1 Operator Instruction Manual For GLOBAL Control

Global Control m
Operator Manual
The information in this document is subject to change without notice, based on
information available at the time of its publication, and should not be construed as a
commitment by MG Systems & Welding, Inc. MG Systems & Welding, Inc. makes no
representation or warranty, expressed, implied, or statutory with respect to, and
assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of
the information contained herein. No part of this manual and/or databases may be
reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying, recording, or information recording, and retrieval systems, for
any purpose other than the purchaser’s personal use, i.e. in-house instructional training,
without the express written permission of MG Systems & Welding, Inc.
Menomonee Falls, Wi 53051

All Rights Reserved.
CONTACT INFORMATION:
MESSER - MG SYSTEMS & WELDING, Inc.

W141 N9427 Fountain Blvd.
Menomonee Falls, WI 53051
Voice (262) 255-5520

Fax (262) 255-5170
sales@messer-mg.com
www.mg-systems-welding.com
Table of Contents
Section 1: Front Panel Layout ........................................................................1-1
Emergency Stop ..........................................................................................................1-1
Power On ....................................................................................................1-1
Cycle Start...................................................................................................................1-2
Cycle Stop ...................................................................................................................1-2
Section 2: Operator Interface..........................................................................2-1
Navigation Toolbar.......................................................................................................2-2
Alarm...........................................................................................................................2-3
Operation Mode Menu .................................................................................................2-4
Automatic ..............................................................................................................2-4
Manual ..................................................................................................................2-5
Home Axis.............................................................................................................2-6
Ripcut....................................................................................................................2-6
Dry Run.................................................................................................................2-6
Simulation .............................................................................................................2-6
Process Menu..............................................................................................................2-7
Position, Coordinate System, Part Rotation and Current Part Program.........................2-7
Speed..........................................................................................................................2-7
Back Button .................................................................................................................2-7
Virtual Keyboard ..........................................................................................................2-8
ISO Icons.....................................................................................................................2-8
Process Dependant Buttons (Gas On, Gas High, Ignition, etc.) ....................................2-9
Process Independent Buttons (Back, Forward, Reset, etc.) ..........................................2-9
Lifter and Height Sensing Configuration ..................................................................... 2-11
Lifter Button(s)..................................................................................................... 2-11
Lifter Selection Button.......................................................................................... 2-11
Auto Height Button .............................................................................................. 2-11
Section 3: Part Programs ................................................................................3-1
Load ............................................................................................................................3-1
More ............................................................................................................................3-1
Search.........................................................................................................................3-2
Delete..........................................................................................................................3-2
Copy............................................................................................................................3-3
Move ...........................................................................................................................3-3
New.............................................................................................................................3-3
Editor...........................................................................................................................3-4
Save ............................................................................................................................3-5
Save As .......................................................................................................................3-5
Close ...........................................................................................................................3-5
Load ............................................................................................................................3-5
Global Control Operator Manual Rev. 1.01

Section 4: Database.........................................................................................4-1
Apply ...........................................................................................................................4-3
Store ...........................................................................................................................4-3
Restore........................................................................................................................4-3
Utilities.........................................................................................................................4-3
Import ..........................................................................................................................4-4
Copy............................................................................................................................4-5
Delete..........................................................................................................................4-6
Exit ..............................................................................................................................4-6
Section 5: Run Screen.....................................................................................5-1
Graphic Toolbar (Pan, Zoom In, Zoom Out, etc.) ..........................................................5-2
Text View.....................................................................................................................5-4
Align Plates .................................................................................................................5-4
Process Information screens (Plasma Process, Oxyfuel Process, etc.) ........................5-6
Section 6: Process Variables ..........................................................................6-1
Reference Points .........................................................................................................6-1
Plasma ........................................................................................................................6-3
Plasma Control ............................................................................................................6-5
Oxyfuel ........................................................................................................................6-6
Markers .......................................................................................................................6-8
Torch Spacing ........................................................................................................... 6-11
Accessories ............................................................................................................... 6-12
Lifters ........................................................................................................................ 6-13
Section 7: Macro Nesting ................................................................................7-1
Section 8: Program Nesting ............................................................................8-1
Section 9: Consumables .................................................................................9-1
Section 10: HMI Control ................................................................................10-1
Section 11: ScopeView..................................................................................11-1
Section 12: PLC Configuration .....................................................................12-1
Section 13: Virtual Service............................................................................13-1
Section 14: About ..........................................................................................14-1
Appendix A: Oxyfuel Database Variable Definitions ................................... A-1
Appendix B: Plasma Database Variable Definitions .................................... B-1
Appendix C: Plasma Marker Database Variable Definitions ....................... C-1
Appendix D: Process Variables – Special .................................................... D-1
Revision Page .....................................................................................Revision-1
Global Control Operator Manual Rev. 1.01

Section 1: Front Panel Layout
3
4
1) Emergency Stop
2) Power On
Press this button to apply power to the machine control circuits. The button
illuminates to confirm the circuits are energized. The white light goes out when
power is turned off by pressing the EMERGENCY STOP pushbutton.
PL-1 Plasma Lifter Only: Press the Power On button in combination with the Cycle
Stop button to perform a homing cycle on the PL-1 lifter. This routine may be helpful
to raise the torch when a torch collision fault is caused by the torch hitting the plate.
Use to jog the machine in the Longitudinal (X) and Transverse (Y) directions or diag-
onally when in Manual Mode.
Global Control Operator Manual 1-1 Rev. 1.01

3) Cycle Start
Press to initiate machine motion. For example, when a part program is initiated or to
begin a machine homing routine.
4) Cycle Stop
Press to stop machine motion or an active process.
The switches or buttons located at 7-10 can perform many different functions. Each Global
Control panel is custom built to match the installed process tools. The exact function will be
identified on the label above the switch. Some typical functions are described below.

Section 2: Operator Interface

The operator interface was designed to keep the most important information and software
controls visible at all times. Therefore, the controls along the top, right, and bottom of the screen
are always available. The remaining screen area is dynamic and will vary depending on the
operator’s interaction with the various controls.

[Operator Controls Always Available]
2.1 Navigation Toolbar
Located on the right-hand side of the screen, the Navigation

Toolbar contains menus used to access various functions.
Press the Operation and Support menu buttons to access
different icons that support the main menu button. The icons
and their functionality will be explained later in this manual.

2.2 Alarm
Once an alarm is triggered by the Global Control, the alarm button will display a short
description of the problem. Color will be used to indicate the severity of the alarm, red is
a critical error while yellow is only a warning. Press the Alarm button to display a window
that may contain more detailed information as well as suggested solutions. Each alarm
will also be date and time stamped to aid in the diagnostic process. Once the condition(s)
that generated the alarm have been corrected, the operator can clear the alarm by
pressing the Close button. The backward (<<) and forward (>>) buttons allow the
operator to scroll through a list of multiple alarm messages.

2.3. Operation Mode Menu

This menu contains a drop-down list of different modes of operation. The choices are
Automatic, Manual, Home Axis, Rip Cut, Dry Run and Simulation.
2.3.1 Automatic
As the part program is executed in Automatic mode, the selected process will
become active.

2.3.2 Manual
Manual mode is used to position (i.e. jog) the machine.
When Manual Mode is active, the joystick or eight directional arrow buttons can be
used to move the machine. The Latch button will latch motion in the chosen
direction until another direction is chosen, the Latch button is pressed again or the
Cycle Stop button is pressed. Use the joystick in combination with the feedrate
override device to jog the machine.

