 Cut flow. Yes
SG2 Start Flow (O2/CH4) Shield Gas 2 Start flow. Yes
SG2 Cut Flow (O2/CH4) Shield Gas 2 Cut flow. Yes
28
section 2 VISION 50P cnc WITH interface BOX

2.3 Plasma Process Parameters (con't.)

Plasma Process Parameters

Parameters Description Hidden
Current used after an arc is established with a pilot. This value is typi-
Current Start Value cally as low as half the actual cutting current, so be sure to allow for No
enough time to get to full cutting current before starting motion.
Current Current used forused
cutting.
for Sometimes
cutting. this value can be reduced to en-
Current Value Value Current No No
Current Off Value hance the hole quality further.
Current used when cutting is done. No
Current before
Time the arc
needs for iscutting
turnedcurrent
off. Thistosetting
ramp influences
up from the lead
Current
Current OffRamp
Value Up Timeout ofCurrent
the hole.Start
The Value
higher totheCurrent
value, the Yes No
Value. gouging occurs. A
more
lower setting can help enhance lead out quality.
Time needs for cutting current to ramp down from
Current Ramp Down Time Time needs for cutting current to ramp from Current Start Value Yes
Current Value to Current Off up
Value. to
Current Ramp Up Time Current Value. On very thin material this time
Time delay to shut down gases after the cutting must be minimized or Yes
Gas Off Delay the arc will go out due to lack of material Yes
current starts ramping down.
Time needs
Plasma forstation
cuttingnumber
current to ramp
from down
1 to 12. from
UsedCurrent
to Value to
Current Ramp Station
Plasma Down TimeNumberCurrent Off Value. Yes Yes
diagnose and monitor the process.
Quality Time delay to shut down gases after the cutting current starts ramp-
Gas Off Type
Delay or Marking Yes Yes
Material Type ing down.
Carbon Steel, Stainless, or Aluminum. Yes
Nozzle Code PlasmaCode
stationto number
identifyfrom 1 to 12.
different Used for process diagnosis and
nozzle. Yes Yes
Plasma Station Number
Water Flow monitoring.
Cut water flow for waterinjection only. Yes
Nozzle Code Code to identify different nozzle. Yes
Water Flow Cut water flow for water injection only. Yes

Current
Value

Current
Start Value
Current
Gas Off Value
AMPERES

Pressure

TIME

Current Ramp
Up Time Gas Off
Delay Current Ramp
Down Time
Graph is for illustration only. Values are not
necessarily in proportion.
29
Page 47 0558008034 Plasma Vision 5x Process_v2_011107.pdf
section 2 VISION 50P cnc WITH interface BOX

2.3 Plasma Process Parameters (con't.)

Gas Selection, m3 CAN Plasma

GS GAS TYPE SG-SG1 SG-SG2 SG-PG1 SG-PG2 PG-PG1 PG-PG2

GS_N2_O2_N2O2 1 2 2 1 3 1
1
(PG1 START, PG2 CUT) N2 O2 N2 O2 N2/O2/AIR O2
GS_AIR_O2_AIRO2 2 2 3 1 3 1
2
(PG1 START, PG2 CUT) AIR O2 AIR O2 N2/O2/AIR O2
GS_N2_N2_N2CH4 1 1 2 2 3 2
3
(N2-PG2 START, N2-PG2 CUT) N2 CH4 N2 N2 N2/O2/AIR N2
GS_N2_H35_AIR 2 - 2 2 2 2
4
(PG2 START, PG1 CUT) AIR N2 N2 H35 N2
GS_N2_H35_N2CH4 1 1 2 2 2 2
5
(PG2 START, PG1 CUT) N2 CH4 N2 N2 H35 N2
GS_ARG_ARG_AIR 2 - 2 1 1 1
6
(PG1 START, PG1 CUT) AIR N2 O2 ARG O2
GS_ARG_ARG_N2 1 - 2 1 1 1
7
(PG1 START, PG1 CUT) N2 N2 O2 ARG O2
GS_AIR_AIR_AIR 2 - 3 3 3 3
8
(PG2 START, PG2 CUT) N2 N2 O2 N2/O2/AIR O2
GS_N2_O2_AIR 1 - 2 1 3 1
9
(PG1 START, PG2 CUT) AIR N2 O2 N2/O2/AIR O2
GS_N2_N2_AIR 2 - 2 2 3 2
10
(PG2 START, PG2 CUT) AIR N2 N2 N2/O2/AIR N2
GS_ARG_O2_N2O2 1 2 2 1 1 1
11
(PG1 START, PG2 CUT) N2 O2 N2 O2 ARG O2
GS_ARG_O2_AIRO2 2 - 2 1 1 1
12
(PG1 START, PG2 CUT) AIR N2 O2 ARG O2
GS_ARG_ARG_H2O 1 1
13
(PG1 START, PG2 CUT) ARG ARG
GS_N2_N2_H2O 2 2 3 2
14
(PG1 START, PG2 CUT) N2 N2 N2 N2

30
section 2 VISION 50P cnc WITH interface BOX

2.4 Vision 50P CNC Operation

Each time the Vision 50P is powered on, the process screen will be loaded as Figure 2.1.

