Esab Vision 500 Manual

January, I996
INSTRUCTION MANUAL FOR THE
VISION 500
COMPUTER NUMERICAL CONTROL
5
VISION
m-
Inl~?lalmlI 1
41 1 South Ebenezer Road

Florence, SC 29501-0545
@ ESAB Cutting Systems, 1996
This manual is ESA6 Part Number F 1408 1
This manual is intended for the convenience and use of the

cutting machine purchaser. l t is not a contract or other
obligation on the part of ESAB.
Printed In U.S.A.
VISION 500
Preface
Preface
The Vision Computer Numerical Control System is a cutting machine CNC
manufactured by ATAS GmbH of Seligenstadt, Germany exclusive for ESAB
Cutting Systems. The Vision CNC may be used on various machines and may
utilize numerous different cutting processes. The Vision CNC is designed for
ease of operation, flexibility , and precise control of cutting processes and
machine motion.
Part programs for the Vision CNC may be manually entered, programmed off-
line, generated from a library of shapes, or digitized from traceable patterns.
There are numerous optional features and components of the Vision CNC
system. For completeness, all of these are described in this manual. However,
not all options or capabilities described in this manual are present on all
machines. In addition, more capabilities and features may be added in the
future, which are not covered in this manual. ESAB Cutting Systems reserves
the right to change or add features and capabilities without notice.
This manual is divided into two main sections. Section 1 is for use by machine
operators for learning the use of the control. Section 2 is for use by
maintenance personnel, for use in setup, maintenance, and troubleshooting of
the machine and the control. Before operating the Vision CNC, one should
become familiar with section 1 in its entirety, with special attention to parts 1 and
2, which explain the general operating principles of the Vision CNC System.
VISION 500
Operation
SECTION 1:
OPERATION
DATA INPUT
MACHINE MOVEMENT
RUNNING PROGRAMS
CONTROLLING PROCESSES
SELECTING STATIONS
VISION 500
Contents
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
1.1 The Control Panel of the VISION 500 . . . . . . . . . . . . . . . . 2
1.2 LCD Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Functions of the Windows . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 General Description of Screens . . . . . . . . . . . . . . . . . . . . . . . 9
Symbol Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 General Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Error Status Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Data Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Movement Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5 Servicewindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.6 Timer Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.7 Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.7.1 Plasma Process . . . . . . . . . . . . . . . . . . . . . 27
3.7.2 Oxy Fuel Process . . . . . . . . . . . . . . . . . . . . 28
3.7.3 Marking Process . . . . . . . . . . . . . . . . . . . . . 30
3.7.4 Plasma Mark Process . . . . . . . . . . . . . . . . . 31
4 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Datawindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.1 UDL (Up .Download) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.2 Floppy Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.3 .Computer Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.4 Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.5 Shape Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.6 Program Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6 Movement Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

6.1 Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.2 Fixed Point Movements . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.3 Reference Point Movement . . . . . . . . . . . . . . . . . . . . . . . 124
6.4 Trace 1 Trace Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.4.1 Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.4.2 Trace Record Setup . . . . . . . . . . . . . . . . . . 133
7 ProcessWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.1 Plasma Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.2 Oxy Fuel Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.3 Punch Mark Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.4 Plasma Marker Process . . . . . . . . . . . . . . . . . . . . . . . . . . 147
VISION 500
Page 2 Introduction
1.1 The Control Panel of the VISION 500
VISION
ESAB
VISION 500
Introduction Page 1
I lntroduction
VISION 500 is a numerical control system especially designed for use with
mechanized cutting machines. Special effort was made to standardize all
operations that must be performed by the operator. The same techniques are
used for controlling and monitoring the part program, machine motion, and
cutting processes.
The basis of the operating concept is that all control operations are performed by
selection of choices from a menu. This, however, is not always sufficient in
order to handle an upcoming requirement quickly and efficiently in any situation:
searching for the necessary menu branch could take too long. Therefore,
"parallel windows" or "concurrent sessions" were introduced as a supplement to
the menu system. With these parallel windows it is possible to switch from one
operating menu to another with just one keystroke.
A multi-tasking operating system supports the "simultaneous" access to different

areas of the CNC. This also allows immediate access to all necessary machine
controls. In addition, the system makes sure that only those menu choices are
offered which apply in the given situation, without cutting back on the variety of
ways to control the cutting process.
One special characteristic of operating the VISION 500 is the use of symbols on
the menus instead of text. While the symbols will require some getting used to,
in the long run they are easier to remember than abbreviations, and sometimes
even easier to remember than explanatory texts which can be more confusing
than clarifying because of their restricted length.
VlSlON 500
Page 2 Introduction
1.1 The Control Panel of the VlSlON 500
VlSlON
-
m
VISION 500
Contents
8 Station Control Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

8.1 Station Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.2 Station Lift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
9 Timer Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

10 Error - Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
11 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
VISION 500
Introduction Page 3
Window and Function Keys
w Window Buttons
Data Input
(Service)
VISION
Station Select
(Station UpIDown)
Menu Extension
Back r a y e function keys
The keys to the right of the screen are called window keys. With these keys
the operator can switch between the main operating groups "data input",
"movement", "process" and "station selection". In combination with "shift", they
switch to the windows "service", "timers" and "station upldown". Normally, it is
possible to switch between the different windows at any time without completing
a task that has already been started. There are a few exceptions, and in those
cases an explanatory message is displayed. The functions performed in each of
the individual windows will be explained at a later point.
The six function keys at the bottom of the screen are used to navigate through
the menu system. This is usually done by selecting a function, and then
selecting from among the choices on the following branch menus, until the
desired function is achieved.
The function of each key in the current menu is indicated by the symbols in the
soft menu above the keys. If the menu item is empty on a certain screen, then
the key underneath does not have any function in that screen.
Shiftifunction keys lead to additional, independent service windows. When a

different window is selected, the activity in the current window is not affected.
VISION 500
Introduction
The backpage key switches back one screen in the sequence of screens. This
can be continued up to the basic screen of the current window.
The combination of shiftlbackpage switches back directly to the basic screen of

the current window.
If there are more than six functions simultaneously available in one menu, there
will be an arrow to the right of the on-screen menu. In this case, the operator
can switch between the two function groups with the menu extension key.
LCD Screen
A standard format is followed with the layout of the LCD screen.
The symbol of the current window will always be displayed in the top left corner
of the screen.
Along the bottom of the screen is the menu, with symbols that indicate the
functions that are currently assigned to the function keys. Empty boxes on the
menu indicate that the corresponding function keys not used in that screen.
With every further branch into submenus via one of the function keys, the symbol
of the key will be added to the top line of the screen. Thus, it is always easy to
see how far the branching of a function has proceeded.
For keys that do not effect further branching but that trigger a command, the
status of the function is usually displayed in the menu by showing the symbol
either in its original form, or in inverse (highlighted). When a symbol is shown
highlighted, it indicates that the function has been turned on. Such symbols are
not added to the top line.
VISION 500
Introduction Page 5
1.3 Functions of the Windows
m Data Input:
All control of part programs:
- Program input-output
- Controlling part program storage
- Programming from the shape library
- Editing part programs
Service: (SHIFT-Data Input)

Functions for servicing the control
- Constant editors
- Station parameters
- Copying the system floppy
- Formatting floppy disks
- Speed measurement
- Rotational speed measurement
Movement:
W All functions for machine movement
- Preparation for program execution

- Processing of a program
- Manual control
- Manual control with the joystick
- Reference point movement
- Fixed point movements
- Trace / Trace Record
Process:
All control of the cutting processes:
- Process selection
- Process setup
- Process control
m Timers: (SHIFT-Process)
Adjustment of parameters for the cutting processes:
- Timer adjustments
- Values for cutting media
VISION 500
Page 6 Introduction
Station Selection:
El
- Turning the cutting stations on and off
Station UplDown: (SHIFT-Station Selection)
- Raising and lowering motorized stations

- Adjusting cutting height
ErrorlStatus: (ShiftlF6)
lel
a - Error 1 status display
VISION 500
Introduction Page 7
Character and Number Block
Backspace Enter
T
-
I I
Character block Number block Station UpIDown keys

VISION 500
Page 8 Introduction
Motion Controls
Rapid
\-Feed rate
J potentiometer
on8
00
\ J
EmergencyStop Stop Start

The motion controls allow for control of machine motion in both manual and
automatic modes. Except for the joystick and feed rate potentiometer, they are
effective in any situation independent of the active window. The function of the
joystick and feed rate potentiometer are dependent on the active window.
The joystick can be used to move the machine in any direction in manual mode
or in case of program interruption. Furthermore, both axes can be moved
simultaneously in a 45 degree direction. The machine is moved as long as the
joystick is being pushed. Releasing the joystick will make the machine come to
a standstill.
When performing the reference point movement, the joystick is only used to
select a direction of movement. The movement itself is triggered with the start
key. Only a short click of the joystick is necessary to select a direction.
In some screens, the joystick and the feed rate potentiometer are used to
control movement of the cursor. In those situations, the joystick is used to
define the direction of movement via the feed rate potentiometer. The direction
depends on the last direction that was given by the joystick. For example, if
using the feed rate potentiometer to move the cursor within in a certain line, the
joystick has to be pushed to the left or right side first. Turning the feed rate
potentiometer to the right, will then move the cursor to the right, turning it to the
left will move the cursor to the left. To move the cursor from one line to the
next, the joystick has to be pushed up or down first. Turning the feed rate
potentiometer to the right will then move the cursor down, turning it to the left
will move the cursor up.
The Rapid key is only effective in the manual mode when using the joystick. It
is used to toggle between high and low jog speeds. The feed rate potentiometer
affects the speed of all movements in both manual and automatic modes.
The operator uses the keys <start> and <stop> keys for controlling automatic
program execution.
VISION 500
Screen Descriptions Page 9
- 2 General Description of Screens
The top line on the screen is used to display general information.
The symbols in the top left corner mark main

groups and the branching of the menu tree for
the active screen.
The symbol at the far left shows which main

window is active. This symbol is always shown
highlighted.
The symbols to the right of the window symbol

display the branches that were used to arrive at
the current window.
Whenever branching down in the menu is

continued by pressing another key, the symbol of
the key will be added to the top line.
The top right corner displays the current speed,

the traversing direction, status of the start and
stop keys and the error symbol. Which kind of
error has occurred is displayed in the error status
screen.
VISION 500
Page 10 Screen Descriptions
The bottom line of the screen displays the menu,

with symbols indicating the current meaning of
the function keys (menu keys). An empty box
above a key indicates that no function is
assigned to that key.
The function keys can fulfill two tasks: further
branching within the menu tree and triggering of
a command.
Whenever a key branches down in the menu

tree, the symbol of the key will be added to the
top left corner in order to indicate which menu
has been selected.
If pressing a function key does not lead to further

branching within the menu tree, then the function
key triggers a command that leads to a status d
change of a control or machine function. When a

symbol is shown highlighted, it means that this
function has been turned on.
When a symbol is not highlighted, it means that