2.3.3. Home Axis

This operation mode is used to establish an absolute zero point for the X and Y
axis relative to a physical location in the working area. Proximity or limit switches
are typically used to establish this location. The example described below is from a
machine with only an X and Y axis. Some machines may have a second Y-axis
(Ya) or a Z-axis.
Select an individual axis button (X or Y), Select

All or Custom. The button(s) will turn green
accordingly. Press the Cycle Start button to
execute the homing routine.
2.3.3.1 X
Press to select the X-axis. The button will turn from white to green.
2.3.3.2 Y
Press to select the Y-axis.
2.3.3.3 Select All
Press to select all axis buttons shown on this screen.
2.3.3.4 Select None
Press to de-select any previously selected axis.
2.3.3.5 Disable Deskew
When this button is green, no automatic motion to correct for the gantry
not being square to the transverse axis (Y-axis) will be performed.
Whatever relationship the gantry axis is to the transverse axis at the
time the control is powered up, will remain after the homing function is
performed.
2.3.3.6 Custom
The Custom button can be used to home a single or multiple axis then
automatically move these axis to a programmed location. Please
contact the Messer Service Department to edit this file.
2.3.4 Ripcut
Select this mode and a process from the Process Menu then use the joystick
and/or jog directional buttons along with the feedrate override device to manually
cut or mark the plate.
2.3.5 Dry Run
When in Dry Run mode, the machine will move as the part program is executed but
the active process will not turn on.
2.3.6 Simulation
An operator may use Simulation mode to check a part program for syntax errors.
After a program has been loaded, press Cycle Start. The program will be executed
without any machine movement.

2.4 Process Menu

This menu contains a list of the available process or processes on the machine.
HD4070, Oxyfuel and ArcWriter processes are shown in the example above but are only
a small sample of the many processes available on a Messer machine. A process can
be manually selected by pressing one of the buttons. Alternatively, a process can be
automatically selected with a T-code in the part program.
2.5 Position, Coordinate System, Part Rotation, and Current Part

Program
This control displays the current X and Y coordinate positions, the current coordinate
system (i.e. absolute or relative), the part rotation in degrees, and the name of the current
part program.
2.6 Speed
The value in big, bold type is the cut speed from the latest database record applied or as
set by the part program (e.g. F-code). The actual speed is displayed below this in
smaller type. Also displayed is a corresponding bar graph and speed override
percentage.
2.7 Back Button

Press this button to display the previously displayed screen.

2.8 Virtual Keyboard Button

Press this button to display a full alphanumeric keyboard.
Press the button to minimize the keyboard.
2.9 ISO Icons

2.10. Process Dependant Buttons

(The following buttons are only visible in Oxyfuel mode)
2.10.1 Gas On
With the Oxyfuel process selected from the Process Menu and at least one Lifter
on, press the Gas on Button to turn low preheat gasses on.
2.10.2 Gas High
Press this button to turn the high preheat gasses on. This function can be used to
cut through a slag puddle or in other situations to increase the temperature of the
cutting flame.
2.10.3 Ignition
With the Gas On button green, press Ignition to remotely ignite an oxyfuel torch.
2.10.4 Ignition Confirm
This button turns on (green) when the Global Control recognizes an oxyfuel torch
as being ignited. For safety reasons, this button needs to be turned on within a
few seconds of the preheat gasses flowing and an ignition signal. The button can
be turned on manually or automatically depending on the machine configuration.
2.10.5 Start from Edge
Press this button skip the high preheat function before the start of the cut.
2.11. Process Independent Buttons
(The following buttons are visible during a Cycle Stop Condition)
2.11.1 Back
While in a cycle stop condition, press this button to move the machine backward
on path. All part program codes to turn the process on will be ignored. Use the
Feedrate Override device to control the machine speed.
2.11.2 Forward
While in a cycle stop condition, press this button to move the machine forward on
path. All part program codes to turn the process on will be ignored. Use the
Feedrate Override device to control the machine speed.
2.11.3 Jump to Start Point
If the part program contains line numbers (e.g. N1, N30, N500), this feature can
be used to quickly jump to these points. Once a number has been entered, the
machine will move directly to this point.
2.11.4 Single Block
Press to execute the part program one line at a time.
2.11.5 Return to Start
Press this button to return the machine to the part program initial start point.
2.11.6 Reset
Press to reset the part program and to refresh the part program graphic display.

(The following buttons are only visible during a Cycle Stop condition while in Oxyfuel Mode)
2.11.7 Extend
Press this button to extend the high preheat time. Press Release or Release
with Update to stop the timer and begin cutting.
2.11.8 Release
Press this button to stop the high preheat timer. The cutting oxygen and low
preheat gasses will turn on.
2.11.9 Release with Update
In addition to functionality provided by the Release button, this button will also
adjust the high preheat time to the value of the timer when this button was
pressed. This new value will be used for all subsequent pierces but will not be
saved to the current database record.
(The following buttons are visible during a Cycle Stop condition)
2.11.10 Auto Return

While in a Cycle Stop condition, the operator may jog the machine using the
joystick or directional buttons on the screen. Press this button to return the
machine to the cut path.
2.11.11 Move Part
joystick or directional buttons on the screen. Press this button to move the cut
path to this new location. Press Cycle Start and the machine will continue
cutting from this new location.
2.11.12 Cut to Path
joystick or directional buttons on the screen. Press this button to cut from this
location back to the original cut path then continue on path.
2.11.13 Reset
Press to reset the part program and to refresh the part program graphic display.

2.12. Lifter and Height Sensing Configuration

2.12.1 Lifter Button(s)
Each Z-axis lifter is assigned an individual button. Three different colors and a “+”
sign are used to indicate the five different states of this button.
A gray button indicates the lifter (i.e. station) is off.
Yellow indicates the lifter has been turned on but automatic height
sensing for this lifter is disabled. The lifter will perform an initial
height sense (IHS) routine with the corresponding process tool.
A yellow button with the “+” sign indicates the process assigned to
this lifter is also selected.
Green indicates the lifter has been turned on and automatic height
sensing for this lifter is enabled. The lifter will perform an initial
height sense (IHS) routine with the corresponding process tool.
A green button with the “+” sign indicates the process assigned to
this lifter is also selected.
2.12.2 Lifter Selection Button

Press this button to view the other features available for the lifters. Press the
button again to exit the Lifter Screen.
2.12.3 Auto Height Button

Press this button to turn automatic height sensing on (green) or off (white) for all
lifters that have height sensing enabled.
The icon on this button is the international “sum of” icon. It is used here to
activate automatic height only for those lifters where the individual Lifter Button is
also on (green).
This button will have no effect on a lifter with a yellow Lifter Button.
The combination of the Auto Height Button and the Lifter Button(s) give the
operator a lot of flexibility to control automatic height sensing for an individual or
all lifters while cutting or marking.

Press one of these buttons to enable height sensing

for an individual lifter. The different states of this
button are described on the previous page.
Press one of these buttons to turn a lifter (i.e. station)

on (green) and enable height sensing at the same
time. Press the button again to turn both off (white).
The arrow buttons grouped on the left are

used to jog a lifter up or down.
The arrow buttons grouped on the right can
be used to jog all lifters currently turned on
up or down accordingly.
When this button is green, the tool on each lifter with a yellow or
green Lifter Button(s) will not perform an IHS routine when the
Cycle Start button is pressed.
Press this button to establish a new cut height by using the current
position of a lifter. It is available only with oxyfuel lifters equipped
with height sensing that support this feature.
Press this button to adjust the Park, Mirror and Likewise buttons.
Press the button again and these buttons will turn gray.
A green Mirror button indicates the corresponding

carriage will move opposite the master carriage.
Mirror capability is optional on some machines.
When a Park button is green, the corresponding
carriage will not move during a transverse axis
move.
A green Like button indicates the corresponding
carriage will move exactly the same as the master
carriage.
Use the Mirror, Park and Like buttons grouped
on the right to quickly set all carriages the same.
.

Section 3: Part Programs

Press this icon in the Operation menu to access CNC part programs from the hard drive, floppy
disk or mapped network drive. In addition to loading a program, the operator may also edit or
delete part programs by pressing the appropriate button.
Press a folder icon or the “+” sign next to a folder icon to open a folder a see a list of files or
additional sub-folders. Use the up, down, left and right arrow buttons to navigate through the file
tree. Once a valid file is highlighted, it will be graphically displayed on the left side of the screen.
Only files with valid extensions are displayed in the list. After a file has been copied into
a folder, it may be necessary to refresh the screen in order for the file to be displayed.
Press the “-“ sign next to a folder icon to collapse the folder. Press the “+” sign to re-
open the folder.
3.1 Load
After a file has been selected, press this button to load the program. The Database icon
in the Operation menu will automatically become highlighted and the Database screen
will become visible.
3.2 More…
Press this button to view additional functions that can be performed with the selected part
program. Press the button again to hide the additional functions.