NOTE:
All of the screen shots that follow were taken under "Service" mode.

Figure 2.1 Process Screen

Before pressing the "START" button or F7, the operator needs to make sure the right TDF file is being
used. The TDF file contains important cutting data and parameters. Cutting processes and Marking processes
have separate TDF files. To select the right TDF file, press the button or F8 to switch to the technol-
ogy data screen shown in Figure 2.2.

31
section 2 VISION 50P cnc WITH interface BOX

On the top of technology data screen, the current TDF selected will be displayed. Press F5 or
to change the TDF file. As shown in Figure 2.3, the customer can choose Quality, Materials, Current, Thickness,
and Gas Type. ESAB’s TDF filename has a predefined format. If needed, the customer can have user-defined ex-
tensions for TDF files. At the lower part of the screen, the needed consumables for the selected TDF or process
are listed and illuminated with pictures.

Figure 2.2 Technology Data Screen

32
section 2 VISION 50P cnc WITH interface BOX

To select the TDF file for plasma marking, press F2 or . The “Plasma Marking” will be high lighted in
green as shown in Figure 2.4. Press F2 again to switch back to "Plasma Cutting". For marking, the customer can
select Materials, Current, Thickness, Gas Type, etc. Again, the consumables necessary to perform the selected
marking process will be displayed. This can help the customer select the right consumables.

Figure 2.3 Cutting TDF File Selection

33
section 2 VISION 50P cnc WITH interface BOX

Figure 2.4 Marking TDF Selection

Press F1 or to confirm the selection. Press F8 or to cancel the selection. Then Vision 50P
will go back to technology data screen again as Figure 2.5.

34
section 2 VISION 50P cnc WITH interface BOX

Figure 2.5 Technology Data Screen

Press ESC button , it will switch to Process Screen as in Figure 2.6. If everything is setup, pressing
button or F7 will start cutting or marking. Process status will be displayed on the screen, such as En-

coder Height, Lift Position, Arc Voltage, Cutting Current, PG Output Pressure, PG2 Flow, SG1 Flow, SG2 Flow, PG1
Pressure, PG2 Pressure, SG Mix Pressure, Required PG Flow and cut water flow, cut water pressure. All the above
statuses can be viewed by pressing button or F1. If the button is not shown, press F9 or

and scroll down to next page as in Figure 2.7.

35
section 2 VISION 50P cnc WITH interface BOX

Figure 2.6 Process Screen

36
section 2 VISION 50P cnc WITH interface BOX

Figure 2.7 Process Screen

37
section 2 VISION 50P cnc WITH interface BOX

Below are some advanced features available to the service engineer, but rarely used by the customer. These
features can only be accessed in Service Mode.

2.4.1 Change and Save TDF File

If the standard TDF files do not work for a special case, the customer can modify and save TDF files. In the tech-
nology data screen (Figure 2.5), change the parameters as needed, press F7 or . A window will pop

up and let you save the changes (F1 or ) or cancel the changes (F8 or ) (Figure 2.8). Then it
will switch back to the technology data screen.

Figure 2.8 Save Changes to TDF

38
section 2 VISION 50P cnc WITH interface BOX

In the technology data screen (Figure 2.5), press but- ton or F6 to see the large view of consum-
ables. (Figure 2.9). Press “X” in the top right corner to close this window.

Figure 2.9 Large View of Consumables

39
section 2 VISION 50P cnc WITH interface BOX

2.4.2 Change Process from Cutting to Marking

Press the “ESC” Button or ESC on the keyboard to go back to the process screen. Then press the “F1”
key to switch between “Cutting” and “Marking" Process. The process number should change from 1 (cutting) to
5 (marking). (see Figure 2.10) This can be verified from the TDF filename shown on the top of the screen.

Figure 2.10 Process Changed to Marking

40
section 2 VISION 50P cnc WITH interface BOX

2.4.3 Gas Test

In the process screen, press the “MORE” button or to get the buttons for gas testing commands (see
Figure 2.11).