this function is off.
The description of the menu functions in this manual do not always indicate
when a function is an optional item which has to be purchased with the machine
in order to be active. In most cases, a function is not shown on a menu if it was
not purchased.
VISION 500
Boxes for Information, Selection, Input and Inquiry
Information Boxes display errors and messages. It does not matter which
window or which screen is active. If there is a limit switch error, for example,
while the editor screen is active in the data window, an information box will be
displayed with the message about the limit switch error.
The current menu line above the function keys

of the actual picture will be overlaid. Above the
F1 key, the symbol for "confirm" is displayed.
The remaining five key fields are empty.
Errors and messages have to be confirmed with the F1 key. At the time of
confirmation the error message will be cleared. However, if the error occurs
again within a certain period of time, the error cause has not been removed.
The error message box will not appear again, but the error symbol at the top
right corner of the screen will not disappear. The error message will still be
displayed in the error status window.
Selection Boxes are displayed for selecting a program. They display a list of
available programs. The names of the programs are listed in alphabetic order.
The programs are selected with joystick, feed rate potentiometer or keys with
letters and digits. With every letter or digit that is typed, the cursor is moved to
the corresponding program.
The current menu line above the function keys of

the actual picture is overlaid. Above the F1 key,
there is the symbol for "confirm". The program
marked by the cursor has been selected.
Selection is cancelled by pressing the F6 key.
VISION 500
Screen Descri~tions
Input Boxes are displayed for functions that require a value. For example, for
jumping to a block number in the editor, the appropriate block number has to be
entered. The input box is then displayed.
Again, the actual menu line of the current picture

is overlaid with the symbol for "confirm" above
the F1 key and the symbol for "cancel" above the
F6 key.
The required data is entered with the letter and

digit keys.
Inquiry Boxes are displayed when the operator carries out actions that might
cause damage. For example, if the operator presses the backpage key during
automatic program processing, the program would be aborted. Such actions
have to be confirmed with the inquiry box.
Again, the menu line is overlaid with the symbol

for "confirm" above the F1 key and the symbol
for "cancel" above the F6 key.
If the F1 key is pressed, the requested action will

be executed. With F6 the operator can return to
the original status without performing the action.
Letter Line
Since not all letters are available on the control panel keys, a line of letters
appears on screen to allow selection from the entire alphabet.
The cursor is positioned on the individual letters

of the letter line by means of the feed rate
potentiometer. With the return key, the selected
character from the letter line is entered into the
input field.
VISION 500
Arrangement of This Manual
This manual consists of pages of screen descriptions. Each of these page

shows:
- a picture of the screen

- the assignment of the function keys for that screen
- any possible additional keys
A description of the function keys follows each screen picture, with a reference
to a page number indicating on which page of the operating instructions the
following screen is described. Therefore, it is easy to follow the operation of the
control by leafing to the referenced page in order to see what screen will appear
when that function key is pressed.
VISION 500
Paae 14 Symbol Overview
3 Symbol Overview
3.1 General Symbols
The following descriptions are of general symbols that can appear in any
window.
Start. This symbol is displayed in the top right corner of the screen
when the program start button has been pressed, and the machine is in
the start status.
Stop. This symbol is displayed in the top right corner of the screen
when the program stop button has been pressed, and the machine is in
the stop status.
Error. This symbol is displayed in the top right corner of the screen
@ when there is an error. Further information is displayed in the error
status window.
Confirm. This symbol is used to prompt the operator to confirm an

action or input, before the control continues.
4 Defining a macro. This symbol is displayed in the bottom left corner

UO when an operating macro is being defined.
t Macro call. This symbol is displayed in the bottom left corner when a
m macro is being executed.
ng Cancel. For cancelling or quitting a function, for example, of an

inquiry box.
Save. This symbol appears in an inquiry box. It is displayed after data

has been changed. This is a request for confirmation that the changed
data should be saved.
Delete. This symbol indicates clearing errors or deleting programs,

% depending on which window is active.
VISION 500
Svmbol Overview Page 15
Direction indicator. Indicates the current direction of

A Y machine motion via the joystick. The indicator is on
every screen in the top right corner.
Standard feed rate. This indicates that the standard speed range is in
% effect. When in effect, this indicator appears on every screen in the
top right corner.
Rapid feed rate. This indicates that the Rapid speed has been
selected. When in effect, this indicator appears on every screen in the
top right corner.
VISION 500
Page 16 Symbol Overview
3.2 Error Status Windows
Error Status window. This symbol is displayed in the top left corner
when the error status window is the active window.
Status lnformation window. For switching to the status information

window that displays the status of various machine functions and
information.
Version Information window. For switching to the version

information window that displays the software version and serial
numbers of the control.
24 Volt power. This symbol is displayed in the top right corner of the
screen when the 24 Volt power has been switched on. The voltage is
switched on by pressing the key combination shiftlstart. This symbol
will appear flashing if the 24 Volt power has not yet been turned on.
The 24 Volt power may be manually switched off with the key
combination shiftlstop. It is also switched off any time the machine's
E-Stop string is broken, or the machine power is turned off.
Reference. The letters to the right of this symbol indicate which axis
has already been referenced.
Drive Enable X. lndicator for drive enable in the X-axis. If this

symbol is not displayed, the drive is not enabled. The machine cannot
be operated along the X-axis.
Drive Enable Y. lndicator for drive enable in the Y-axis. If this

symbol is not displayed, the machine cannot be operated along the Y-
axis.
System Processing Enable. lndicator for System Processing Enable.

If this symbol is not displayed, no program codes or key functions will
be processed.
Motion Enable. lndicator for motion enable. Motion Enable is set by

the machine interface.
VISION 500
Symbol Overview Page 15
Direction indicator. Indicates the current direction of

A Y machine motion via the joystick. The indicator is on
every screen in the top right corner.
Standard feed rate. This indicates that the standard speed range is in
% effect. When in effect, this indicator appears on every screen in the
top right corner.
Rapid feed rate. This indicates that the Rapid speed has been
selected. When in effect, this indicator appears on every screen in the
top right corner.
VISION 500
3.2 Error Status Windows
Error Status window. This symbol is displayed in the top left corner
when the error status window is the active window.
Status lnformation window. For switching to the status information

window that displays the status of various machine functions and
information.
Version lnformation window. For switching to the version

information window that displays the software version and serial
numbers of the control.
screen when the 24 Volt power has been switched on. The voltage is
The 24 Volt power may be manually switched off with the key
combination shiftlstop. It is also switched off any time the machine's
E-Stop string is broken, or the machine power is turned off.
has already been referenced.


axis.

be processed.

VISION 500
@ Feedhold. Motion is disabled. The machine cannot be operated.
Memory Reset. For clearing and resetting the battery backed up

memory.
0 Time. For setting the time kept by the system clock.
Stop time. Highlighted symbol indicates that stop time parameter is

10) active.
lO/Ll Auxiliary function. Highlighted symbol indicates that a process M-

code is being executed, such as torch ignition.
Feed rate reduction. Highlighted symbol indicates that feed reduction

I%MIPI is active.
Emergency stop. Highlighted symbol indicates that emergency stop is

1[5TOP1) active.
ElX-axis Motion blocked. Highlighted symbol indicates that movement
of X-axis is blocked.
Y-axis Motion blocked. Highlighted symbol indicates that movement

of Y-axis is blocked.
VISION 500
Symbol Overview
Data Window
Data window. This symbol is displayed in the top left corner of the
screen when the data window is the active window.
Internal memory. This symbol is usually displayed in combination

with another symbol. It indicates that the function effects the internal
-
memory (read write functions).
-
Input output. This symbol is usually displayed in combination with
% another symbol. It indicates that the function effects an external
device. (read - write - selection functions)
Computer Link. For connecting to an external computer for data

PC transfer via Computer Link basic RS-232 protocol.
~ U D UDL.
L For selecting an external computer for data transfer with UDL
protocol.
Floppy disk drive. This symbol is usually displayed in combination

with another symbol. It indicates that the function effects the floppy
disk drive. (read - write - directory functions).
Directory. This symbol is displayed only in combination with a device

? symbol. It displays the directory of all main programs of the
corresponding device.
Shape Library. For selecting the generation of main programs from

standard shapes.
VISION 500
Editor. For selecting the editor in order to generate and change main
I-- 3 programs.
-* Overwrite 1 insert. Switches between the overwrite and insert mode

in the editor.
,
,
,
,/ Delete line. Deletes the line marked by the cursor in the editor
Search block number. For searching a block number in the editor.

-, #
Letter line. For changing a part program line by using the letter line.
RBC
Search auxiliary function. Allows searching for an auxiliary function
-) -L in the editor .
-L+-% Replace auxiliary function. Allows replacing an auxiliary function in

t the editor.
Mark. For marking lines in the editor.

d@
EM Delete block. Deletes marked lines in the editor.

E
-- crn
Insert block. Inserts a deleted block in the editor
VISION 500
3.4 Movement Window
Movement window. This symbol is displayed in the top left corner of

the screen when the movement window is the active window.
Automatic Mode. For running part programs.
Manual jog. This symbol is displayed in the base menu of the

movement window and it indicates that the machine can be operated
manually with the joystick.
Standard feed rate. Indicates that the standard feed rate range is in
effect.
Rapid feed rate. lndicates that the Rapid feed rate has been
selected.
Fixed point movements. For moving to the program zero point or

machine fixed points.
Fixed point movement. For moving to machine fixed point 1.
Zero point movement. For moving to program zero point.