3.3 Search
Press this button to search for a file. The following screen will appear…
First select a folder then touch the white area

next to ‘Search text’ to bring up a keyboard. As
you start typing in the name of the file, the
control will automatically jump to files that match
the input characters.
For example, if the ‘Customer B’ folder was

selected as shown here and the operator started
typing Bracket1234, the highlight bar would have
jumped to the program as soon as “b” was
entered on the keyboard. Press the Min or
Enter buttons to close the keyboard.
Press Search to cancel the search function or

Load to load the program for execution.
Press Load to load the selected program.
3.4 Delete
Press this button to delete the selected file. A box will appear asking to confirm the
request.

3.5 Copy
Select a file from the list then press the Copy button.
Navigate to another location on the file menu

tree and press Save to copy the file to the new
location or Cancel to abort.
The operator may also touch the white dialog

box next to ‘File name:’ and change the name of
the file before storing it in another location.
3.6 Move
Follow the same steps as the Copy function except the result is the file is moved to
another location rather than being copied.
3.7 New
Press this button to create a new text file.
Navigate to a folder the new file should be

created in and press New. Touch the white
dialog box next to ‘File name:’ and type in the
name of the new file. Press Enter on the
keyboard and you will be directed to the Editor
screen.
Press Cancel to abort the operation.
Press Min to minimize the keyboard.

3.8. Editor
Press this button to enter the program editor.
3.8.1 Edit
Press Edit to modify the CNC code.
Use the keyboard on this screen to make changes to the file. Press Edit again to
switch between viewing the keyboard and viewing a graphical display of the file.

3.9 Save
This button will become active after any modifications have been made to the file. Press
Save to accept any changes made to the file.
3.10 Save As…

Use Save As… to save the modified file with a different name.
3.11 Close
Press this button to close the program Editor and return to the main Part Programs
menu.
3.12 Load
Press this button to load the program. The Database icon in the Operation menu will
automatically become highlighted and the Database screen will become visible.

Section 4: Database
Section 4: Database
Many parameters are required to properly operate a process tool. The Global Control simplifies
this process by including a machine specific, pre-configured database of these parameters. The
operator makes only a few quick selections to quickly configure the tool(s).
There are actually three separate databases used on the Messer Global Control. The operator is
able to modify values in the Working database. The buttons shown below are from the Global
Control and show how they are used to manipulate records between the databases.
A record is a group of parameters stored in a database and labeled in such a way that they can
be easily retrieved.
For example, included in the Messer Default database is a record for a high quality cut on 10 mm
mild steel with an HD4070 plasma system. This record contains all the optimum parameters to
properly configure the cutting process. Additionally, an operator may choose to modify this
record and overwrite the default record or store them as a different record all together. At the
time of installation the default values would be the same in all three databases. As the operator
makes a change to these values he/she is actually modifying values in a record in the Working
database. If the changes are then stored, they are being stored into the User Default database.
Records can only be pulled from the Messer Default database using the Import or Copy
functions.
Messer Default Database (Read only)
Import Copy
User Default Database
Store Restore Delete
Working Database
The diagram shown illustrates how records are stored within the Global Control and how they are
later retrieved. However, this record of process parameters must still be “sent” to the cutting or
marking tool. After the operator selects the database record from the list, he/she must press
Apply to send the database values to the “Current value” field in the software PLC. The PLC will
then use these values to properly setup the process tool.
Typical scenario: An operator completes a nest of 12 mm material and now switches to a job of
10 mm. He selects 10 mm; Best quality from the database menu and starts cutting. Not long into
the job he notices the cut quality is not as good as it usually is. The problem is he did not press
Apply therefore the cutting tool is still configured with the process parameters for 12 mm.
Always confirm the values in the “Current value” field match the desired database
record before executing the part program.

Section 4: Database
The first time the Database icon in the Operation menu is pressed, a screen similar to the one
below may be displayed. The operator must first select a process database.
The database search tree will now appear on the left and a table of database records will
appear on the right. The operator can select a specific database record by navigating through
the search tree until the final requirement is highlighted. This can be accomplished by
pressing on the icons in the tree view or by using the Up, Down, Left, and Right arrow buttons.
As an alternative, the operator can navigate through the table of database records, highlight
the desired record and then press the Select button. Note: The database search tree may
be different than the one shown above as it is unique for each process and machine.

Section 4: Database
At the far right of the database manager view, consumable pictures and corresponding part
numbers are displayed. Since all parameters cannot be shown in one view due to space
constraints, there are Up and Down arrow buttons at the bottom of this view to allow you to
scroll through the various pages of parameters.
The database manager view displays the parameter values for the selected database record
on top of the “Current value” being used by the process. If the two values are different a
Copy current value button will be visible to the right of the parameters. Press this button to
copy the “Current value” into the corresponding database parameter field.
4.1 Apply
Press this button to accept the material database record and send it to the selected
process. Notice in the example screen shown above, the values for cut speed, kerf
and arc voltage do not match their corresponding “Current value”. The Apply button
must be pressed to properly setup the process tool. After this button is pressed, the
Run Screen icon in the Operation menu will automatically become highlighted and
the Run Screen will become visible.
4.2 Store
Press this button to store changes made to the displayed record in the Working
database to the User Default database. The original record in the User Default
database will be overwritten. The operator must use the Import function to restore
the factory default record the Messer Default database to the User Default database.
4.3 Restore
Press this button to restore values from the User Default database to the Working
database.
4.4. Utilities
Press this button to access tools or utilities used to Import, Copy or Delete records
from the three separate databases.

Section 4: Database
For detailed parameter definitions and timing diagrams for the various processes, please see
Appendix A.
4.4.1 Import
Press the Import button and a search tree will appear on the left and Import
and Cancel buttons will be on the right. Select a record from the list on the
left and press Import. The selected record (material file) will be copied from
the Messer Default database to both the User Default and Working databases.

Section 4: Database
4.4.2 Copy
The Copy function allows an operator to create a new database record with an
existing record serving as the template. This method simplifies the creation of
new records by copying similar parameters from a current record.
Press the Copy button and a Working database search tree will appear on the
left. Navigate through the search tree to the Quality level by pressing on the
icons in the tree view or by using the Up, Down, Left, and Right arrow buttons.
A list of Materials will now appear on the right.
The operator can either select one of the materials listed or enter a new
material name. To select one of the materials, press one of the material
names listed or use the Up and Down arrow buttons. To enter a new name,
touch the white dialog box next to “new value:” and enter a new material name.
Press the Next button and follow the same procedure to select or modify the
various items in the search path (e.g. Units, Thickness, Quality, Amps, etc.).
The Copy button will again be displayed when the last item in the search path
has been entered. If any of the items from the database search tree were
modified, a new record will be created in the User Default and Working
databases when the Copy button is pressed. If none of the items were
modified or were modified to match an existing database record, the operator
will be given the option of overwriting an existing record in the User Default
and Working databases when the Copy button is pushed.
Press the Back button during this procedure will open the previously
displayed screen.
Press the Cancel button at any time to abort the procedure and go back to the
Utilities (Transfer Data) screen.

Section 4: Database
4.4.3 Delete
Press the Delete button and a Working database search tree will appear on
the left. Navigate through the search tree to the Quality level by pressing on
the icons in the tree view or by using the Up, Down, Left, and Right arrow
buttons. A list of Materials will now appear on the right. Select a record and
the Delete button will turn from gray to blue indicating the record can be
deleted. Press the Delete button again to remove the record from the User
Default and Working databases.
4.4.4 Exit
Press this button to return to the Database screen.

Section 5: Run Screen

The Run Screen, like the rest of the screens, is dynamic meaning the buttons displayed on it vary
as different modes or processes are selected. This screen will display a graphical picture of a
part program, text view of a part program (Automatic, Dry Run and Simulation mode), Jog buttons
(Manual and Rip Cut mode), Plate Alignment buttons (Manual mode) as well as some process
dependant buttons.
When a part program has been loaded, a graphical picture of a part or nest will be displayed.
Entities that will are to be cut will be shown in black and those entities that are not to be cut (i.e.
rapid positioning moves) will be shown in blue.