Figure 2.11 Gas Test

41
section 2 VISION 50P cnc WITH interface BOX

Press the “F1” or to view different parameters: Encoder Height, Arc Voltage, Lift Position, Cutting
Current, PG Output Pressure, SG1 Flow, PG2 Flow, SG2 Flow, PG1 In Pressure, SG Mix Pressure, PG2 In Pressure,
and Required PG Flow. Press the “Start Gas Test” button to test the start gas without cutting. Flow values are only
shown when using PG2 as the start gas. Press “Start Gas” button again to stop the start gas test. Press “Cut Gas
Test” button to test the cut gas. It will display the output cut pressure during cutting, but the flow will be larger
without the arc. Press “Cut Gas Test” button to stop testing.
Press “Shield Gas Test” button and “Start Gas Test” button to display the actual Shield Gas Flow during the start
of plasma (see Figure 2.12). Press “Start Gas Test” button again to stop testing.

Figure 2.12 Test Shield Gas During Plasma Start

42
section 2 VISION 50P cnc WITH interface BOX

While the “Shield Gas Test” button is selected, press the “Cut Gas Test” button to display shield gas flows during
cutting. The plasma arc does not influence shield gas flow.

Figure 2.12a Test Shield Gas During Cutting

43
section 2 VISION 50P cnc WITH interface BOX

2.4.4 Troubleshooting of Remote CNC Interface Box

For troubleshooting, with a keyboard press “Alt+3” or click the top menu on the touch-screen directly to display
the pull down menu (see Figure 2.13), and then select “Shift P5-Diagnosis” (see Figure 2.14) on this screen. It will
display the PLC version.

Figure 2.13 Menu

44
section 2 VISION 50P cnc WITH interface BOX

Figure 2.14 Diagnosis Window

Press the “More” button or (see Figure 2.15), then F3 or (see Figure 2.16), expand
Stations and Substations and select Substation 1.4 (see Figure 2.17). The version numbers for the hardware, firm-
ware and PC can be found in the diagnostics screen.

45
section 2 VISION 50P cnc WITH interface BOX

Figure 2.15. Additional Buttons for Diagnosis

46
section 2 VISION 50P cnc WITH interface BOX

Figure 2.16. Stations and Substations

47
section 2 VISION 50P cnc WITH interface BOX

Figure 2.17. Select Substation 1-4

48
section 2 VISION 50P cnc WITH interface BOX

Press “F2” or to check the signals for the CNC Interface Box (Figure 2.18). You can use
“F6” and “F7” to switch between digital output/input and analog output/input screens. Figure 2.18

displays the digital output screen.

Those output signals can be forced to a specific value. For example, in Figure 2.19, the signal Rem_Motion_En-
able is forced. From customer CNC, one can check if the motion enable is received as “1”.

Figure 2.18. Signals on CNC Interface Box

49
section 2 VISION 50P cnc WITH interface BOX

Figure 2.19 Digital Output is Forced

50
section 2 VISION 50P cnc WITH interface BOX

2.5 Operation without Height Control

The following signals are required between the remote/customer CNC to Vision 50P Control.

2.5.1 Signals from Remote CNC to M3-CAN plasma system

The signal from Pin “E” (Wire#5), ‘Cycle Start’, activates the plasma system. And the signal from Pin “D” (Wire#4),
‘Mark Mode’, selects marking or cutting mode. The ‘Mark Mode’ signal must be ENABLED in order to select
marking mode. If parameters or TDF files are chosen properly, Vision 50P can automatically switch between the
selected marking and cutting files.

2.5.2 Signals from M3-CAN plasma system to Remote CNC

The signal from Pin “B” (Wire#2), ‘Motion Enable’ will be passed over to Remote CNC after piercing delay is com-
pleted. Remote CNC should start cutting motion when ‘Motion Enable’ signal is true after the cycle starts. The
signal from Pin “A” (Wire#1) is Fault. Any gas error, power supply error, and CC-11 error can activate this signal
(becoming high). When Fault is high, the plasma system will be turned off, and ‘Motion Enable’ will be removed
so that the Remote CNC can remove the ‘cycle start’.

2.6 Sequence of Operation without Height Control

1. Select Cutting and Marking file from Vision 50P. Information will be saved in Vision 50P’s flash memo-
ry, after Vision 50P is powered on, those information will be loaded again. You don’t need to change
files again until you change nozzle, material, or material thickness.

2. Make sure No Height Control ( ) is ON (touch the screen or press ‘F2’). This informs Vision 50P
that there is No Height Control used.
3. The default mode is Cutting. Turn on Marking Mode if desired.
51
section 2 VISION 50P cnc WITH interface BOX
4. Turn on and hold ‘Cycle Start’ signal from customer CNC. After the piercing delay (about 100 msec),
check for ‘Motion Enable’ signal. If ‘Motion Enable’ signal is true, customer CNC can start motion.
5. Always check ‘Motion Enable’ signal during cutting/marking. If ‘Motion Enable’ signal turns OFF, arc
has been lost and CNC must remove ‘Cycle Start’. Vision 50P will automatically turn the plasma off if
arc is not detected after a delay time.
6. Remove ‘Cycle Start’ signal at the end of geometric motion during normal marking/cutting. During
hole-cutting, CNC should remove ‘Cycle Start’ before the end of geometry in order to improve the
roundness and overall quality. The pre-stop time depends upon the type of material, thickness, and
current.
7. Repeat (1)-(6) for the second part.