I B
b Reference point movement. For referencing (homing) the machine.
a Recycle last program. For repeating the last program that was run in
the automatic mode.
Sectional Pre-kerf. Calculates the kerf during operation. For running

A large programs.
VISION 500
After power failure. For restarting a program that was interrupted

271 because of power failure.
+ Step and Repeat. Accesses the Step and repeat setup window.
e
-*
': X Repetitions. For entering the number of repetitions in the X -
direction.
-*
@ ': Y Repetitions. For entering the number of repetitions in the Y -
direction.
1- X: X Repetition spacing. For entering the spacing between parts in the

X direction. The controller assumes a rectangular container
encompassing all extents of the program. The spacing is the distance
between the sides of the containers. If the spacing is set to zero, the
containers will be located directly next to one another.
1-1 y: Y Repetition spacing. For entering the spacing between parts in the
Y direction.
Plate alignment. For determining both the rotation angle of and the
3 J21 zero point of the plate.
Plate alignment. This symbol is displayed during plate alignment. It

indicates that the controller is waiting to adopt the location of a point
on the right edge at the top of the plate.

indicates that the controller is waiting to adopt the location of a point
on the right edge at the bottom of the plate.

f--J indicates that the controller is waiting to adopt the location of a point
on the front edge at the left of the plate.
VISION 500
TracelTrace Record. This symbol is displayed in the base menu of

the movement window and indicates that the machine can be operated
in the TracePTrace Record mode.
In TraceITrace Record mode it is the symbol for the Trace

function.
Trace Record. This function allows a pattern to be traced and

recorded as a main program.
Scan lineledge. If the line width of the pattern is more than 1 mm,
"edge" mode must be used.
Manual controlltracing. For switching between manual jog mode and

tracing mode from within the tracing window.
Turn-in direction. For switching between "trace left" and "trace right".
Searching for pattern. The tracer is searching for the contour.
On pattern. The tracer has found the contour and the scanning of the
contour is active.
Pattern Lost. The tracer has lost the contour. Tracer and machine
are stopped.
Lead-in type. Switches between "straight" and "circular" lead-in for

the program generated by Trace Record mode.
Lead-out type. Switches between "straight" and "circular" lead-in for

md~. the program generated by Trace Record mode.
Lead-in lengths. For entering angles and lengths of lead-in and lead-
+Htout for the program generated by Trace Record mode.
VISION 500
=c+= Point-to-point distances. The larger the minimum point-to-point

distance, the larger the smallest line section. High speed playback
cannot be achieved with small line sections.
0 Completed contour. The Trace Record process has stopped.

because the contour is closed.
Zero point adoption. For setting the program zero point for automatic
operation.
Return to contour. For returning to the program contour after using

Lficmthe joystick to jog off contour in automatic mode.
Program offset. For returning to program execution after the program

. was interrupted in the automatic mode and was moved to a new
location using the joystick. The program will be continued in the new
location.
Switch coordinate display. Switches between machine coordinates

1 and program coordinates during automatic operation.
Forwards 1 Reverse. Switches between forward and reverse

movement during automatic operation.
VISION 500
3.5 Service window
Service window. This symbol is displayed in the top left corner of the
screen when the service window is the active window.
Constant editor. For editing machine, device, system and MIP

constants, and displaying the configuration constants.
Station parameters. For initializing the stations and editing the

station parameters.
u Speed Measurement. For automatic measurement of the speed of

eachaxis.
Rotational speed measurement. For displaying the actual speed of

each axis with an adjustable output voltage.
rn Square wave output. 1 Hz square wave output for drive optimization.
Copy System disk. For making copies of the system floppy disk.
N+N
w5 Formatting. For formatting a floppy disk in drive B.
..- ~ v Reauest for confirmation with the functions that
Insert f l o ~ disk.
8+0 create system floppy disks and format floppy disks. Insert a floppy
disk in drive B.
VISION 500
3.6 Timer Window
Process parameters. This symbol is displayed in the top left corner

of the screen when the timer window is the active window.
Change timer. This key is pressed to enable changes to the timer

@ settings by turning the speed potentiometer.
VISION 500
Pane 26 Symbol Overview
3.7 Process Window
Process window. This symbol is displayed in the top left corner of

the screen when the process window is the active window.
1 Station. Station numbers from 1 to 6. All available stations are

W visible. If the symbol is highlighted, the station has been selected.
Master up. For raising all motorized station lifts.

rt
+ Go To Process display.
VISION 500
3.7.1 Plasma Process
Plasma.
Plasma options.
AHC allow.
AHC onloff.
Plasma Start.
Test preflow.
Water table low.
Water table medium.
Water table high.
Manual plasma-punch mark.

VISION 500
3.7.2 Oxy Fuel Process
Oxy Fuel.
Oxy Fuel options.
GAS AHC allow.
GAS AHC onloff.
Cutting Oxygen.
High preheat.
Ignite.
Water table control.
M73 process stop (leave preheats on).
Travel.
M70 process start.
Edge start.
VISION 500
Water table low.
Water table medium.
Water table high.

M
Manual punch mark.
M71 process stop (turn off all gases).

M71
VISION 500
3.7.3 Marking Process
Punch.
Punch marking options.
AHC allow.
AHC onloff.
Water table low.
Water table medium.
Water table high.

VISION 500
3.7.4 Plasma Mark Process
Plasma Mark.
Plasma Mark options.
AHC allow.
AHC onloff.
Plasma Mark Start.
Water table low.
Water table medium.
Water table high.

VISION 500
Symbol Overview
3.8 Station Selection and Movement
Cutting Station. This symbol is displayed in the top left corner of the
screen when the station selection or station movement window is the
active window.
r1 Station raise and lower. When this symbol is highlighted, the

corresponding station can be moved up and down.
1 Station selection. When this symbol is highlighted, the corresponding

C11 station has been selected.
VISION 500
Error Messages Page 33
4 Error Messages
The following is a list of all error messages that appear on the Vision control.
Text inside pointed brackets "< >" are variable, the actual error message will
contain a parameter such as a station number or the letter of an axis. Some of
the errors can be corrected by the operator. Other errors that influence the
serviceability of the machine should be reported to maintenance immediately.
When an error occurs which is not recognized, or cannot be cleared, it is

important to have as much information as possible in order to correct these
errors. Be sure to write down the following information regarding the error:
- Error number (displayed right before the error text in round brackets)
- Parameter of the error text (such as station number, axis, etc.)
- With which function does this error occur?
- What is on the screen?
- Which data are involved?
(program, parameter such as kerf width, speed, etc)?
- Did inconsistencies occur before the error appeared?
- Were there any apparent connections between the error occurring and
the operation that was being carried out?
A detailed description of the error makes it easier and faster to eliminate

the error.
VISION 500
Page 34 Error Messages
(100) PROGRAM DOES NOT EXIST
A non-existent program has been selected for processing. For example:
Nesting: One of the programs listed in the nest has been erased from
memory. Go to nesting and delete the program name from the
nest, or replace the missing program in memory.
UDL: There are no programs available on the host computer. No
programs can be transferred from the host to the control system.
10: A non-existent program has been selected for transfer. When this
error occurs the system floppy disk might be defective, since
programs can only be selected from the directory displayed by the
control system.
Auto.: A non-existent program has been selected for processing. This
can occur during a subroutine call or processing of nest. Check
selected program.
(101) ERROR READING PROGRAM <n>
Program file <n> is defective and cannot be read.
If you have tried to read from an optional external drive, insert or check floppy
disk in drive.
If the error occurs when accessing the internal memory (system floppy disk), use
a copy of the backup disk.
(102) FORMAT ERROR
Error message in program editor
There is a format error in the program line marked by the cursor.
Correct error or exit editor with SHIFTIBACK.
This error can also occur when data is entered in an EIA format although there is
no system add-on "EIA Format (DIN 66025)".
If the system add-on "EIA Format (DIN 66025)" does exist, the translation file on
the system floppy disk might be defective. Use a backup copy of the system
disk in this case.
The translation file of the EIA format is named EIAWDL.BIN.

VISION 500
(103) INTERNAL STRUCTURE ERROR
Error during program interpretation. A program line is more than 80 characters

long. This line cannot be processed. The program cannot be used.
(104) ERROR IN KERF CALCULATION
Error during kerf calculation. If this error has occurred in a program do not
continue using this program. The machine can still be used.
Inform maintenance and have the following data available for error correction.
- program that caused the error
- the kerf width value chosen
- the machine constants
(105) STATION en> REPORTS en>
Only for machines with ATHC stations.
This message only appears if the MIP simulation bit 3 (SYS.KON15)is set. In
that case, all messages from the ATHC boards are displayed (only for stations
that are logged on).
Station cn> = Station 1 - 16

reports cn> = Message 0 - 15 with the following meaning:
0 Voltage error
1 Collision
2 External station switched off
3 Lower limit switch
4 AFUE error
5 Station constants invalid
6-9 not assigned
10 Guide limit switch tripped
11 Guide limit switch released
12 Upper limit switch tripped
13 Upper limit switch released
14 IHS error1 download error
15 IHS confirmation Idownload confirmation
VISION 500
(106) 8031 BOOT LOADER NOT AVAILABLE
The control system is equipped with a multiprocessor system. Some of its

operating systems are loaded from the system floppy disk.
If this message is displayed one or more system files for the 8031 subsystem are
defective or missing.
The control system can no longer be operated. Use a backup copy of the
system disk.
The names of the system files for the 8031 subsystem are:
BOOT8031.HEX
NOS8031.BIN (Machines with ATHC stations)
BOS8031.BIN (ABIMBO version).
(108) FREQUENCY ERROR IN AXlS en>
A frequency error is displayed when there is interference in the connecting lead

between the encoders and the control system. This means that the machine is
provided with wrong encoder pulses and, thus, with wrong path data.
Possible causes for this interference are:

- cable break or connector not plugged in correctly
- extreme electromagnetic interference (plasma interference)
Check machine grounding and shielding. Try making dry runs to verify that the
problem is caused by plasma interference. Contact maintenance.
(109) LOOP ERROR IN AXlS en> AT SPEED
The loop error D is defined as the difference between the target position value
and the actual position value. The deviation is constantly monitored.
The maximum deviation Dm, is defined by the ratio of maximum speed ,V

,, to
control loop amplification LA.
During normal operation, the value of deviation is almost zero, i.e. the machine
is located at the position that was calculated beforehand.
If a loop error occurs, it means that the axis drive was not able to reach the
target value given by the control system within one control cycle. The value of
VISION 500
the deviation exceeded the maximum deviation.
Possible causes are:

- the velocities measured by the Speed Measurement Test of the axes have
been changed .
- the direction of rotation of the encoder has been changed .
- inappropriate data was entered into the machine constants for the control
loop amplification.
- the value entered into the machine constant of acceleration time is too
small, i.e. the required acceleration is too high.
- the machine ran into an obstacle
- a motor or an encoder has failed.
Check machine constants. If necessary, perform the new Speed Measurement

Test again. If the error cannot be corrected, contact ESAB service.
(110) CABLE ERROR AXIS <n>
There is a break in the cable between control system and encoder of axis <n>.
A cable error is indicated when the connecting lead between encoders and
control system has been interrupted.
Possible causes for this interference are:

- cable break or connector not plugged in correctly
- extreme electromagnetic interference (plasma interference)
Inspect the encoder cable for the <n> axis. Contact maintenance.
(111) CONSTANTS NOT FOUND
System files are missing on the system floppy disk. Proper functioning of the
control system cannot be assured.
Use a backup copy of the system disk.

VISION 500
(112) ERROR WRITING <n>
File en> cannot be written on the floppy disk. There is, most probably, a
physical defect of the floppy disk which may provide incorrect data when reading
central files, such as the machines constants.
(1 13) ERROR LOADING MACHINE PROGRAM
Each control system is equipped with a machine interface program MIP that has
been adapted to the machine. It is read from the system floppy disk when the
system is started. If this error message is displayed, the machine interface
program is missing, the file on the floppy disk defective or the contents of the file
invalid. This error message is displayed at system start, when the voltage is
turned on and when you try to activate process-related windows (process
window, parameter window, station window).
The file with the machine interface program is named MIP45.MIP.
(114) SUBSYSTEM MALFUNCTION
The control system is equipped with a multiprocessor system. The 8031

subsystem is responsible for the functionality of the control panel and the bus
inputloutput signals. If this message is displayed, the 8031 subsystem is
malfunctioning.
The control system can no longer be operated. Contact ESAB service.
Possible causes are problems in reading the files necessary for the subsystem
BOOT8031.HEX and/or
NOS8031.BIN (machines with ATHC stations) or
BOS8031.BIN (ABIMBO version)
on the system floppy disk. A defective 8031 subsystem board (DIO) may also
have caused this error message.
VISION 500
(115) MEMORY OVERFLOW
This system error is displayed in the following cases:

- the machine interface program, MIP (MIP41.MIP), does not fit into the
memory. The error message is displayed when the system is started.
lnform our after-sales service.