5.1. <Graphic Toolbar>

Press anywhere on the white grid area to view a toolbar used to graphically zoom in/out,
pan or to swap the position of the graphical part view and the CNC code view. This is
sometimes helpful to debug problems within the part program.
5.1.1 Close Toolbar

Press this button to close the toolbar.
5.1.2 Select
This button is currently not used.
5.1.2 Pan
Press this button then touch the lower half of the graphical view to shift the part
program display up. Touch the upper half of the graphical view to shift the part
program display down. Touch the right half of the graphical view to shift the part
program display left. Touch the left half of the graphical view to shift the part
program display right.

5.1.3 Zoom Window

Press this button then touch one corner of an area within the graphical view.
Touch the opposite corner of an imaginary rectangle to complete the zoom in
process.
5.1.4 Zoom In
Press this button then touch a location in the graphical view. The area around this
location will become magnified.
5.1.5 Zoom Out

Press this button and the image in the graphical view will become smaller.
5.1.6 Zoom Extents

Press this button to display a full size view of the part program.
5.1.7 <Switch Display>
Press the Graphics + Program button to show a large image of

the part program and a small display of the NC code.
Press the Program+ Graphics button to show a large image of
the NC code and a small image of the part program.
Press Cancel to close this menu.

5.2 <Text View>

(This window is only visible in Automatic, Dry Run and Simulation mode)
The CNC code of the current program will be displayed in this window. As the program is
executed, the current block will be highlighted with a blue bar. Lines within the program
with errors will be highlighted in red.
5.3. Align Plates

(These screens are only available in Manual mode)
The plate alignment feature is used to orientate the part program to the angle of the plate.
Press this button to see begin the procedure.
5.3.1 Options
Press this button to access the options for plate alignment.
5.3.2 Reset
Press this button to start the plate alignment process over.
5.3.3 Done
Press this button after the plate alignment points have been
identified.

5.3.4 Align Method

Select the number of points from the drop-
down list that will be used to define the angle of
the plate.
5.3.5 Align Corner
Select a corner of the plate from the drop-down
list that will be used to define the angle of the
plate.
5.3.6 Active Reference Point
The angle of the plate will be stored in the
Reference Point location selected by this
button.
5.3.7 Done
Press this button after these options have been
set.
5.3.8 <Blue arrow buttons>

Position the selected cutting torch, laser pointer or
cross hair in camera view at a point on the edge of the
plate reference one of the blue buttons. Once the
device is at this point, press the corresponding button
with the blue arrow to capture the point. The button
will turn from white to green. Repeat this process with
each of the blue arrow buttons until all are green.
5.3.9 Options
Press this button to select new options for plate alignment.
5.3.10 Reset
Press to clear all selected points.
5.3.11 Done
After this button is pressed, the control will calculate the angle of the plate based
on the information provided. The angle will be stored in the Reference Point
previously selected and displayed in yellow at the top of the screen. Go to
Operations Menu | Process Variables | Reference Points to modify or reset this
angle to zero.

5.4. <Process Information>

(These screens are only visible in Automatic, Dry Run, Rip Cut and Simulation mode)
This area of the Run Screen contains key information or buttons relative to the selected
process and database record currently loaded. Some of this information is independent of
the selected process (oxyfuel, plasma, etc.) such as Material, Thickness and Plan Size. Data
fields with a white text box next to them (e.g. Preheat Time, Kerf, Cut Height and Pierce
Height) are dependant of the selected process. Elapsed Time is active only in Auto Mode
and displays a running time to execute a part program. It is paused during a Cycle Stop
condition and reset when a new part program is loaded or the Reset button is pressed.
Touch the white text box next to any of the fields to quickly change a value. Any changes
made to these values are not permanent. Press the Database icon on the Operation Menu to
save the changes to either the Working or User Default database(s). The process
independent fields are read-only and therefore grayed out.
5.4.1 <Plasma Process>
5.4.2. <Oxyfuel Process>
5.4.2.1 Cut Low

Will turn low pressure cutting oxygen on.
5.4.2.2 Cut High
Will turn high pressure cutting oxygen on.
5.4.2.3 Pre Low
Will turn low preheat gasses on.
5.4.2.4 Pre High
Will turn high preheat gasses on.

Section 6: Process Variables

The Process Variables menu is used to access several features of the Global Control. Also
under this menu are several configuration parameters that are not dependant on a particular
process or database record. For example, an oxyfuel or plasma lifter may have a parameter that
allows the operator to set a height to raise the lifter to after each cut. This parameter will typically
not vary significantly between 6mm and 30mm material therefore, it can be set one time in this
section rather than in each database record.
Some of the screens under the Process Variables menu are unique to each machine. The Global
Control is configured to match the process tools and options purchased with the machine. Some
of the more common options are described in this section. See Appendix D for descriptions of
several other options that are available.
6.1 Reference Points
Sometimes called table home positions, there are 20 locations that can be used by the
operator to quickly align the machine to points (i.e. fixture locations) within the working
area.

To Define Points:
Touch the white dialog box next to a Reference Point to set the X dimension. Enter
a dimension from the absolute home position of the X axis to a point in the working
area. Repeat this step to define the Y dimension point. An angle may also be
assigned to each Reference Point.
An alternate method to set a Reference Point is to jog the machine to a location
within the working area, press one of the Reference Point buttons then press Use
Current Position. The current X and Y dimensions of the machine will
automatically be stored in the Reference Point.
Use the Up and Down arrows to scroll through the pages of Reference Points.
To Select a Point:
Press one of the numbered

Reference Points (1, 2, 3-20).
The button will turn from white
to green indicating this
Reference Point is now active.
Press Move to Active

Reference Point. The
machine will move to the
location defined by the
coordinate values.

6.2. Plasma
6.2.1 Sample Voltage Mode

Toggle this button on/off to configure the control to use either the set point arc
voltage in a database record or to sample the arc voltage at each pierce point.
Please see Appendix B for information on the Sample Voltage Delay parameter in
a database record. The default for this button is on (green).
6.2.2 Stop on Number of Lost Arc
This parameter determines how many arc transfer signals need to be lost before
the machine enters a cycle stop condition.
Suppose a machine is marking with two plasma markers simultaneously and this
parameter is set to 2; then both markers need to lose their arc before the machine
will stop. Set the parameter equal to 1 to stop the machine after only one marker
loses its arc.
6.2.3 Arc Off Delay
This parameter value is the time before the Global Control recognizes the plasma
arc has been lost. If the value is too low, the control might inadvertently stop the
machine if the lead-out is too long. The downside of having too big of a number is
if the cut is lost while cutting a continuous segment, the machine will continue on
path for this amount of time before stopping. The operator must then use the Back
button to reverse the machine on path before restarting the process.

6.3. Plasma #1
(The exact name of each plasma system will be displayed)
6.3.1 Partial Raise

When this button is turn on (green), the plasma lifter will retract after each torch off
command to the distance set in the Partial Raise Height parameter. When the
button is turn off (white), the plasma lifter will retract to the full up position. The
default for this button is off (white).
6.3.2 Partial Raise Height
The distance the torch will retract to from the top of the plate. Must have Partial
Raise button turned on for the control to use this parameter.
6.3.3 Safe Raise Height
The distance the torch will retract to before allowing machine motion to the next
pierce point. This parameter is used to decrease cycle time since the lifter only has
to retract to this height rather than to Partial Raise Height before moving. This
parameter should be set to the same or lower number than Partial Raise Height.
6.3.4 Tool Offset
Press this button to show the X and Y coordinates from this plasma torch to the
master tool or pointer (e.g. laser or camera). To set this torch as the master tool,
enter 0 for both the X and Y dimensions. Press this button again to hide the
coordinates.