2.7 Operation with Height Control

Make sure ‘No Height Control’ is OFF (press or press F2) to informs Vision 50P that operation needs
height control. This needs to be done only once because this information is saved in flash memory after Vision
50P is powered off. The following signals are required between the Remote CNC and Vision 50P.

2.7.1 Signals from Remote CNC to M3-CAN Plasma System

1. Pin “E” (Wire#5), ‘Cycle Start’, activates the plasma system.
2. Pin “D” (Wire#4), ‘Mark Mode’, selects marking or cutting mode. The ‘Mark Mode’ signal must be
ENABLED in order to select marking mode. If parameters or TDF files are chosen properly, Vision 50P
can automatically switch between the selected marking and cutting files.
3. Pin “H” (Wire#8), ‘Station On’ switches ON/OFF the station. Vision 50P can also switch ON/OFF sta-
tions. The last ON / OFF command from Vision 50P and remote CNC will be effective.
4. Pin “K” (Wire#10), ‘Station Down’, moves down torches. This signal is not time sensitive.
5. Pin “L” (Wire#11), ‘Station Up’, moves up torches. This signal is not time sensitive.
6. Pin “F” (Wire#5), ‘Corner’: This signal prevents torch from diving down when the machine slows
down in the geometry corner or at the start/end of line. A False Corner Signal (0) means CNC is mov-
ing at a constant cutting speed. A True Corner Signal (1) means CNC is approaching corner and AHC
will be blocked. Customer CNC must provide this signal if the height control is used.
7. Pin “G” (Wire#7), ‘Enc/ArcVolt’, selects Encoder height control or Arc Voltage height con-
trol. True or ‘1’ means ArcVolt; false or ‘0’ means Encoder. Encoder height control is use-
ful during hole-cutting. In Process Screen, button or F4 can do the same func-
tion. When is ON, ArcVolt is selected; otherwise, Encoder is selected. This signal is also
saved on flash memory and will be automatically loaded when Vision 50P is powered on.

2.7.2 Signal From M3-CAN Plasma System To Remote CNC:

1. Pin “B” (Wire#2): This signal will be different depending on station constant #214 in SPS.KON. "Mo-
tion Enable" will be passed over to Remote CNC after piercing delay is completed. Remote CNC
should start cutting motion when "Motion Enable" signal is true after the cycle starts. “Arc On":
becomes activated immediately after the main arc is ON. “Arc On After Piercing Delay” become
activated after the piercing delay is done and the arc must be ON.
2. Pin “A” (Wire#1) is Fault. Any gas error, power supply error, and CC-11 error can activate this signal
(becoming high). When Fault is high, the plasma system will be turned off, and ‘Motion Enable’ will
be removed so that the Remote CNC can remove the ‘cycle start’.

52
section 2 VISION 50P cnc WITH interface BOX

2.8 Sequence of Operation with Height Control

1. Select Cutting and Marking file from Vision 50P. Information will be saved in Vision 50P’s flash memo-
ry, after Vision 50P is powered on, those information will be loaded again. You don’t need to change
files again until you change nozzle, material, or material thickness.
2. Make sure No Height Control is OFF. This informs Vision 50P that there is Height Control used.
3. The default mode is Cutting. Turn on Marking Mode if desired.
4. Turn on and hold ‘Cycle Start’ signal from customer CNC. After a short delay (about 100 msec), check
for ‘Motion Enable’ signal. If ‘Motion Enable’ signal is true, customer CNC can start motion. When a
constant speed is reached, remove the ‘Corner’ signal to activate automatic height control if arc volt-
age mode is selected. During corner or anytime the machine slows down, the ‘Corner’ signal must
be ON to prevent torch from diving inside corners.
5. Always check ‘Motion Enable’ signal during cutting/marking. If ‘Motion Enable’ signal turns OFF, arc
has been lost and CNC must remove ‘Cycle Start’. Vision 50P will automatically turn plasma off if arc
is not detected after a delay time.
6. Remove ‘Cycle Start’ signal at the end of geometric motion during normal marking/cutting. During
hole-cutting, CNC should remove ‘Cycle Start’ before the end of geometry in order to improve the
roundness and overall quality. The pre-stop time depends upon the type of material, thickness, and
current.
7. Repeat (1)-(6) for the second part.