- the data file ALL.SHP of the standard shapes is too large. The message is
displayed when the editor of the standard shape is activated.
Inform our after-sales service.

- the program that is to be edited is too large.
- when using the copy function in the program editor, because the "clipboard"
memory uses part of the program memory. The program to be processed is
very large.
If possible, do not use the editor's clipboard.
(116) DRIVE NOT READY
Message displayed during a read-write operation on the floppy disk. The floppy
disk is missing or not inserted correctly into the drive.
Insert floppy disk (correctly).
(1 19) MACHINE STILL RUNNING
This message may be displayed in automatic mode. The desired function will
not be executed as long as the machine is still running.
Press STOP and wait for machine standstill.
(121) SYSTEM ERROR IN STANDARD SHAPES
This error occurs only in conjunction with standard shapes.
An error has occurred during evaluation of a standard shape. Possible error

causes are:
VISION 500
- Erroneous parenthesized expressions

- Invalid characters within standard shape
- Invalid statements in computational section
- System file ALL.SHP is defective.
(122) CONSTANT TOO LONG
A constant (number) exceeds the maximum number of digits. A maximum of 10

digits are admissible. This is caused by a logic error in the program structure of
the standard shape.
(123) INVALID SYMBOL @
This error .occurs only in conjunction with standard shapes.
The variable declaration of an internal standard shape variable is faulty. This is

caused by a logic error in the program structure of the standard shape.
(124) INVALID PARAMETER
This error occurs only in conjunction w'lth standard shapes.
The variable declaration of an input variable is faulty. This is caused by a logic

error in the program structure of the standard shape.

VISION 500
(125) ERROR IN OFFSET
The offset declaration is incorrect. This is caused by a logic error in the program
structure of the standard shape.
(126) ERROR USING #F+
The loop statement "#F+" must not be nested. This is caused by a logic error in
the program structure of the standard shape.
(127) INVALID NUMBER OF SIGNS
A geometric statement with a wrong number of signs was found in the standard
shape. This is caused by a logic error in the program structure of the standard
shape.
(128) SMOOTHING ERROR
One of the two lines necessary for smoothing or recessing is missing. This is
(129) AXES TOO SHORT (WITH #K OR #R)

VISION 500
When smoothing or recessing between two lines, one of the lines is too short or
the radius of the smoothedlrecessed section is too large.
Possible causes are:

- Logic error in the standard shape program structure.
Have standard shape checked.
- Wrong input values with standard shape evaluation.
Evaluate again with corrected input values.
(130) BLANK LINE
A blank line was found in the standard shape. Blank lines are not permissible in
standard shapes. This is caused by a logic error in the program structure of the
standard shape.
lnform our after-sales service and have standard shape checked.
(131) ERROR IN SKIP FUNCTION
A variable assignment is expected after a skip function. This is caused by a logic

error in the program structure of the standard shape.
(132) CALCULATION ERROR
This error message is displayed if a calculation error has occurred in

mathematical functions (for example, negative root argument SQRT(-5)).
Mathematical functions are often used with standard shapes and kerf width
calculations. Possible error causes are:
- Logic error in program structure of standard shape.

VISION 500
- Number overflow because input values are too high.
Evaluate again with smaller input values.
(133) PROCESS STILL RUNNING
A download of station constants can only be e!xecuted if the basic state for the
pre-selected process has been set.
Press the "Process Off' button.
(134) SELECT PROCESS FIRST
After a station setup with the so-called station constants download, it is possible
that no processes are pre-selected anymore. If you nevertheless switch to the
display of process-dependent parameter values (parameter window), this
message will be displayed.
Pre-select process in "process control" (TECH window).
35) ALFE REPORTS ERROR <n>

(I
Only for machines with an ALFE subsystem (Trace Record Equipment).
Apart from the ALFE subsystem faults that are reported explicitly, other
messages from the ALFE subsystem are displayed if the servicing mode is
active. <n> is a hexadecimal number whose bits each have a different
significance. Only the following bits are assigned:
xxxx xxxx xxxx xxxl 0001 RAM fault.

The power-on self-test by the ALFE subsystem has
discovered a memory error. The ALFE subsystem is no
longer functioning reliably. LFE board defective.
xxxx xxxx xxxx xxlx 0002 ALFE system cycle time has been exceeded.
The ALFE subsystem is no longer functioning reliably.
Restart the control system. If the fault occurs again, inform
our after-sales service.
The next three errors occur only in conjunction with the ASOD test system:
xxxx xxxx xlxx xxxx 0040 Overflow at ALFE interface.
Only in conjunction with an ASOD test system connected
to the LFE board. Check the interface parameters.
xxxx xxxx Ixxx xxxx 0080 Framing error at ALFE interface.
VISION 500

xxxx xxxl xxxx xxxx 0100 Parity error at ALFE interface.
xxxx xxlx xxxx xxxx 0200 error 24 Volts.

See error (220).
xxxx xlxx xxxx xxxx 0400 error 15 Volts.
See error (221).
xxxx Ixxx xxxx xxxx 0800 DMA error.
See error (222).
Ixxx xxxx xxxx xxxx Internal ALFE error. The ALFE subsystem is no longer
functioning reliably. Restart the control system. If the error
occurs again, inform our after-sales service.
(136) AUXILIARY FUNCTION <n> REPLACED <n> TIMES BY <n>
Message in the program editor after the function "replace auxiliary function" has
been performed. Thus: Auxiliary function 7 replaced 3 times by 51. Instead of the
auxiliary function 7, the auxiliary function 51 has been ,employed, and this 3
times.
(137) KEY <n> DEPRESSED
When starting the system, all keys of the control panel are checked. If one key is
recognized as being depressed, this message is displayed.(except for keys
activating the servicing mode).
If you have not pressed any key (including the joystick) during system startup, a
key might be jammed. Switch off machine, press all keys and restart the system.
If the fault has not been eliminated this way, the control panel might be
defective.
Il?form ESAB service.

VISION 500
(138) SERVICING MODE ACTIVATED
The servicing mode is activated by pressing the key combination SHlFWFl

during the booting process of the control system. The following functions are
then switched on:
- Blocked machine constants may now be edited
- Additional displays
- Display of synchronization errors of the ATHC and Panel-ASIOB-Bus
- Display of all messages of the ALFE subsystem
- Normalizing the battery RAM is now possible
- Expanded representation of the cutting data
You can only exit the servicing mode by restarting the control system.
(143) FUNCTION NOT ADMISSIBLE DURING PROGRAM RUN. SET INITIAL

SCREEN IN MOVEMENT WINDOW
During automatic program processing, functions such as "Edit constants" or

Speed Measurement functions must not be used.
Wait until the program is finished.
(144) END FUNCTION
Functions such as "Edit constants" do not allow window switching. Enter all data
in the servicing menu first and then end function with the Backpage key.
(145) END PROGRAM EXECUTION
You have tried to switch to the servicing menu while a program execution was
running in the movement window. This is not allowed. Changing constants or
executing start-up functions while the machine is processing a program would
interfere with the processing of the program.
VISION 500
(147) - (150) WRONG PARAMETER INTERFACE en>

An invalid value has been entered in the component constants for the serial
interface <n>. This error message can also occur when a component has been
assigned to more than one interface.
Check component constants.
(152) PROGRAM DIMENSION OVERFLOW
The extent of the program for automatic processing is larger than the current
working area, or the starting point (program zero point) is located at the wrong
place in the working area. The program extent can also exceed the limits
because of incorrect scaling. However, the program can be executed until it
reaches the software limit switch.
Check the program zero point.

Check scale setting.
Check the part program.
(153) FLOPPY DlSK <O I I > IS WRITE PROTECTED

Floppy disk is write protected.
Remove write protection or use a different floppy disk.
(154) FLOPPY DlSK <O I I > IS FULL
A maximum of 200 programs or 1MB can be stored in the internal memory

(floppy disk 0). If these limits are exceeded, delete some existing programs.
A maximum of 224 programs or 1.44MB can be stored in the external memory

(floppy disk 1). If this error occurs on the external drive (option), a different
floppy disk can be used.
VISION 500
(155) FLOPPY DISK <O I I > : GENERAL ERROR en>

Error when accessing the floppy disk. Floppy disk 0 is the system floppy disk
(internal memory), Floppy disk 1 is the external (operator accessible) drive.
Possibly a problem with the floppy disk, or a problem with the floppy disk reader.
Note error number <n> and discard the defective floppy disk. If the defective
floppy disk is the system floppy disk, try using a backup copy of the system disk.
(156) ERROR READING FROM en>
File <n> on the system floppy disk is defective or missing. An error-free

functioning of the control system is no longer assured.
(158) MACRO DEFINITION FlLE NOT FOUND
The control system can be equipped with the option "Key Teach". With "Key
Teach", operating sequences can be recorded and later executed by just one
keystroke. In order to have these operating sequences available even after
restarting the machine, they are stored in the system file MAKROS.DEF. If this
file cannot be read from the system floppy disk, this error message is displayed.
MAKROS.DEF is created empty.
Functions for controlling the cutter-holding carriage that are connected to macro
keys can no longer be executed. If this is the case, use a backup copy of the
system disk.
(159) SYNTAX ERROR IN MACRO DEFINITION FlLE
The control system may be equipped with the system add-on "Key Teach". With
"Key Teach", operating sequences (macros) can be recorded and later executed
by just one keystroke.
The macro definition file MAKROS.DEF is defective.
MAKROS.DEF is created empty.
Functions for controlling the cutter-holding carriage that are connected to macro
keys can no longer be executed. If this is the case, use a backup copy of the
system disk.
VISION 500
( I 60) WATCHDOG ERROR
The 8031 subsystem broke down or is malfunctioning. If this error occurs, the
voltage is switched off immediately. The Digital I10 board (DIO) may have failed.
If this error occurs repeatedly, contact ESAB service.
(161) ASIOBIATHC-2 ERROR
Data transfer to and from the control system and the stations is done with a
serial bus, the ASIOB. For machines with ATHC stations, the data is transferred
to these station boards. For the ABIMBO version, the bus ends at a converter
board. The serial transfer of the ASIOB is protected by a "synchronization error
bit". Si,ngle errors are compensated by the subsystem software. If there are
more than an average of 30% synchronization errors within a certain period, this
error message will be generated.
Possible causes are: A fault in the Digital I10 board or the ABIMBO board; or
strong electrical interference (especially with plasma machines).
If the error occurs again after restarting the system, inform ESAB service.
In the servicing mode, the display of synchronization errors gives information on

the rates of interference errors that have occurred.
(162) PANEL ERROR
Keyboarc! information is sent from the control panel to the control system via a
serial bus, the ASIOB. The serial transfer of the ASIOB is protected by a
"synchronization error bit". Single errors are compensated by the subsystem
software; key information may be lost. If there are more than an average of 30%
synchronization errors within a certain period, this error message will be
generated. Possible causes are: A fault in the bus boards (DIO, ABIMBO)
concerned or strong interference fields (especially with plasma machines).
An interruption of the connection (cable) to the control panel can also cause this
error.
If the error occurs again after restarting the system, inform our after-sales
service.
In the servicing mode, the display of synchronization errors gives information on

the rates of interference errors that have occurred.
VISION 500
( I 63) BREAK IN E-STOP CHAlN
The E-Stop chain has been interrupted by one of the following:

- the "Emergency stop" button is pressed
- a travel limit switch has been hit
- the 24 volt power supply is interrupted
Check E-Stop chain. Check the 24 Volt power supply.
(164) # cn> FORMAT ERROR
Program line <n> contains a syntax error.
Program format ESSI:

- wrong number of signs
- auxiliary function not recognizable.
- wrong axis index
- wrong parameter
Programming format EIA:
- EIA programming option is not enabled
- wrong M function
- invalid addresses
- if EIA programming option is enabled, the file EIAWDL.BIN on the
system floppy disk might be defective. Use a backup copy of the
system disk.
Check program structure.
(165) # cn> CIRCLE ERROR
The programmed geometry in program line <n> is not correct .