6.4 Plasma Control

6.5. Plasma # 1
(The exact name of each plasma system will be displayed)
6.5.1 Arc Voltage

The number initially displayed in this field comes from the Arc Voltage value in
the latest database record applied.
If the Sample Voltage Mode button is green, the control ignores this
parameter.
If the Sample Voltage Mode button is white, the control will use this value
when height sensing is active to set the height of the lifter above the plate while
cutting. The operator can adjust the Arc Voltage value for each individual torch
to compensate for unequal consumable wear. The new value will be
remembered by the control and must be reset by the operator (by entering the
database value into this field) when the torch consumables are changed.
6.5.2 Current Arc Voltage
This read-only field will display the actual plasma arc voltage value from the
database record or measured during voltage sampling mode.
6.5.3 Remote On
This button will only be active for those plasma systems that support remote
on/off of the power supply. The button will turn green to indicate the power
supply has been instructed to turn on.

6.6. Oxyfuel
6.6.1 Leave Flame On

When this button is turned on (green) the selected oxyfuel torch/torches will stay lit
after a cut is complete and while the machine is positioning to another pierce
location. If this button is turned off (white) the gas will turn off after each torch off
command in the part program. The default for this button is off.

6.7. Oxyfuel
6.7.1 Partial Raise

When this button is turn on (green), the oxyfuel lifter will retract after each torch
off command to the distance set in the Partial Raise Height parameter. When the
button is turn off (white), the oxyfuel lifter will retract to the full up position. The
default for this button is off (white).
The distance the torch will retract to from the top of the plate. Must have Partial
Raise button turned on for the control to use this parameter.
The distance the torch will retract to before allowing machine motion to the next
pierce point. This parameter is used to decrease cycle time since the lifter only
has to retract to this height rather than to Partial Raise Height before moving.
This parameter should be set to the same or lower number than Partial Raise
Height.
6.7.4 Tool Offset
Press this button to show the X and Y coordinates from this oxyfuel torch to the
master tool or pointer (e.g. laser or camera). To set this torch as the master tool,
enter 0 for both the X and Y dimensions. Press this button again to hide the
coordinates.

6.8 Markers
6.9. Plasma Marking (ArcWriter)
The following parameters are available when the Power Supplies

button is green. These parameters will be duplicated for each identical
power supply.
6.9.1 Arc Voltage

The number initially displayed in this field comes from the Arc Voltage value in
the latest database record applied.
If the Sample Voltage Mode button is green, the control ignores this parameter.
If the Sample Voltage Mode button is white, the control will use this value when
height sensing is active to set the height of the lifter above the plate while
marking. The operator can adjust the Arc Voltage value for each individual torch
to compensate for unequal consumable wear. The new value will be
remembered by the control and must be reset by the operator (by entering the
database value into this field) when the torch consumables are changed.
6.9.2 Current Arc Voltage
This read-only field will display the actual plasma arc voltage as the torch is
marking.
6.9.3 Remote On
This button will only be available for those plasma systems that support remote
on/off of the power supply. The button will turn green to indicate the power
supply has been instructed to turn on.
The following parameters are available when the Parameters button is

green.
6.9.4 Sample Voltage Mode

Toggle this button on/off to configure the control to use either the set point arc
voltage in a database record or to sample the arc voltage at each pierce point.
Please see Appendix B for information on the Sample Voltage Delay parameter in
a database record. The default for this button is on (green).

6.9.5 Stop on Number of Lost Arc

This parameter determines how many arc transfer signals need to be lost before
the machine enters a cycle stop condition.
Suppose a machine is marking with two plasma markers simultaneously and this
parameter is set to 2; then both markers need to lose their arc before the machine
will stop. Set the parameter equal to 1 to stop the machine after only one marker
loses its arc.
6.10. ArcWriter
6.10.1 Partial Raise

When this button is turn on (green), the oxyfuel lifter will retract after
each torch off command to the distance set in the Partial Raise
Height parameter. When the button is turn off (white), the oxyfuel
lifter will retract to the full up position. The default for this button is
off (white).
The distance the torch will retract to from the top of the plate. Must
have Partial Raise button turned on for the control to use this
parameter.
The distance the torch will retract to before allowing machine motion
to the next pierce point. This parameter is used to decrease cycle
time since the lifter only has to retract to this height rather than to
Partial Raise Height before moving. This parameter should be set
to the same or lower number than Partial Raise Height.
6.10.4 Speed
Set the speed of the marking process. An F-code in the part
program will override this parameter.

6.10.5 Speed Low

Set this value to establish a low threshold for detecting marking
speed. During marking, if the machine speed drops below this
threshold, the marking current will be reduced to the “Current Low”
value.
6.10.6 Current
Set this value to remotely control the arc current of the plasma
marker. The plasma marker must be configured to support this
feature.
6.10.7 Current Low
Set this value to control the plasma marking current when the
machine speed is less than the Speed Low value.
6.10.8 Tool Offset
Press this button to show the X and Y coordinates from this plasma
marker to the master tool. To set this torch as the master tool, enter
0 for both the X and Y dimensions. Press this button again to hide
the coordinates.
6.10.9 Down Between Marks

When this button is turned on (green) the marker will not raise
between marker on and off codes. This is will reduce cycle time
however; there is a possibility of damaging the marking tool as the
machine positions to the next marking point.

6.11. Torch Spacing

This optional screen allows the operator to quickly set a distance between multiple
torches (i.e. carriages). It is an alternative to embedding torch spacing commands in a
part program.
6.11.1 Home Y
After this button is pressed, all slave carriages will unclamp from the beam and
band. The master carriage will then push all slave carriages to the Y-home
position. This sequence must complete prior to setting an accurate distance
between torches.
6.11.2 Change Minimum Distance
Press this button then enter the physical distance between sequential torches.
This distance will be automatically subtracted from the <Distance> parameter.
The result is the operator only needs to enter the desired distance between
torches to properly set the spacing. Press this button again to hide the physical
distance(s).
6.11.3 <Distance>
Touch the white dialog box then enter a distance to set between torches.
6.11.4 Space All
After this button is pressed, all torches will move until they are equally spaced
per the <Distance> parameter.
6.11.5 Space From and Space To
This screen also provides the unique ability to set an unequal distance between
torches. Press these buttons to select two torches to set a distance between.
6.11.6 Space Next
Press this button to space the two torches set by the Space From and Space To
buttons a distance set by the <Distance> parameter.
6.11.7 <Torch Distance>
This read-only field shows the current distance between each torch as set by
the buttons and parameters on this screen. The number is only valid if the
torches are not manually adjusted after torch spacing.

6.12. Accessories
6.12.1 Laser Pointer

6.12.2 Rail Cleaner
6.12.3 Table Exhaust
Press one of the buttons next to a feature

to show a dropdown list of options.
On will turn the device on.

Off will turn the device off.
Auto will automatically turn the device on
or off in predefined situations as directed
by the Global Control.
6.12.4 Laser Pointer Offset

Press this button to show the X and Y coordinates from the laser pointer to the
master tool. To set the laser pointer as the master tool, enter 0 for both the X
and Y dimensions. Press this button again to hide the coordinates.

6.13. Lifters
6.13.1 IHS Traverse Distance

The lifter (e.g. PL-1) will move (at maximum speed) this distance from the full-up
position down towards the plate before slowing down in order to achieve a more
accurate ignition or pierce height. To avoid a torch collision situation, the lifter
must reach this point before the torch comes in contact with the plate.
6.13.2 Lifter Jog Speed
Use this parameter to adjust the manual jog speed of many different types of Z-
axis lifters available with the control (e.g. PL-1).

Section 7: Macro Nesting

A library of standard shapes or macros has been included to allow an operator to quickly create a
nest of generic parts. This is an alternative to having parts created with an off-line CAM software
package.
7.1 Plan length (X)

Touch the white dialog box next to this parameter and enter the desired length of the
plate.
7.2 Plan width (Y)

Touch the white dialog box next to this parameter and enter the desired width of the plate.
7.3 Nesting start corner and direction

The blue dots on these buttons indicate the corner of the plate the parts will be nested
from and the direction they will be nested.
7.4 Cutting sequence method

The blue lines on these buttons indicate the direction the carriage(s) will take as the
machine completes one row of parts and moves vertically up/down the plate.
7.5 Create Plan

Press this button after the plate size has been entered and the nesting pattern options set.