53
section 2 VISION 50P cnc WITH interface BOX

During cutting small holes, parts are falling down before the geometry cutting is completed, the arc may not be

detected. Button or ‘F8’ in Process Screen can turn the cut loss signal on or off. If this button is ON, it
will ignore any cut loss after the arc is established; but for normal cutting, this button should be OFF.

54
section 2 VISION 50P cnc WITH interface BOX

2.9 Cutting Holes With Plasma

2.9.1 Introduction
The intent of this section is to provide the information necessary to produce good hole quality when using the
plasma process. This capability is becoming more of a necessity as customers begin to expect more and more
from the plasma process. There are several different areas which have to be addressed to obtain the required
results. These areas are height control, good speed regulation via the motion device, a power supply capable of
providing stable current output at all amperages, and a good programming package which allows you to pro-
gram the needed arc lead in and lead out segments. Each one of these areas will be discussed individually.

2.9.2 Encoder Height Control

Height control can be broken down into three separate areas. It is very important to understand how each of
these areas affect the overall hole quality.

The first area is the encoder height control. This control sets three separate heights that are critical to the opera-
tion.

The first area is initial height. This is the height above the work piece, in inches, the torch is set to establish the
correct height for the pilot arc to transfer to main cutting height.

The second area that the encoder height control is set to is the pierce height, which is the height the torch rises
to after the main arc transfer. This setting is used to protect the nozzle and shield from any material blow back
as a result of the main arc transfer.

55
section 2 VISION 50P cnc WITH interface BOX

2.9.2 Encoder Height Control (con't.)

The third area is the actual cutting height at which to cut the required part. When cutting holes, this feature
directly controls the side wall straightness of the hole. Do not use arc voltage control to maintain torch height
when cutting holes. Usually the diameter of these holes is so small that the arc voltage never activates. Instead,
use the encoder height control. Increasing this cutting height raises the torch to a higher position above the
work piece. This increases the arc voltage (stand off) thus increasing the taper to the side walls of the hole. This

A6 Plasma Lift As
causes what is referred to as a positive cut angle. Decreasing the stand off physically lowers the torch, causing
the voltage to be lower, thus producing a negative cut angle. The definition of a positive cut angle is one where
the top of the hole is a wider diameter than the bottom diameter. The definition of a negative cut angle is one
in which the top diameter of the hole is smaller than the diameter of the bottom of the hole

Description
The encoder cutting height controls the straightness of the side wall, which helps make the top and bottom di-
ameter of the hole the same dimension. If cutting holes with diameters 2.00" (50.8mm) and smaller, the encoder
Int
height control is to be used. Holes with diameters greater than 2.00" (50.8mm) should be cut using the arc volt-
age control. The A6
PT-36 p
slide co
spindle
plate a
from C
limit sw
lower o

The lift
necess
initial, p
contro
of SDP
is auto
measu
surface

Finally,
protec
switche
A6 Lift If the to
station
be sen
B4 Lift will det
For illu
manua

56
section 2 VISION 50P cnc WITH interface BOX

2.9.3 Cutting Speed Regulation

The cutting machine must have good speed regulation. For years, it has been assumed that when you are cut-
ting small holes, it was necessary to reduce the cutting speed from the normal speed when cutting a larger part.
The general rule is to reduce the cutting speed by 50% of normal travel speed. An example would be if cutting
0.50” (12.7mm) thick carbon steel at 100ipm (2540mmpm), then a 0.50” (12.7mm) diameter hole would be 50ipm
(1270mmpm). This is just a starting point. It may be necessary to reduce the cutting speed even lower.

When attempting to cut small holes it is necessary to reduce the cutting speed. This reduction in speed helps
control the roundness of the hole. Most machines have difficulty in trying to cut holes at high speed. This is
because of the mass and weight of the machine. The inertia of the machine wants to sling the torch around
thus producing an oblong or an oval hole. In addition, slowing the machine down also helps improve the wall
straightness.

It is very important that the machine design has minimum backlash. Any unwanted movement will show up in
the cut quality.

To summarize: The speed at which the hole is cut contributes to the roundness of the hole.

57
section 2 VISION 50P cnc WITH interface BOX

2.9.4 Power Supply

All of the power supplies ESAB manufactures today are referred to constant current devices. Unlike the power
supplies of yesterday, these units are capable of sustaining a constant current output at any cutting voltage,
providing they are within the design specification of that unit. The CNC controls of today interact with these
power supplies and are capable of remotely controlling current output from these units. In addition, because of
the remote capability, the control can regulate current output in the beginning, during the cut, and at the end.
In many cases when cutting small diameter holes, complete current control is required to control hole quality,
especially at the completion of the cut. In addition, all of ESAB power supplies for mechanized plasma applica-
tions are designed for 100% duty cycles. This means continuous operation 60 minutes per hour.