- the machine constant "circle mode" is not set correctly
- the radius of the circle measured from starting to center point deviates by
more than 10 programming units from the radius between center and f i n i d
point.

VISION 500
(166) # en> LOSS OF AUXILIARY FUNCTION
The auxiliary function in program line <n> is not being executed. Possible
reasons for this are:
- there are too many auxiliary functions following one another in the program
- geometries with a path length of zero are generated because coordinates
are too small. Auxiliary functions that originally belonged to these
coordinates are assigned to the following geometry. A wrong kerf value or
scale can also cause existing geometries to be disregarded.
(167) # en> LOSS OF COMMENT
Comment in program line <n> cannot be displayed during program execution.
(168) # en> LOSS OF GEOMETRY
The secondary axis geometry in program line en> is not being executed. There
are too many secondary axis geometries in the program following one another
directly without a main axis geometry.
(169) # en> CENTER OR END POINT GREATER THAN 1.3 MILES
The circular arc in program line <n> contains a value that exceeds the maximum
size (1.3 miles or 1*106inches) of the internal working cells. The arc can not be
processed.
VISION 500
(170) REFERENCE CAM en> - FREE AXIS

The reference point of the machine can only be recognized if the machine does
not find the reference point switch until it is moving. This error message is
displayed if the machine is located at a reference switch when the operating
mode "Reference movement" is activated.
Free machine from reference cam by manual control.
(171) DEFINITION FOR STATION en> NOT FOUND
Parameters that are used to set an intelligent station (ATHC board) are read
from a file on the system floppy disk. Every station has its own parameter file.
The parameters for station en> do not exist on the system floppy disk or the
relevant file is defective.
This error message is only relevant for stations which are attached to the
machine. If there is a station attached to the machine, Use a backup copy of the
system disk.
The parameter files are called STATn.KON. Replace "nu by a number from 01 to
06.
(172) ERROR WRITING en>
File <n> cannot be written. If this error occurs when accessing the internal
memory (system floppy disk), error-free functioning of the control system can no
longer be assured.
Use a copy of the backup disk and inform our after-sales service.
If the machine is equipped with the optional external drive, the floppy disk might
be defective.
Insert or change floppy disk in external drive. If the error cannot be corrected in
this way, inform our after-sales service.
VISION 500
(174) FORCE LIST FULL
At the control system, there is a "signal display" used as a servicing aid. With
this display messages from and to the machine program (MIP) can be traced and
partially changed. Changing input and output signals is done by forcing. This
message indicates that the maximum number of signals (16) that can be forced
simultaneously, has been reached.
Cancel forcing orders that are no longer necessary.
( I 75) TI MEOUT
Serial link could not be established within predefined time (component

constants). This error can occur if:
- the timeout value for an interface is set too low
- interface parameters are set incorrectly
- the serial link cable is defective.
Increase timeout value in component constants or check serial link.
(177) TRANSFER ABORTED
Error during program transfer with UDL. Data transfer is protected by a

checksum. After the transfer of a block has been completed, the receiving
computer calculates the checksum. If the calculated checksum does not
correspond to the one transferred, the receiving computer sends a negative
acknowledgment. If this error occurs three time in a row the control system
aborts the data transfer.
(180) INVALID CONSTANTS AT STATION <n>. EXECUTE DOWNLOAD!
The ATHC board of station <n> reports that the parameters set are not logical
Execute a station-constants download to this station. If this error occurs
repeatedly the ATHC board might be defective.
Contact ESAB service.

VISION 500
(181) DOWNLOAD ERROR AT STATION en>
After parameter transfer to station <n> (station-constants download), the control

system has not received positive acknowledgment from the ATHC board that the
download was successful. This station should not be used, since it is not certain
with which parameters the station is provided at the moment.
(182) POWER SUPPLY INTERRUPTED AT STATION en>
The ATHC stations report defective states to the control system. If the power
supply is interrupted at a station, this error message is displayed:
- if the power supply is interrupted at an active (selected) station
- if you try to select the station via the keyboard or the main program
- with every MIP initialization. A MIP initialization takes place every time the
voltage is switched on.
(183) TURN VOLTAGE ON
The 24 Volt switching power has to be turned on for certain functions such as
traversing or controlling processes.
Press SHIFTISTART to turn on the voltage.
(184) NO RESPONSE FROM STATION en>
No response from the station after a station-constants download (set-up) to the

station.

VISION 500
The ATHC board must react to a download in form of either a negative or a

positive confirmation. If there is no response after the period of time necessary
for reaction, this message is displayed.
This error message is not displayed when the MIP simulation bit 2 (SYS.KON,5)
has been set.
(185) AUTOMATIC REFERENCE MOVEMENT NOT POSSIBLE
Only for machines with the system add-on "Automatic reference point
movement".
The automatic reference point movement cannot be executed due to incorrect

machine constants. For this movement, direction and sequence of the individual
reference point movements are entered in the machine constants MC 64 and MC
65.
Check machine constants MC 64 and MC 65.
(186) BATTERY RAM CHECKSUM ERROR cn>
If this message is displayed after a change in software, ignore it. If it occurs

during operation, the RAM module may be defective, or the battery may have run
down. Replace the D l 0 board. It may be possible to continue work; however, all
input data and parameters such as repetitive offsets have to be checked for
correctness. <n> indicates the battery RAM area.
If this error occurs repeatedly, inform ESAB service.
(187) INCOMPATIBLE FLOPPY DISK FORMAT
System cannot write to Double Density 720KB floppy disks.
Use High Density 1.44 MB floppy disk.

VISION 500
(195) NO POTENTIOMETER DATA
This error message is displayed when the menu for additional cutting records
(flame control menu) has been selected, the corresponding data, however,
cannot be read error-free, .
(196) THIS MACRO KEY HAS BEEN ALLOCATED MACHINE FUNCTIONS

ANDCANNOTHAVEANEWMACRORECORDED
You have tried to record a macro for a macro key that is pre-assigned to a
machine function, such as "Raise station". This is not allowed. Only those macro
keys can be re-assigned that are not already assigned to machine functions.
(197) MACRO RECORDING TERMINATED, MEMORY FOR MACRO KEYS

FULL
The control system may be equipped with the system add-on "Key Teach". With
"Key Teach", operating sequences can be recorded and later executed by just
one keystroke. The necessary data is stored in a "macro memory". If no more
memory is available during recording, this message is displayed. The recorded
macro cannot be used.
Delete macros that are no longer needed.
(200) TOO MANY INPUT VARIABLES
There are more than 45 input variables declared in the standard shape. This is

VISION 500
-
(201) FOR RENEWED PROCESSING SELECT PROGRAM AGAIN
In automatic mode with sectional prekerf, a processed program cannot be

processed again by pressing the START key, because the necessary data has to
be read again.
Select program again.
(202) cX Y Y2 P> AXIS REACHED SOFTWARE LIMIT SWITCH
The corresponding axislaxes hasthave reached the software limit switch.
Jog the machine in the opposite direction.
Software limit switches are set in the machine constants (MC).

If the multiple working area option was purchased, it is possible that the machine
is operating in the wrong working range. Cycle the power off, then on, then
home the machine, then select the desired working area.
(203) TOO MANY DATA RECORDS FOR PROGRAM PREPARATION
The program that has been selected for automatic processing is too large. It
cannot be run.
A software option called "Sectional prekerf" is available for processing larger

programs.
(204) REFERENCE NECESSARY FOR THIS FUNCTION
This message is displayed when you select the Automatic or the Trace Record
mode.
After switching on the control system or after a power failure, the current position
of the machine in relation to the machine zero point or the reference point is
unknown.
If the machine is equipped with a reference point system (MC 52 = I),

a
reference point movement has to be executed.
For machines without a reference point system (MC 52 = O), the machine has to
be moved to the zero point. This position will then be accepted as a reference
point.
VISION 500
(205) SET REFERENCE POSITION OF MAlN TOOL FIRST
The control system supports the measuring of the tool offsets when several tools
are put into operation.
Before the tool offsets can be measured, the reference position of the main tool
has to be defined.
(206) REFERENCE POSITION OF MAlN TOOL ALREADY SET
This message is displayed during the adjustment of tool offsets. In order to re-
specify the reference position, the function has to be terminated and restarted
from the beginning.
(207) PPT ACTIVE
This message is displayed when PPT and UDL have both been installed at using
one interface, and an attempt is made to activate UDL a PPT data transfer is
active. A UDL connection cannot be established at the moment because the line
is used for PPT.
Wait and try again later.
(208) <Type of error> IN FUNCTION <Mathematical function>
For example, DOMAIN IN FUNCTION SQRT. If this error occurs, inform our
after-sales service. The machine must be restarted. Possible error causes are:
- Standard shapes were evaluated with nonsensical values
- Kerf width calculation with very small coordinates
- Discrepancy between programming unit and geometry (extremely large,
extremely small)
(209) DIVISION BY ZERO AT en>
Internal error. Normally, it is possible to continue processing after restarting the

current function.
Note message together with current function and inform ESAB service.
VISION 500
-
(210) CAUTION INVALID SYSTEM CONFIGURATION!
The checksum of the system file ANCDEF.KON is not correct. A different

configuration of the machine has been entered compared to the one at the time
of delivery. It is possible that optional functions are no longer available or that
functions are displayed that the machine is not equipped with.
The machine can still be operated. Use a backup copy of the system disk.
(212) COMPLETED CONTOUR
This message is displayed in Trace Record. The contour has been completed
and the recording was stopped.
(213) # <n> TOO LONG
This message is displayed during program execution. Block number <n> has
more than 80 characters. Only the first 80 characters are interpreted. This might
result in geometry being lost or the block being shortened to such an extent that
a format error arises.
The execution of the program should be aborted. Check program structure.
(214) FUNCTION ABORTED
(215) ERROR READING CUTTING-DATA FILES
The cutting data (timer and process values) are displayed in the "timer" window.
When starting the system, they are read from the corresponding files on the
system floppy disk. When this error occurs, one or more of these files are
defective or missing.
If the machine is equipped with the function "Programmable cutting data" this
message is also displayed when you try to reload a defective cutting file. Use a
copy of the backup disk and inform ESAB service.
The cutting-data files include:
DEF.TEC
PARAM.CUT
and POTI.CUT if the machine is equipped with "Flame control".
VISION 500
(216) NO CUTTING DATA AVAILABLE
This error only occurs if the machine is equipped with the function
"Programmable cutting data".
This message is displayed if the identifiers for the cutting data cannot be found
in the cutting file when it is reloaded, or if a main program contains cutting-data
identifiers but no cutting data.
(217) NO VALID CUlTlNG DATA STORED
This message is displayed when the "parameter" window is activated and there
are no valid cutting data available. A possible reason for this is an incorrect
reading of the cutting files at system start, i.e. the files
are defective or missing.
(219) EXCESSIVE NESTING OF SUBROUTINES
Message during a program execution. Subroutines within subroutines within

subroutines are being called. The maximum nesting level is ten deep. The
program cannot be executed.