7.6 Distance between parts

Touch the white dialog box next to this parameter to set the scrap distance between parts
in the nest.
7.7 Distance between part and plate

Touch the white dialog box next to this parameter to set the scrap distance from the parts
to the edge of the plate.
7.8 Part rotation

Touch the white dialog box next to this parameter to set the rotation angle of the parts to
be nested.

7.9 Lead-in/Lead-out Configuration

The following set of buttons and fields are used to define the type and length of the lead-
in and lead-out for the macros.
7.10 Apply
Press this button to accept the information on this screen and to enter the macro
selection screen.

7.11 Macros
Press the Macros folder or the “+” sign to see a list of available macros.

7.12 Open
Navigate through the list using the arrow keys. After you have identified the desired
macro, press Open.

7.13 <Macro Parameters>

Each shape will have a unique set of parameters. Match the parameter name to the
graphical representation then touch the white area next to each parameter and enter the
desired dimension. Notice in the picture above, AY refers to the width of the part. Some
shapes may have several parameters. Use the up/down arrow keys access them.
7.14 Quantity
Touch the white dialog box and enter the quantity needed.
7.15 Nest
Press this button to create a nest of the parts.
7.16 Load
Press this button to load the nest of parts. You will then be automatically directed to the
Database menu.
7.17 Load Parameters

Press this button to restore setup parameters previously stored for the macro.
7.18 Save Parameters

Modify the default parameters as necessary to achieve the desired macro then press
this button to store the current parameters. The software allows you to save these
values so they can be quickly reloaded.
7.19 Select Macro

Use this button to select another (or different) macro from the macro library.
7.20 Nesting Options

Press this button to return to the screen where you can adjust such parameters as the
distance between parts, rotation and the lead-in/out values.

7.21 Undo
Press this button to un-nest previously nested parts in the order they were placed on the
plate.
7.22 Redo
The opposite of Undo, this button allows you to re-nest parts as they were previously
nested.
7.23 New Plan

Press this button to start at the beginning of the Macro Nesting process. You will then
be able to create a new plate size and define the nesting pattern. Once directed to the
next screen you may press Cancel to return to this screen. Press New Plan again on
the new screen and all previous nesting data will be lost.
7.24 Save As…

Press this button to save the current nest of macro parts as a part program. This
program can then be loaded at a later time using the Part Programs menu.

Section 8: Program Nesting
Section 8: Program Nesting

This feature is not yet implemented.

Section 9: Consumables
Section 9: Consumables

Section 10: HMI Control
10.1 Shut Down Control

Press this button to shut down the control. The result is the same as choosing Shut
Down from the Windows Start menu. Note: This button will only shut down the PC and
control panel display; electrical power will still exist on other components.
10.2 Restart Control

Press this button to reboot the control. The result is the same as choosing Restart from
the Windows Start menu.
10.3 Switch Units

This button will toggle between English (inch) and metric mode. Always reload the
current part program after pressing the Switch Units button.
10.4 Use source program as target program

When the button is on, the part program code (source code) will not be converted. If the
button is off (white), the source code will be converted to the preferred NC code used by
the Global Control. This button is on (green) by default.

10.5 Backup db to floppy

Press this button to compress and save the Messer Default, User Default and Working
Databases to the floppy disk drive. After pressing the Backup db to floppy button, the
following dialog box will open. Press the Yes button to perform the backup.
After pressing the Yes button, the following dialog box will open. Press the Close
button.

10.6 Restore db from floppy

Press this button to copy the Messer Default, User Default and Working Databases to
the Global Control. After pressing the Restore db from floppy button, the following
dialog box will open. Press the Yes button to replace existing databases with databases
on the floppy disk.
After pressing the Yes button, the following dialog box will open. Press the Close
button.

Section 12: PLC Configuration
Section 11: ScopeView

Press this icon in the Support menu to access ScopeView files. In addition to opening a
ScopeView file, the operator may also delete ScopeView files by pressing the appropriate buttons.
This feature is normally used only by MG Service personnel to aid in diagnosing machine
problems. Therefore, a discussion of how to use ScopeView once a ScopeView file is opened is
not included in this manual.
Press a folder icon or the “+” sign next to a folder icon to open a folder a see a list of files or
additional sub-folders. Use the up, down, left and right arrow buttons to navigate through the file
tree.
11.1 Delete Button

Press this button to delete a selected ScopeView file.

11.2 Open Button

Press this button to open a selected ScopeView file (see example ScopeView file below).

12.1 Store Setup

Press this button to store various numeric data and button states (e.g. Process
Variables data, reference points data, etc.) After storing the setups, the control will load
the saved data whenever the control is powered up or the Load Setup button is pressed.
12.2 Load Setup

Press this button to load previously stored parameters to the Process Variables screens.

Section 13: Virtual Service
Section 13: Virtual Service
13.1 Start Virtual Service

Press the Start button to allow MG System’s Service personnel to access the control.
13.2 Stop Virtual Service

Press the Stop button to end the Virtual Service session.

Section 14: About…
Section 14: About …
14.1 HMI Version

Displays the current version of the operator interface (HMI) software.
14.2 .Net Framework Version

Displays the current version of the .Net Framework.

Appendix A: Oxyfuel Database Variable Definitions
Appendix A:
Oxyfuel Database Variable Definitions
Auto height delay

After machine motion starts, the delay before automatic height control will control the torch
height during the cut. This value is normally set to a value that will allow the torch to get past
the pierce puddle and allow the torch gases to stabilize.
Bevel height
Only used in conjunction with triple torch oxyfuel bevel cutting. The distance from the top of
the land to the tool center point (TCP). The TCP is the intersection of the bevel torch axis
and the straight torch axis (usually located on the top surface of the plate).
Bottom angle
Only used in conjunction with triple torch oxyfuel bevel cutting. The angle of the torch cutting
the bottom bevel on the plate.
Creep speed factor
This value should always be a number greater than 0 and less than or equal to 1. The creep
speed will be set equal to Cut speed * Creep speed factor. Normally, used to minimize
piercing blow back onto the torch consumables. Minimizing piercing blow back onto torch
consumables increases consumable life. Also, used to reliably start a cut.
Creep time
After piercing, the amount of time the torch will travel at the creep speed before the torch will
accelerate to the Cut speed. The creep speed is equal to Cut speed * Creep speed factor.
Normally, used to minimize piercing blow back onto the torch consumables. Minimizing
piercing blow back onto torch consumables increases consumable life. Also, used to reliably
start a cut.
Cut gas pressure economy
Cut gas pressure high
Cut oxygen pressure high.
Cut gas pressure low
Cut oxygen pressure low.
Cut height
The height of the torch tip relative to the surface of the plate during cutting.
Cut speed
The speed at which the torch will travel while cutting.
Cut type
Only used in conjunction with triple torch oxyfuel bevel cutting. The plate edge cut type
(e.g. I, K, X, etc.).
Fuel gas
Type of fuel gas supplied to the torch (e.g. acetylene, propane, natural gas, etc.).
Fuel gas pressure economy
Global Control Operator Manual A-1 Rev. 1.01