58
section 2 VISION 50P cnc WITH interface BOX

Part Programming Techniques

2.9.5 Part Programming Techniques

D
Although there are several techniques to programming small holes (diameter of 1.5 x plate thickness and lower), h
weAlthough there
will look at two are several
techniques techniques to programming small holes (diameter of 1.5 x
in depth. a
m
plate thickness and lower), we will look at two techniques in depth. p
ESAB controllers can be set up to utilize special codes to achieve very good plasma cut m
¶
holes. The ESAB Vison5X controllers also have variables and timers that will L
dramatically affect the quality of the hole. Set properly, they can enhance the quality and h
p
if set incorrectly, can deteriorate the hole quality. Here is a list of the aforementioned N
variables and timers: o
h
A
c
tu
ti
a
59 p
to
o
o
section 2 VISION 50P cnc WITH interface BOX

2.9.6 Codes That Can Affect Hole Quality

The M57 command will do two things. First, if there is no encoder height control, it will simply
M57 freeze the voltage height control. Second, it can be used to enable the encoder height control
by placing the M57 before the M65 (plasma on command).
F The “F” can be inserted to call a different feedrate (e.g F50.0) that will enhance hole quality.
“Flying Off” - This code will shut off the plasma at the point it is inserted in the program without
M174 stopping machine motion. This function will not utilize the current ramp down, current off value
and gas off delay parameters.

2.9.7 Selection Of Lead-In Type

This depends on the size of the hole. A straight lead in works well in most cases versus a radius lead in which
works well on mostly larger holes. This can be seen in the illustrations below. The green path is the programmed
path and the red path is the torch path. Look at where paths intersect on the radius lead in illustration. This area
usually leaves a flat spot or hump. This can be attributed to the arc expanding as it travels into the previous cut
path. The straight lead in has a much smaller previous cut path therefore reducing the flat spot.

60
section 2 VISION 50P cnc WITH interface BOX

2.9.7 Selection Of Lead-In Type (con't.)

61
 In the graphic below, notice we led in from the center of the hole at 90 degrees.
section 2 1 and red code).
(Refer to point VISION 50P cnc WITH interface BOX
The M57 inserted before the M65 tells the controller that we are going to use the encoder
for height control. The encoder height value can be optimized to give us the best cutting
height for the hole which may be different from standard contour cutting. After the
piercing routing completes,
2.9.7 Selection Of Lead-In the machine
Type (con't.)will lead into the contour at 90 degrees and
continue in a counter-clockwise direction to cut the hole. As the machine approaches the
leadgraphic
In the in kerf, there
below, arewe
notice a couple of different
led in from the center ofthings weatcan
the hole 90°.do. One
(Refer is to 1use
to point andtheredM174.
code). This
will turn the plasma off at the entry point of the lead in or shortly after it. This code
The M57 inserted before the M65 tells the controller to use the encoder for height control. The encoder height
should not be limited to either before or after. Material type, amperage, hole size and gas
value can be optimized to give the best cutting height for the hole which may be different from standard con-
tourselection all influence
cutting. After the piercingon where
routing this code
completes, theshould
machinebewillplaced tothe
lead into optimize
contour the
at 90°hole
and quality.
continue
in a(Refer to point 2direction
counter-clockwise and blue code).
to cut Remember
the hole. that the
As the machine M174 the
approaches is alead
“Flying
in kerf, Off” command
there are a couple
and willthings
of different shutthat
off can
thebeplasma
done. Oneon the
is to fly. WeM174.
use the use an
Thisover burn
will turn the(refer
plasmatooffpoint
at the3entry
andpoint
green
of
thecode)
lead into
or shortly after it. This code should not be limited to either before or after.
keep the machine moving beyond the intersection of the lead in and the end of Material type, amperage,
hole size and gas selection all influence where this code should be placed to optimize the hole quality. (Refer to
the hole contour as the plasma goes out.
point 2 and blue code). Remember that the M174 is a “Flying Off” command and will shut off the plasma on the
fly. We use an over burn (refer to point 3 and green code) to keep the machine moving beyond the intersection
of the lead in and the end of the hole contour as the plasma goes out.

N0031 G41
N0032 M57
N0033 M65
N0034 G01 X1.442 Y-1.231
N0035 G03 X1.548 Y-1.014 I1.718 J-1.231
N0036 G03 X1.442 Y-1.231 I1.718 J-1.231
N0037 M174
N0038 G03 X1.447 Y-1.281 I1.718 J-1.231
N0039 M66
N0040 G40