VISION 500
(220) ALFE - 24-VOLT SUPPLY MISSING

Only for machines with an ALFE subsystem.
The ALFE subsystem requires a 24-volt supply. This is no longer available.

Possible reasons for this include:
- Cable break.
- Plug has slipped off the LFE board.
- LFE board is defective.

- Power supply unit is defective.
The controls continue to operate correctly, but the Trace Record function is no
longer available.
(221) ALFE - 15-VOLT SUPPLY MISSING

Only for machines with an ALFE subsystem.
The ALFE subsystem requires a 24-volt supply. If this is no longer available, the
15 volts generated from it are also missing. Causes for the lack of the 24-volt
supply are described under error number 220.
If only the message that the 15-volt supply is missing appears, the voltage
transformer of the LFE board is defective.
longer available.
Inform ESAB service.

VISION 500
(222) ALFE - DMA ERROR

Only for machines with the an ALFE subsystem.
DMA is a technique for transmitting data between the AK5 camera head and the
LFE board. If no data can be transmitted, this message is generated. Possible
causes are:
- Plug of LFE<->AK5 connecting cable is not plugged in properly (on AK5 or
on LFE board).
- Break in LFE<->AK5 connecting cable.
- AK5 camera head defective.
- LFE board defective.
longer available.
Inform ESAB service.
(223) INTERNAL LOGGING ERROR A:<n> D:<n> B:<n>
An error has occurred when writing the logging data The current data record is
lost. If this error occurs note the values displayed in the error message, store
logging file on external floppy disk and inform our after-sales service.
The machine can be operated as before.
(224) IMAJE TIMING ERROR, STATUS <n>
The lmaje inkjet printer did not respond within the time interval expected. The
time interval is set among the interface constants, under the keyword TIMEOUT.
If the value 0 has been set there, that may be the reason for this error message.
The program will continue to be processed completely, except for the printing
function.
VISION 500
(225) IMAJE DOES NOT UNDERSTAND, STATUS <n>
An attempt has been made to initialize the lmaje inkjet printer, but without
success.
The program will continue to be processed completely, except for the printing
function.
Check the cable at the respective interface.
(226) DISTANCE BETWEEN CARRIAGES Yen> AND Y<n> TOO SMALL.

TANGENTIAL FOLLOWER NOT IN BASIC POSITION.
This error message can only occur in conjunction with more than one motor-
driven cutter tool holding carriages. The distance between adjacent cutter
carriages is monitored so as to avoid collisions. The distance is calculated from
the machine constants for the width of the cutter carriage. For cutter carriages
with variable bevel angle units (VBA), the carriage width can vary as a function
of the angle to which the variable bevel unit is set. So two widths are specified
for each cutter carriage. The narrower of the two widths is used if the variable
bevel unit is in its neutral position.
The error message signifies that two motor-driven carriages have approached
one another more closely than the wider carriage width allows. The distance is
not less than the one derived from the narrower carriage width. But this position
is still not permissible, because the variable bevel units are not in their neutral
positions.
(227) PLATE THICKNESS <n> NOT AVAILABLE IN ORGANIZATIONAL

PROGRAM
Only if the machine is equipped with a plasma tangential follower.
Message that the plate thickness <n> entered is not present in the organizational
program. The next smaller plate thickness will be used.
(228) NEXT SMALLER PLATE THICKNESS en> USED
Only if the machine is equipped with a plasma tangential follower.
Message that the plate thickness entered is not present in the organizational
program, so the next smaller plate thickness <n> is used.
VISION 500
(230) # <n> ANGLE LARGER THAN TANGENTIAL RANGE OF UNIT.
Variable bevel units for the plasma-cutting process only allow a restricted range
of rotation of the tangential control. The maximum tangential range is usually
between two and three rotations. The control system automatically finds a
suitable starting angle for the variable bevel unit if a program requires a larger
tangential range than 360 degrees. This starting angle is set anew for each cut.
This error message is issued if the program contains a continuous cut for which
the variable bevel unit's tangential tracking would have to traverse an angular
range that exceeds the limiting angle set in the machine constants.
(231) DIRECTORY TRANSFER IS ACTIVE
Message during UDL. You have requested the host computer's directory. As long
as this message is displayed, transmission of the directory is active. This may
take some time, depending on how many programs there are on the host
computer.
As long as this message is showing, no UDL function keys can be pressed.
(232) MEASURING POINT CANNOT BE REACHED
During automatic plate alignment, the edges of the plate are detected at three
points with a sensor. For this measuring procedure, the sensor is lowered into its
operating position and traversed in the direction of an edge of the machine.
This error message is issued if no plate edge is detected.
Possible causes of the error:

- The sensor is defective or set incorrectly
- The sensor cannot reach the edge of the plate because its positioning
range does not allow it to detect the plate edge. It may be necessary to
place the plate in a different position on the machine.
VISION 500
(233) THIS FUNCTION IS BLOCKED BY ANOTHER FUNCTION AT THE

MOMENT.
Different sections of the control system use the same memory area to store data.
Thus, certain functions cannot be performed at the same time. These are:
Editor and Trace Record

Editor and editing constants
Nesting and Trace Record
Nesting and editing constants
Standard shapes and Trace Record
Standard shapes and editing constants
Check which of these functions is still active. This function must then be ended
first, before the desired new one can be performed.
(234) BLOCK <n> 1 OFFSET en> NOT FOUND IN FILE en>.
Message during a program run. The return from a subroutine cannot be

executed. Processing is faulty. Execution of the program should be aborted.
The most likely cause of this message is that the main program has been
overwritten by a parallel program transfer, so that the return address from the
subroutine back to the main program can no longer be found.
(236) SENSOR TRIGGERED
During automatic plate alignment, the edges of the plate are detected at three
points with a sensor. For this measuring procedure, the sensor is lowered into its
operating position.
This error message is issued if the sensor already detects the plate surface
before being lowered into the starting position for the measurement.
Possible causes of this error:
- The sensor is defective

- The measuring station's automatic height sensor is set so the station does
not retract the sensor far enough from the plate surface in its idle state.
- The sensor's sensitivity has been set incorrectly.
VISION 500
(237) PLEASE WAIT, MIP BEING INITIALIZED
At each MIP initialization (switching voltage turned on), the ATHC stations are
normalized. During this period, you must not switch to the process, parameter, or
station windows. If this is attempted, this message will be issued.
((238) MEMORY MANAGEMENT ERROR IN MODULE en>
Fatal error. An error has occurred in the internal memory management

functions. The control system must be restarted in all cases. Inform ESAB
service.
VISION 500
Paae 66 Data Window
5 Data Window
The data window allows for entering, receiving, controlling, changing and
generating part programs. The main tasks are displayed in the base menu of the
data window, shown below.
Program input-output (see below)
Directory (page 87)
Shape library (page 90)
Edit programs (page 96)
Program Input-Output
Program input-output allows for transfers main programs from and to a host
computer with one of the following protocols:
UDL (Up Down Load) (page 68)

Computer Link (Page 81)
Tape Reader
Accesses the optional floppy disk drive. (page 74)

VISION 500
Data Window Page 67
Directory
Directory of all main programs

Deletion of programs that are no longer necessary
Shape Library
Shape Library shapes are programs with predefined contours. By changing the
variable dimensions of these programs, main programs can be generated. These
are the steps:
Selection of which shape to use

Enter variables with help from the graphic display
Graphical display of the generated main program for verification
Edit Program
The program editor supports the functions:
Creating a new program

Changing an existing program
Graphical display of a program
Line deletion
Block deletion
Copying of blocks
Searching help functions
Searching line numbers
Replacing help functions
VISION 500
Page 68 UDL (Up - Download)
5.1 UDL (Up - Download)

UDL is the abbreviation for Up - Down Load. UDL is used for the data transfer
from an external computer to the control system. Data transfer is protected by
automatic error correction. Upon connecting to the host computer, the operator
is presented with the directory of the host computer, from which main programs
can be selected. UDL supports transfer of programs to and from the host
computer.
Data transfer with UDL is an optional feature of the control. The symbol for UDL
is only displayed if the option was purchased.
To use UDL, start from the Data Window, as shown below:
Program input-output (page 69)
Directory
Shape Library
Edit programs
VISION 500
UDL (Up - Download) Page 69
Selecting UDL
From the Data Window Input - Output screen, select UDL.
Select UDL (page 70)
Select floppy disk drive
Select XON/XOFF-mode
Select Tape Reader

VISION 500
UDL - Basic Screen

The basic screen for UDL shows two options, loading and storing main
programs. Select loading (F1) to download programs from the host computer to
the Vision control. Select storing (F2) to upload programs from the Vision
control to the host computer.
PROGRAMMNUHHER BAHB I1
Load main programs (page 71)
Store main programs (page 72)

VISION 500
UDL (UD - Download) Page 71
Loading Main Programs
When this option is chosen, a selection box with the directory of the host
computer will be displayed. Using the joystick or feed rate potentiometer, place
the cursor in front of the desired program in the directory. Press confirm (FI) to
download that program. Press abort (F6) to quit without downloading.
PROGRAHHNUHH
IJI Confirm, start transfer of selected program.
Abort. Terminate loading function.

VISION 500
Storing Main Programs
When this option is chosen, a selection box with the directory of the Vision
control is opened. Use the joystick or the feed rate potentiometer to move the
cursor to the desired program. Press confirm (FI) to select that program and
begin transfer to the host computer. Press abort (F6) to quit without transfer.
PROGRAMMNUHM
IJI Confirm. Start data transfer to host computer.
El Abort. Terminate the storing function.