Appendix A: Oxyfuel Database Variable Definitions
Fuel gas pressure high

Fuel gas pressure low
Fuel gas pressure low. Used during torch ignition.
Kerf
The width of the gap left by the cutting operation. This value is normally adjusted to obtain
the proper part size.
Land height
Only used in conjunction with triple torch oxyfuel bevel cutting. The thickness of the vertical
face of the bevel cut.
Material
The material that is to be cut (e.g. Mild Steel).
Motion delay
The time from when the Preheat time expires to when machine motion is allowed. If a
moving pierce is desired, then the value for Motion delay should be set to a value less than
the value for Pierce time. A moving pierce is normally used to minimize piercing blow back
onto the torch consumables. Minimizing piercing blow back onto torch consumables
increases consumable life.
Pierce down delay
The time the torch will stay at the Pierce height before moving to the Cut height. This time
is adjusted to allow the torch to clear the pierce puddle.
Pierce height
The height of the torch tip relative to the surface of the plate during piercing operation.
Pierce time
After the Preheat time expires and the torch reaches the Pierce height, the low cut gas
pressure will be turned on for this amount of time. This time is adjusted to allow the cut
oxygen stream to pierce through the plate.
Preheat gas pressure high
Oxygen gas pressure used during preheating for faster preheating.
Preheat gas pressure low
Oxygen gas pressure used to maintain a flame.
Preheat time
After the torch is ignited and initial height sensing is complete, the plate will be preheated for
this duration using the Preheat gas pressure(s). The plate will be preheated to kindling
temperatures.
Quality
The desired cut quality (e.g. Best, Good, Fast). Higher quality levels will normally achieve
better part edge quality and/or have less dross than lower quality levels. The advantage of
the Fast quality level is that the cut speed is faster than Good quality and much faster than
the Best quality.
Thickness
The thickness of the material to be cut.
Top angle
Only used in conjunction with triple torch oxyfuel bevel cutting. The angle of the torch cutting
the top bevel on the plate.
Global Control Operator Manual A-2 Rev. 1.01

Appendix B: Plasma Database Variable Definitions
Appendix B:
Plasma Database Variable Definitions
Amps
The current the plasma power supply will use to cut the plate. The allowable current settings
are a function of the particular plasma power supply. Normally, the higher the current setting
the thicker the material that can be cut. If multiple amperage settings are available for a
certain material and thickness, the higher amperage setting will normally allow the material to
be cut faster, however, the cut quality is normally better with the lower amperage setting.
Arc Offset 15 Degrees
Only used in conjunction with a rotator cutting a continuously changing bevel angle. This is
the arc voltage offset percentage that will be used when the torch bevel angle is between 0
and 15 degrees. The value should always be a number greater than 0 and less than or equal
to 1. Entering a value of 0.9 would mean the Arc voltage set point at 15 degrees would be
modified to be 0.9 times the database Arc voltage value. An interpolation algorithm is used
to determine the arc voltage set points between 0 and 15 degrees.
Arc Offset 30 Degrees:
Arc Offset -15 Degrees
and -15 degrees. The value should always be a number greater than 0 and less than or
equal to 1. Entering a value of 0.9 would mean the Arc voltage set point at -15 degrees
would be modified to be 0.9 times the database Arc voltage value. An interpolation
algorithm is used to determine the arc voltage set points between 0 and -15 degrees.
Global Control Operator Manual B-1 Rev. 1.01


the arc voltage offset percentage that will be used when the torch bevel angle is between -15
algorithm is used to determine the arc voltage set points between -15 and -30 degrees.
Arc voltage
Arc voltage set point. When sample voltage mode is Off, the torch tip to plate distance will be
controlled by this voltage set point. The higher the voltage the higher the torch tip will be off
of the plate. When sample voltage mode is on, this parameter is not used.
Assist gas
Only valid for Komatsu plasma systems. Gas that is ported to the shield of the torch.
Auto height delay
After the cut height is reached, the delay before automatic voltage control will control the
torch height during the cut. When sample voltage mode is off, this value is normally set to a
value that will allow the torch to get past the pierce puddle and allow the torch gases to
stabilize. When using sample voltage mode, this value must be set to a value greater than or
equal to the value for Sample voltage delay so a voltage set point is established before
trying to automatically control the voltage.
Creep time
Normally, used for plate thicknesses greater than 12.7 mm to minimize piercing blow back
onto the torch nozzle and shield. Minimizing piercing blow back onto torch consumables
increases consumable life. Also, used to reliably start a cut.
Cut height
The height of the torch tip relative to the surface of the plate during cutting.
Cut speed
The speed at which the torch will travel while cutting.

Creep speed factor

Normally, used for plate thicknesses greater than 12.7 mm to minimize piercing blow back
onto the torch consumables. Minimizing piercing blow back onto torch consumables
increases consumable life. Also, used to reliably start a cut.
Distance before cut height
Currently not available. The vector distance the torch will travel at the Pierce height before
moving to the Cut height. This distance is adjusted to allow the torch to clear the pierce
puddle. Normally, used for plate thicknesses greater than 12.7 mm.
Down delay
The time the torch will stay at the Pierce height before moving to the Cut height. This time
is adjusted to allow the torch to clear the pierce. Normally, used for plate thicknesses greater
than 12.7 mm.
Ignition height
The height of the torch tip relative to the surface of the plate during torch ignition (i.e. after
initial height sense is established). Usually set this value to a height between the Cut height
and Pierce height.
Kerf
The width of the gap left by the cutting operation. This value is normally adjusted to obtain
the proper part size.
Material
The material that is to be cut (e.g. Aluminum, Stainless Steel, Mild Steel, etc.).
Override 15 Degrees
the Cut speed offset percentage that will be used when the torch bevel angle is between 0
to 1. Entering a value of 0.9 would mean the Cut speed set point at 15 degrees would be
modified to be 0.9 times the database Cut speed value. An interpolation algorithm is used to
determine the cut speed set points between 0 and 15 degrees.
Override 30 Degrees
Override 45 Degrees

Override 52 Degrees
Override -15 Degrees
equal to 1. Entering a value of 0.9 would mean the Cut speed set point at -15 degrees would
be modified to be 0.9 times the database Cut speed value. An interpolation algorithm is
used to determine the cut speed set points between 0 and -15 degrees.
the Cut speed offset percentage that will be used when the torch bevel angle is between -15
used to determine the cut speed set points between -15 and -30 degrees.
Pierce height
The height of the torch tip relative to the surface of the plate during piercing operation.
Usually set to a value equal to twice the Cut height.
Pierce time
The time from when the torch reaches the pierce height to when machine motion is allowed.
This time is adjusted to allow the plasma arc to pierce through to the bottom of the plate.
Pilot arc current
Only used with Komatsu plasma systems. The current required to establish a plasma arc
between the electrode and nozzle. This value is usually adjusted so that the arc is reliably
transferred to the plate during the ignition cycle. Setting this value as small as possible and
still obtain reliable torch ignition will extend consumable life.
Plasma gas
The primary cutting gas.

Plasma gas variable 1

Depends on plasma cutting system. Usually, plasma gas pressure or flow rate (%) in the
order presented in the plasma system manufacturer’s cut charts.
Quality
The desired cut quality (e.g. Best, Good, Fast). Higher quality levels will normally achieve
better part edge quality and/or have less dross than lower quality levels. The advantage of
the Fast quality level is that the cut speed is faster than Good quality and much faster than
the Best quality.
Sample voltage delay
After the cut height is reached and machine motion begins, the delay before the arc voltage
will be sampled to determine the arc voltage set point. This value is normally set to a value
that will allow the torch to clear the pierce puddle and allow the torch gases to stabilize so
stable voltages are acquired during voltage sampling. When using sample voltage mode, the
Auto Height Delay must be set to a value greater than or equal to the Sample Voltage
Delay.

Sensitive height control

Only valid for capacitive height sensing. When turned on, the torch height will react quicker
to height changes on the surface of the plate (e.g. sloped plate, pierce puddle, etc.). When
turned off, the torch will respond slower to height changes on the surface of the plate.
Shield gas
Gas that is ported to the shield of the torch.
Slope down time
Delay for plasma power supply current to ramp down at the end of a cut before raising the
torch. This value is normally adjusted to stop the arc from snapping prematurely at the end of
a cut which can reduce consumable life.
Thickness
The thickness of the material to be cut.
Time before cut off
This is the time prior to the end of a cut that the power supply current will start ramping down.
This value is normally adjusted to try to minimize the nick left in the part when cutting internal
circles.
Torch angle
The bevel angle the torch will cut at relative to the surface of the plate.