62
 section 2 VISION 50P cnc WITH interface BOX
Another way to program the hole is to follow the example below. Here we still use the
encoder for height control, still lead in at 90 degrees but do not use the M174 at the end
of the cut. 2.9.7 Selection
Instead, we use Of the parameter
Lead-In “Current Off Value” to turn the current down
Type (con't.)
after the over burn move. You see that the M66 code comes after the over burn which
turnsAnother way to program the hole is to follow the example below. Here we use the encoder for height control,
the plasma off. When the controller sees this code, the current goes to the current
still lead in at 90° but do not use the M174 at the end of the cut. Instead, use the parameter “Current Off Value”
off value
to turnwhich candown
the current be optimized in conjunction
after the over burn move. The M66with
code the ramp
comes down
after the over time and turns
burn which the over
the
burnplasma
distance for the
off. When hole and
the controller seesmaterial you
this code, the are goes
current cutting.
to theIf the Current
current Offcan
off value which Value is at the
be optimized
samein conjunction with the ramp down time and the over burn distance for the hole and material being cut. If the
value as the cutting current value, then the plasma will gouge the contour of the
Current Off Value is at the same value as the cutting current value, then the plasma will gouge the contour of the
hole hole
instead
insteadofofleaving a smooth
leaving a smooth area atarea at the
the lead lead out point.
out point.

63
 section 2 VISION 50P cnc WITH interface BOX

2.9.7 Selection Of Lead-In Type (con't.)

One should be careful also to check for the kerf offset when cutting very small holes. The
Always check for the kerf offset when cutting very small holes. The angle of the straight lead in will have to
angle of the straight
be modified lead
to allow the inposition
start will have to beinmodified
to remain the center oftothe
allow
hole. the startthis
Ignoring position to lead
offset can remain
to the
in the center
plasma of on
starting thethehole.
edge Ignoring thisedge
or outside the offset
of thecan lead to the plasma starting on the edge or
hole.
outside the edge of the hole.

• Make sure the plasma starts in the center of the hole.

Make sure sure
• Make the the
plasma
plasmastarts
torch isinatthe
the center of thebefore
correct height hole.it reaches the edge of the contour.
Make sure sure
• Make the the
plasma torch
feed rate is at the correct height before it reaches the edge of the
is correct.
contour.
• Follow either of the previous two examples to end the cut with minimal deformation to the hole.
Make sure the feed rate is correct.
Follow either of the previous two examples to end the cut with minimal deformation to
the hole.

64
section 2 VISION 50P cnc WITH interface BOX

Error List for Vision 50P SPS

ID Description Possible Solutions

1. Touch signal is already closed.
11002 IHS Timeout
2. Check for short on reference sensor #1 or #2.
1. If no spark from torch, the gas pressure is high, or the open circuit
voltage is low.
2. If there is spark from torch but not transfer, the initial height is too
11003 Ignition Fault high, or the start current is too low.
3. Pilot arc relay is not energized.
4. Pilot arc relay contact is bad.
5. Pilot arc resistor is open.
1. Pierce height is too high during start.
11004 Cut Loss 2. No plate under torch during cutting.
3. Pierce time is too long.
Error When 1. SPS.KON is not readable.
11005
Reading SPS.Kon 2. Make sure SPS.KON exist and is not used by other program.
1. Reset torch holder.
2. Arc voltage is too low.
11006 Torch Collision
3. Crossing large Kerf without AHC blocked.
4. Machine is moving too slow.
No Supply Voltage 1. Check 24VDC power supply to substation.
11007
On Substation 2. Check CAN cable connections.
Lower Limit
11012 1. Lift is at lower limit switch. Machine should not be able to move.
Switch Activated
11014 Process Is Not Available 1. Please select available process.
11016 No Valid Station Selected 1. Please select a valid station.
1. Coolant through torch is less than 1.0 GPM (4.5 l/Min.). The minimum
flow through torch is 1.3 GPM (5.9 l/Min.) @175PSI (12.1 bars).
11019 Coolant Error
2.Check the water pump output pressure (175PSI / 12.1 bars).
3. EPP-360 is in slave mode.
1. Shield cup too small.
2. Ensure correct consumables.
11024 SG1 Flow Is Low
3. Check hoses for blockages.
4. Check input pressures of SG box.
1. Shield cup too small.
2. Ensure correct consumables.
11025 SG2 Flow Is Low
3. Check hoses for blockages.
4. Check input pressures of SG box.
1. Gas off delay must be shorter than the current ramp down time.
11026 Gas Off Delay Is Too Long
2. Gas off delay will be set equal to the current ramp down time.
1. Arc voltage is 10volts lower than required.
11027 Arc Voltage Is Too Low
2. Please decrease VDR ratio in SPS.KON.
1. Arc voltage is 10volts higher than required.
11028 Arc Voltage Is Too High
2. Please increase VDR ratio in SPS.KON.