VISION 500
UDL (Up - Download) Page 73
During Data Transfer
The number of transferred lines is displayed during data transfer, in both

downloading and uploading functions.
PROGRAMMNUMMER ADLER2
ELOCKNUMMER 00 126
The function keys have no effect during transfer.
The backpage key terminates a data transfer.

VISION 500
Page 74 Floppy Disk Drive
5.2 Floppy Disk Drive
To use the Floppy Disk Drive, select program input-output from the Data window,
as shown below:
m
1071
Program input-output (page 75)
Directory
I Shape Library
Edit program
VISION 500
Floppy Disk Drive Page 75
Selecting Floppy Disk Drive
The floppy disk drive is an optional feature. The symbol is only displayed in this
menu if the option has been installed.
Select Floppy Disk Drive (F2) from the device menu, shown below:
Select UDL.
Select floppy disk drive (page 76)

Select XONIXOFF-mode
Select Tape Reader

VISION 500
-
Floppy Disk Drive Basic Screen
. disk
Three options are available for the f l .o. ~ ~ v reader: loading programs, storing
programs, and directory of the disk.
Load programs from disk (page 77)
Store programs to disk (page 78)
Display directory of the disk (page 79)

VISION 500
Loading Main Programs From Disk
The directory of the floppy disk will be displayed. Using the joystick or feed rate
potentiometer, select which main program to read from the disk. Press Confirm
(FI) to select that program and begin loading. Press Abort (F6) to quit without
loading.
IJI Confirm, begin loading program from floppy disk.
Abort without loading.

VISION 500
Storing Main Programs
The directory of the Vision control will be displayed. Using the joystick or the
feed rate potentiometer, select the program to be written to the floppy disk.
Press Confirm (FI) to select that program and begin writing to the disk. Press
Abort (F6) to quit without writing to the disk.
1 &#!I
HEXE
m Confirm and start storing program on floppy disk.
113231 Abort without storing on floppy disk.

VISION 500
Directory Of All Main Programs On Floppy Disk
The directory displays a list of all main programs stored on the floppy disk. The
list contains three columns. The second column shows the file size in bytes.
The right hand column shows the date that the the file was created.
Use the feed rate potentiometer or the joystick up / down in order to display the
remaining programs.
The program marked by the cursor can be deleted.
PUZZLE 261 18.08.93

SNAKE 2231 22.12.92
SPIRALE3 483 26.01.94
SUPER 3996 00 .OO .80
UNICORN 4303 00 .OO .80
USAMAP 2658 22.12.92
WIKINGER 9377 11.02.94
Delete program marked by cursor. (Page 80)
Press backpage to exit the directory display.

VISION 500
Delete programs
When delete is pressed, a confirmation box is displayed, to make sure that files
will not be deleted accidently. To delete the file,. press
. Confirm (FI). To return
to the directory without deleiing, press Abort (F6).
,
'v00100
PUZZLE 26 1
SNAKE
SPIRALES
SUPER
UNICORN
USAMAP
WIKINGER DONALD 1
Delete the program and return to the directory. (Page 79)

IJI
1 Return to the directory without deleting this file. (Page 79)

VISION 500
Computer Link Page 81
5.3 Computer Link
To use computer link, start by selecting program input-output from the Data
window.
m Program input-output. (Page 82)
Directory.
( Shape Library.
IB I Edit program.
VISION 500
Page 82 Computer Link
Selecting Computer Link
Computer Link is an optional software feature. The symbol will only be displayed
if the option was purchased.
To select computer link, press F3 from the device menu, as shown below:
Select UDL.
Select floppy disc drive.
Select Computer Link. (Page 83)
Select tape reader.

VISION 500
Basic Screen Computer Link mode
Two options are available in computer link, loading and storing of main
programs. To download main programs from the host computer, press F1. To
upload main programs to the host computer, press F2.
PROGRAMMNUMMER WG
I XON
Load main programs. (Page 84)
Store main programs. (Page 85)

VISION 500
Loading main programs
During data transfer, the number of lines that have been sent is displayed.
Since computer link does not transmit a filename separate from the file itself,
then the filename must be embedded in the program header. If no filename is
found, then the control will store it under "NONAME".
PROGRAMMNUMMER 83688 PC
BLOCKNUMMER 80036
I XON
m The function keys have no effect during transfer.
m The backpage key terminates the data transfer. (Page 83)

VISION 500
Storing main programs
The directory of the main programs in the Vision control will be displayed.
Using the joystick or feed rate potentiometer, select the program to be
transferred to the host computer. Press Confirm (FI) to select the program and
begin transmitting to the host computer. Press Abort (F6) to quit without
transmitting the program.
TEST
PROGRAMMNUMM 12345678
I XON
1 Confirm, start transfer to the host computer. (Page 86)
Abort, terminate the storing function.

VISION 500
During program transmission
The number of lines transferred is displayed during data transfer.
PROGRAMMNUMMER
BLOCKNUMMER
XON
I
Function keys have no effect during program transmission.
The backpage key will abort the program transfer. (page 83)
I
VISION 500
Directory Pane 87
5.4 Directory
This provides a directory of all main programs in the internal memory.
To view the directory, press F2 at the main Data window, as shown below:
Program input-output
Directory (page 88)
Shape Library
Edit programs
VISION 500
Page 88 Directory
Directory Of All Main Programs
The directory screen that appears has three columns. The first column lists the
names of the programs in the internal memory. To the right is the corresponding
size of the program in bytes. The last column shows the date that the file was
created. The program marked by the cursor can be deleted by pressing F1.
BANBI 1 11686 14.01.93

BIG1 28037 10.02.94
BULL 4974 08.02.94
DOLPHIN 537 17.08.93
DONALD1 10977 14.01.93
ESAB 2070 22.12.92
FRAU1 2256 03.02.94
Delete program marked by cursor. (Page 89)

VISION 500
Directory Page 89
Delete program
To make sure that files will not be deleted accidently a inquiry box appears. To
. , Press Abort (F2) to return to the directory
delete the file, press Confirm (FI).
without deleting the file.
BAMBI 1 11686 14 .01.93

BIG1 28037 10.02.94
BULL 08.02.94
DOLPHIN 17.08.93
DONALD1
ESAB 22.12.92
FRAU I
m Confirm, delete program and return to the directory. (page 88)
i Abort, return to the directory without deleting the file. (page 88)
VISION 500
Page 90 Shape Library
5.5 Shape Library
Shape library shapes are programs with predefined contours. By changing

variables, main programs can be generated from these shapes.
The shape library provides a graphic picture of each of the shapes that are
available.
When changing the variables, an on screen pointer on the graphical display of

the shape shows which dimension is being affected by each variable.
Once the desired dimensions have been entered, the shape is re-drawn on
screen to depict the appearance of the new program before it is generated. This
allows the operator to verify that there were no mistakes made while entering the
dimensions.
To use the shape library, press F3 from the main Data window, as shown below.
Directory
Shape Library (page 91)
Edit programs
VISION 500
Shape Library Page 91
Selecting Which Shape To Use
Selection of a shape from the library can be done in one of two ways, by looking
through each of the shapes until the desired one is found, or by selecting the
shape number from the directory of shapes.
To look through the shape library one shape at a time, use the Search Forward
(F3) and Search Backward (F2) keys. Each time a key is pressed, the picture of
the next shape will be drawn on screen. When the desired shape is displayed,
press Confirm (FI) to select that shape for processing.
To view a directory of all shape library shape numbers, press F4.
a FESTP 8081
+05000 a
m Confirm, select the displayed shape (page 93)
Search backward
I + I Search forward
Directory of all available shapes (page 92)

VISION 500
Selecting a Shape from the Directory
A selection box is displayed with the first four shape numbers. Use the joystick
or the feed rate potentiometer to scroll up and down through the list, or type in
the program number directly using the keyboard. The cursor will then be
positioned automatically.
When the cursor is positioned at the desired shape number, press Confirm (FI)
to select that shape-for processing.
+05000
0 FESTP 8001
Confirm, select shape then return to the previous screen. (page 91)
Abort, return to the previous screen without selecting a shape. (page

91)
VISION 500
Shape Library Paae 93
Entering the Name of the Main Program to be Generated
When a library shape is used, it will be given dimensions and then stored as a
new main program, which can then be treated just like any other main program.
The first step to generating this new main program is giving it a name. Enter a
name for the program that is to be generated. Use digit or letter keys, or the
letter line on the screen. Up to 8 characters may be used.
When finished, press F1 to confirm the entry and go on to the parameter

screen.
PROGRAHHNUMMER 12345678
Confirm the program name continue to the parameter screen (page

94)
VISION 500
Changing Parameters
This screen allows the operator to enter the desired dimensions for the new
shape. The flashing line in the graphical representation moves with the cursor in
the variable list. This makes it clear which dimension will be affected by the
current variable.
Enter a value for each variable. When finished, press F1 to confirm the entries,
and display the new shape.
305000
Q. FESTP 8001 1234 678
VISION 500
Shape Library Page 95
Display the Generated Main Program
The display shows what the new program will look like with the values that have
just been entered in the parameter screen. If this looks correct, press F1 to
accept the values and generate the new main program. If something is incorrect,
press Backpage to return to the parameter screen and adjust the values.
Fl
Accept the values, generate the main program (page 90)
Press backpage return to the parameter screen. (page 94 )

VISION 500
Page 96 Program Editor
5.6 Program Editor
The program editor allows the operator to create andlor edit main programs.
When selecting the program editor, enter the name of the program to be edited.
If the program is available from the internal memory, it will be loaded into the
editor. Otherwise, a new program will be created.
To access the program editor, press F4 from the main Data window.
m
El
Directory
I Q I Shape Library
Edit programs (page 97)

VISION 500
Program Editor Page 97
Selecting a Program Name
Before editing, the operator must enter the name of the program to be edited. If
it is an existing program, the operator may type in the name or select the name
from the directory.
Enter the name of the program using the digit or letter keys, or the letter line on
the screen. When finished typing, press F1 to confirm the name and enter the
editor.
To select the file name from the directory of internal memory, press F2.
PROGRAMMNUMMER 12345678
m
El
Confirm program name and enter into program editor. (page 99)
Select the program name from directory of internal memory (page 98)
VISION 500
Selecting a Program Name from the Directory
Select a program with the joystick or the feed rate potentiometer. Or enter the
program name directly. The cursor will then be positioned automatically. When
the desired program name is found, press Confirm (FI) to select the program
and open the program editor.
Press Abort (F2) to return to the program name entry screen without selecting a
program.
I PROGRAMNNUMMER 01
88F
9988
ADLER2
ALF
m Confirm name, open program in the editor. (page 99)
hl Abort. Return to program name entry without selecting. (page 97)