Appendix C: Plasma Marker Database Variable Definitions
Appendix C:
Plasma Marker Database Variable Definitions
Amps
The current the torch will use to mark the plate. The allowable current settings are a function
of the particular plasma power supply. Normally, the higher the current setting the deeper the
scoring will be.
Arc voltage
Arc voltage set point. When sample voltage mode is Off, the torch tip to plate distance will be
controlled by this voltage set point. The higher the voltage the higher the torch tip will be off
of the plate. When sample voltage mode is On this value is not used.
Assist gas
Only valid for Komatsu plasma systems. Gas that is ported to the shield of the torch.
Auto height delay
After the cut height is reached, the delay before automatic voltage control will control the
torch height during the mark. When sample voltage mode is off, this value is normally set to
a value that allows the torch gases to stabilize. When using sample voltage mode, this value
must be set to a value greater than or equal to the value for Sample voltage delay so a
voltage set point is established before trying to automatically control the voltage.
Cut height:
The height of the torch tip relative to the surface of the plate during marking.
Cut speed
The speed at which the torch will travel while marking.
Ignition height
The height of the torch tip relative to the surface of the plate during torch ignition. Usually set
this value equal to the Cut height.
Material
The material that is going to be marked (e.g. Aluminum, Stainless Steel, Mild Steel, etc.).
Pilot arc current
Only used with Komatsu plasma systems. The current required to establish a plasma arc
between the electrode and nozzle. This value is usually adjusted so that the arc is reliably
transferred to the plate during the ignition cycle. Setting this value as small as possible and
still obtain reliable torch ignition will extend consumable life.
Plasma gas
The primary cutting gas.
Quality
The desired marking quality (e.g. Best, Good, Fast). The advantage of the Fast quality level
is that the cut speed is faster than Good quality and much faster than the Best quality.
Sample voltage delay
After the Cut Height is reached, the delay before the arc voltage will be sampled to
determine the arc voltage set point. This value is normally set to a value that will allow the
torch gases to stabilize so stable voltages are acquired during voltage sampling. When using
sample voltage mode, the Auto Height Delay must be set to a value greater than or equal to
the Sample Voltage Delay.
Global Control Operator Manual C-1 Rev. 1.01

Appendix C: Plasma Marker Database Variable Definitions
Sensitive height control

Only valid for capacitive height sensing. When turned on, the torch height will react quicker
to height changes on the surface of the plate (e.g. sloped plate, pierce puddle, etc.). When
turned off, the torch will respond slower to height changes on the surface of the plate.
Shield gas
Gas that is ported to the shield of the torch.
Slope down time
Delay for plasma power supply current to ramp down at the end of a mark before raising the
torch. This value is normally adjusted to stop the arc from snapping prematurely at the end of
a mark which can reduce consumable life.
Time before cut off
This is the time prior to the end of a mark that the power supply current will start ramping
down.
Global Control Operator Manual C-2 Rev. 1.01

Revision Page
Appendix D:
Process Variables - Special

Air Scribe Marker
Speed
Set the speed of the marking process. An F-code in the part program will override this
parameter.
Motion Delay
The length of time the machine will not move after the tool turns on.
Tool Offset
Press this button to show the X and Y coordinates from this torch to the master tool or
pointer (e.g. laser or camera). To set this torch as the master tool, enter 0 for both the X
Global Control Operator Manual Revision-1 Rev. 1.01

Revision Page
Skew Axis Plasma Bevel Rotator
Partial Raise
When this button is turn on (green), the oxyfuel lifter will retract after each torch off
command to the distance set in the Partial Raise Height parameter. When the button is
turn off (white), the oxyfuel lifter will retract to the full up position. The default for this
button is off (white).
Partial Raise Height
The distance the torch will retract to from the top of the plate. Must have Partial Raise
button turned on for the control to use this parameter.
Safe Raise Height
The distance the torch will retract to before allowing machine motion to the next pierce
point. This parameter is used to decrease cycle time since the lifter only has to retract to
this height rather than to Partial Raise Height before moving. This parameter should be
set to the same or lower number than Partial Raise Height.
IHS Height
The distance between the plate and the torch after IHS (initial height sense) is complete.
The torch will raise the difference between the Ignition Height and the IHS Height before
starting the plasma arc.
Arc Voltage Delta Low
Not used at this time.
Arc Voltage Delta High
If the actual arc voltage is greater than the set value by this amount, the torch will stop
actively height sensing.

Revision Page
Arc Voltage Delta High Time

When a delta high voltage occurs, the arc voltage will stop height sensing for the length
of the delta high time. After this time, the delta high arc voltage is ignored and height
sensing is turned on until the delta high voltage goes away.
Press the down arrow to view page 2 of the parameters available for the skew axis plasma
bevel rotator.
Tool Offset
Arc Control Gain

This number represents the gain of the arc voltage closed loop. A typical number
would be 600 to 1200. This value will impact the smoothness of the Z-axis lifter
during active height sensing and the angle that it can track.

Revision Page
Drill
Spindle Speed
This parameter is dependant on the type of electric drill installed on the machine. It is
used to set the rotation speed (rpm) of the shaft.
Off Delay
The length of time the machine will not move after the tool turns off.
Feed Rate
This parameter is dependant on the type of electric drill installed on the machine. It is
used to set the downward speed of the drill bit. The value of this parameter will be shown
in bold type (e.g. 1000) at the top of the Operator Interface screen when Ripcut mode
and the Drill process are both selected.
Tool Offset
(These buttons are only available when in Ripcut mode and Drill is selected from the Process Menu)
Manual Start
Press this button to start a manual drill cycle.
Retract
Press this button to interrupt the manual drill cycle or to reverse the drill direction and
return to the full up position.

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Global Control m

Menomonee Falls, Wi 53051

MESSER - MG SYSTEMS & WELDING, Inc.

Voice (262) 255-5520

Global Control Operator Manual Rev. 1.01

Global Control Operator Manual Rev. 1.01

Section 1: Front Panel Layout

Global Control Operator Manual 1-1 Rev. 1.01

Global Control Operator Manual 1-2 Rev. 1.01

Section 2: Operator Interface

Global Control Operator Manual 2-1 Rev. 1.01

[Operator Controls Always Available]

2.1 Navigation Toolbar

Located on the right-hand side of the screen, the Navigation

Global Control Operator Manual 2-2 Rev. 1.01

Global Control Operator Manual 2-3 Rev. 1.01

2.3. Operation Mode Menu

Global Control Operator Manual 2-4 Rev. 1.01

Global Control Operator Manual 2-5 Rev. 1.01

2.3.3. Home Axis

Select an individual axis button (X or Y), Select

Global Control Operator Manual 2-6 Rev. 1.01

2.4 Process Menu

2.5 Position, Coordinate System, Part Rotation, and Current Part

2.7 Back Button

Global Control Operator Manual 2-7 Rev. 1.01

2.8 Virtual Keyboard Button

Press the button to minimize the keyboard.

2.9 ISO Icons

Global Control Operator Manual 2-8 Rev. 1.01

2.10. Process Dependant Buttons

Global Control Operator Manual 2-9 Rev. 1.01

2.11.10 Auto Return

Global Control Operator Manual 2-10 Rev. 1.01

2.12. Lifter and Height Sensing Configuration

A gray button indicates the lifter (i.e. station) is off.

2.12.2 Lifter Selection Button

2.12.3 Auto Height Button

Global Control Operator Manual 2-11 Rev. 1.01

Press one of these buttons to enable height sensing

Press one of these buttons to turn a lifter (i.e. station)

The arrow buttons grouped on the left are

A green Mirror button indicates the corresponding

Global Control Operator Manual 2-12 Rev. 1.01

Section 3: Part Programs

Global Control Operator Manual 3-1 Rev. 1.01

First select a folder then touch the white area

For example, if the ‘Customer B’ folder was

Press Search to cancel the search function or

Press Load to load the selected program.

Global Control Operator Manual 3-2 Rev. 1.01

Navigate to another location on the file menu

The operator may also touch the white dialog

Navigate to a folder the new file should be

Press Cancel to abort the operation.

Press Min to minimize the keyboard.

Global Control Operator Manual 3-3 Rev. 1.01

Global Control Operator Manual 3-4 Rev. 1.01

3.10 Save As…

Global Control Operator Manual 3-5 Rev. 1.01

Messer Default Database (Read only)

User Default Database

Store Restore Delete