65
section 2 VISION 50P cnc WITH interface BOX

Error List for Vision 50P SPS

ID Description Possible Solutions

Current Ramp Down 1. Current ramp down time must be longer than the gas off delay.
11029
Time Is Too Short 2. Current ramp down time will be set equal to the gas off delay.
11030 Not Used
11031 PG2 Output Pressure Is High 1. Nozzle too small.
11032 PG1 Output Pressure Is High 1. Nozzle too small.
1. Please add more coolant.
11049 Coolant Level Low
2. Check switch for activation when cooler is full.
1.Please set correct slow down distance in station constant and correct plate
11062 High Speed Touch
thickness in TDF file.
11063 PG2 Input Pressure Is High 1.PG2 input pressure (PG box inlet) is high.
1.Nozzle too small.
11064 PG2 Flow Is Low
2.Hose is blocked between PG box and torch.
11065 PG1 Output Pressure Is Low 1.Nozzle too large.
11066 PG2 Output Pressure Is Low 1.Nozzle too large.
1.Shield cup too large.
2.Ensure correct consumables.
11067 SG1 Flow Is High
3.Check hoses for leakages.
4.Check input pressures of SG box.
1.Shield cup too large.
2.Ensure correct consumables.
11068 SG2 Flow Is High
3.Check hoses for leakages.
4.Check input pressures of SG box.
11069 PG1 Input Pressure Is Low 1.PG1 input pressure (PG box inlet) is too low.
11070 PG2 Input Pressure Is Low 1.PG2 input pressure (PG box inlet) is too low.
1.Nozzle too large.
11071 PG2 Flow Is High
2.Leak between PG box and torch.
1.Short between nozzle and shield cup.
11072 Sensor Short
2.Clean trash inside torch.
Proportional Valve Power 1.Proportional valve (water injection only) has no power.
11073
Fault 2.Check 24VDC power inside the water injection box.
1.The requested output current is not available for the selected power sup-
Power Supply Can Not Out-
11074 ply.
put The Requested Current
2.Check SPS.Kon to make sure the right power supply is selected.
1.Cut water hose is blocked.
2.Cut water valve is not ON.
11075 Cut Water Flow Is Blocked.
3.Smaller nozzle.
4.Proportional valve does not work.
Arc Current Is lower Than 1.The actual current is less than the requested current.
11076
Requested 2.Check the control cable between RAS box and power supply.

66
section 2 VISION 50P cnc WITH interface BOX

Error List for Vision 50P SPS

ID Description Possible Solutions
Arc Current Is higher Than
11077 1. The actual current is higher than the requested current.
Requested
11078 PG1 Input Pressure Is High 1. PG1 input pressure (PG box inlet) is too high.
Plasma Power Supply 1. Check the front panel for error code. Look for solution in the manual for
11079
Failed. plasma power supply.
Cut Water Pressure Is Too
11080 1. Check water pump.
Low
Cut Water Pressure Is Too
11081 1. Check proportional valve.
High
11082 Cut Water Flow Is Too Low 1. Check water valve.
11083 Cut Water Flow Is Too High 1. Check proportional valve.
1. Disable Auto Mark Selection (SPS.KON#220).
Marking file is manually
2. Select the right marking file manually.
11084 selected while Auto Mark
3. Select any other cutting file, and then remotely select the cutting file
Selection is enabled
needed.
Marking is not available for
11085 1. Choose another marking file.
current over 400A
Plate Thickness for this
11086 1. Please select correct thickness for this nozzle.
nozzle is not valid
Marking for selected nozzle
11087 1. Please select less than 450amp nozzle for marking.
is not available
Marking for Aluminum is
11088 1. Please select MS or SS for marking.
not available
1. Please load or create cut data for this thickness
No cut data for the selected
11089 2. You are using auto selection, but you manually select TDF file; please re-
thickness
motely select any other cutting file, then select the cutting file needed.
1. Please load or create cut data for this current.
No cut data for the selected
11090 2. You are using auto selection, but you manually select TDF file; please re-
current
motely select any other cutting file, then select the cutting file needed.
1. Please load or create cut data for this nozzle code.
No cut data for the selected
11091 2. You are using auto selection, but you manually select TDF file; please re-
nozzle code
motely select any other cutting file, then select the cutting file needed.
Cut Water Pressure out of
11092 1. Please check the cut water pressure.
range

67
section 2 VISION 50P cnc WITH interface BOX

Error Codes for SG and PG Boxes

Error ID Description
89 CRC error during downloading station constants
90 Module carried out a reset
200 Value range of CAN reference setting has been exceeded
201 Inlet pressure for PG1 is too low
202 Inlet pressure for PG1 is too high
203 Inlet pressure for PG2 is too low
204 Inlet pressure for PG2 is too high

68
 revision history

1. Initial release - 04 / 2009

2. Revision 04/2010 - added vision 50P mounting diagram.
3. Revision 02/2012 - updates per K. Li.

69
 ESAB Welding & Cutting Products, Florence, SC
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