VISION 500
Selecting a Program Name
Before editing, the operator must enter the name of the program to be edited. If
it is an existing program, the operator may type in the name or select the name
from the directory.
Enter the name of the program using the digit or letter keys, or the letter line on
the screen. When finished typing, press F1 to confirm the name and enter the
editor.
To select the file name from the directory of internal memory, press F2.
PROGRAMMNUMMER 12345678
1 Confirm program name and enter into program editor. (page 99)
Select the program name from directory of internal memory (page 98)
I;
VISION 500
Selecting a Program Name from the Directory
Select a program with the joystick or the feed rate potentiometer. Or enter the
program name directly. The cursor will then be positioned automatically. When
the desired program name is found, press Confirm (FI) to select the program
and open the program editor.
Press Abort (F2) to return to the program name entry screen without selecting a
program.
I PROGRAMMNUMMER 01
P-l Confirm name, open program in the editor. (page 99)
1 Abort. Return to program name entry without selecting. (page 97)

VISION 500
Program Editor - Basic Screen

In the basic screen, the name of the current program is displayed in the top line.
The cursor is controlled with the joystick or the feed rate potentiometer. Up to
seven lines of the program will be displayed. The basic menu includes Insert
mode (F2), Delete line (F3), Goto block number (F4), and letter line (F5). Use
the backpage key to exit the program editor. Use the menu extension key to
access additional functions.
Insert mode (highlighted) or overwrite mode (normal). Default setting

is insert .
Delete line in which the cursor is positioned.
Go to block number. An input box opens and the desired block

number can be entered. (page 101)
An input box opens and the letter line appears. (page 100)
Exit the program editor (page 106)
Additional functions (page 102)

VISION 500
Using the Letter Line
Program lines may be changed using the digit or letter keys, or the letter line on
the screen. Once the letter line is displayed, the feed rate potentiometer is used
to select a letter in the letter line. The selected letter is added in the program
line by pressing the enter key.
Once finished with the letter line, press Confirm (FI) to save the changes and
return to the editor screen. Press Abort (F6) to quit without making changes
from the letter line.
m Confirm, save changes and go back to basic screen.
m Abort, quit without making changes.

VISION 500
Searching Block Number
This feature allows the operator to jump directly to a specific line number in the
program. Enter the block number to be searched, then press Confirm (FI).
Press Abort (F6) to quit without searching.
Confirm, search for the specified block number. (page 99)
?
a Abort, quit without searching (page 99)
VISION 500
Program Editor - Additional Functions

When the additional functions key is pressed in the base menu, the following
functions are accessed. Search for auxiliary function allows the operator to
search for a specific M-Code. Replace auxiliary function allows the operator to
replace all occurences of one M-code with a different M-code. Mark lines to
delete is used to mark a block of program lines to be deleted all at once. Insert
block at cursor position will insert the previously deleted block in a new position.
14 :-l38+90
15 :+960+760
16 :-30+40
li' :-970-770
18 :-130+95
19 :+l815+888
20 :-25+45
F l Search auxiliary function (page 103)

1 Replace auxiliary function with auxiliary function (page 104)
1
7
1Mark lines to delete (page 105)
r l Insert block at cursor position
The menu extension key switches back to the basic screen. (page
99)
VISION 500
Searching Auxiliary Function
Enter the auxiliary function (M-Code) for which to search. Then press Confirm
(FI) to conduct the search, or press Abort (F6) to quit without searching.
IJI Search specified auxiliary function (page 102)
w Terminate function. (page 102)

VISION 500
Replacing Auxiliary Function With A Auxiliary Function
This procedure will replace all occurences of an M-Code in a program with a

different M-code. An inquiry box will appear requiring two entries. First enter
the auxiliary function (M-Code) that has to be replaced, followed by the new
auxiliary function to be inserted. When finished, press Confirm (FI) to go ahead
with the replacements, or Abort (F6) to quit without doing the replacements.
Confirm, replace all specified auxiliary functions (page 102)
Abort, without doing the replacements. (page 102)

VISION 500
Marking Program Lines
This function allows the operator to mark a block of program lines, which may
then be deleted permanently, or deleted and re-inserted in a different location.
Mark the program lines with joystick and feed rate potentiometer. When the
desired block of lines is highlighted, press Delete marked lines (F5) to remove
the block from the program. If the lines need to be re-inserted in a new location,
then move the cursor to the new location and press Insert deleted lines (F6).
Search auxiliary function.
Replace auxiliary function with a auxiliary function.
"Mark lines to delete" is active. Pressing the key again will

deactivate the marking function.
Delete marked lines.
Insert deleted lines at cursor position.

VISION 500
Exiting The Editor
Exit the program editor by pressing Backpage. If any changes were made to the
program, a box will open and the program name can be entered. The current
program name will always be offered. If the program should be saved under a
different name, enter the new name in box. Saving under a different name will
create a new program file, but not erase the existing one.
To save the changes,

- press Confirm (FI).
. To abort without saving the changes,
,
press F6.
I aCDEFI;H I JKLMNOPQRSTUUWXYZ
Confirm, Save and exit editor.
Abort, exit editor without saving.

VISION 500
Movement Window Page 107
6 Movement Window
The movement window provides access to all functions that are necessary to
move the machine manually and to prepare and control the automatic execution
of a program. This includes the automatic mode, manual jogging of the machine
with the joystick, referencing (homing) the machine, moving to fixpoints, and
using the tracer.
The main screen of the Movement window is shown below. It is accessed at any
time by pressing the Movement window button.
m Automatic mode (page 109)
IbI Fixed point movements (page 122)
El Reference point movement (page 124)
Trace I Trace Record (page 127)
Basic Menu
At the main level of the movement window, the machine can be moved using the
joystick. The screen displays the X and Y axis machine coordinates, and the
setting of the feed rate potentiometer. The displayed coordinate values are with
reference to the machine zero point, which is defined by referencing the
machine. The features accessed by each of these submenus are listed below.
VISION 500
Page 108 Movement Window
Automatic Mode
- Automatic processing of main programs.
- Selecting a program from the directory of internal memory or the floppy

disk.
- Entry of processing parameter such as speed, offset, scale and rotation.

- Resuming a program that was previously discontinued.
- Step and repeat of a main program.
- Plate alignment.
Fixed Point Movements
- Moving to program zero point.
- Moving to machine fixed point.

In case of more than one working range, select one working range and move to
the fixed point within this working range.
Reference Point Movement
- Referencing (homing) the machine after switching on the machine power.
Trace 1 Trace Record
- Tracing the contour without recording.

- Tracing the contour with recording.
- Enter the contour to the left / to the right.
- Different types of lead-in and lead-out.
- Minimum Point-to-Point Distance.
- Scan line / edge.
- Set reference point.

VISION 500
Automatic Mode Page 109
6.1 Automatic Mode
The Automatic Mode allows the operator to run part programs. The cutting feed
rate, kerf offset, part rotation, part scaling, and step and repeat are all set up
before starting the program execution. Once the program has been started, the
operator has the ability to stop, restart, reverse, quit, relocate, or temporarily
interrupt the program processing. Programs that were previously interrupted
can also be restarted in the Automatic Mode.
To access the Automatic Mode, press F1 from the main Movement window, as
shown below.
1
Automatic mode (page 110)
Fixed point movements.
IcI Reference point movement.
M Teach 1 Trace Record

VISION 500
Automatic Mode
-
Automatic Mode Selection Window
The menu options that appear in the selection window depend on the previous
actions of the controller. There are at the most four possibilities for selecting a
program, as shown in the menu below.
The symbol for resuming a program (F5) that was discontinued because of
termination or power failure is only displayed if the corresponding data exists.
When this function is selected, the parameter entry is skipped.
When Recycle (FI) is pressed, the parameter entry is also skipped, and the
same parameters are used as during the previous run of the program.
F2 and F3 allow the operator to select a program to run from either the internal
memory, or the floppy disk reader
Recycle the last program using the same parameters (page 120)
Select program from internal memory (page 111)
Select program from external floppy disk (page 111)
Resume processing the program after power failure (page 120)

VISION 500
Selecting a Program
When either F2 (Select program from internal memory) or F3 (Select program

from external floppy disk) are pressed from the selection window a selection box
will be displayed with the appropriate list of program names. Selection is done
with the joystick or the feed rate potentiometer. When the desired program
name is selected, press Confirm (FA) to select that program and move on to the
Automatic Setup screen.
Press Abort (F6) to go back to the selection screen without selecting a program.
ADLERZ
ALF
FRAU1
HEXE
m Confirm, select program and go to Automatic Setup screen (page 112)
W Abort, return to selection window without selecting. (page 110)

VISION 500
Page 112 Automatic Mode
Automatic Setup Screen
This screen allows the operator to enter values for program processing, including
feed rate, kerf offset, scale, rotation, and start block number. Numeric values
are entered directly with the digit keys. The joystick or the feed rate
potentiometer are used to move up and down through the list of parameters.
The menu that appears is dependent on control configuration, sectional prekerf

is an optional feature that will not appear on all machines.
I PROGRAM ADLER2
SPEED CMMPHI 00380
KERF CMMI 023.4
SCALE C1,10001 1000
START AT BLOCK 0001
PLATEROTATION CDEGI 000.000
PROGRAMROTATION CDEGI 000.000
End input. Prepare entire program before starting movement.

(page 120)
End input. Prepare program in sections. Start program execution after
partial preparation. (page 120)
Set program zero point (page 114)
bl Plate alignment (page I 15)
El Step and Repeat. (page 117)
Parameter Explanation
Speed: is the feed rate of the cutting tool during program

execution. If the feed is programmed in the part program, it
overwrite this value. During program processing, the feed
rate can only be altered via the feed rate potentiometer.
VISION 500
Kerf: is the total cut width for which the program path will be
compensated. If kerf is programmed in the part program, it
over writes these input values. The kerf cannot be altered
during program processing.
Scale: The value 1000 corresponds to the ratio 1.1, i.e. the
program is processed in original size.
The value 500 corresponds to the ratio 1.2, i.e. the sizes in
this program are halved.
The value 2000 corresponds to the ratio 2.1, i.e. the sizes
in this program are twice as big as the programmed sizes.
Starting block
number Block number at which processing is started. Normally,
this value is set to 1, i.e. processing starts with block 1
Plate rotation: Rotation to align a plate that is not straight on the cutting
table. The rotation is done for all repetitions around the
bottom right corner of the plate. The angle for this rotation
can be entered directly or determined automatically with
the function "Plate alignment".
Program rotation: Rotation of the individual program around the program zero
point. This rotation car1 be used in order to achieve a
better utilization of the plate when processing single
programs.
VISION 500
Plate Alignment
Plate alignment is an optional feature that provides the ability to measure and
calculate the angle of the plate and the zero point with the machine. This is
helpful for maximizing plate utilization and for fitting large programs on a
misaligned plate.
The position of the plate is determined by finding three points along the edges of
the plate. Once all three of the points have been found, the angle is
automatically entered under "Plate rotation" in the automatic setup screen, and
the program zeropoint is also calculated.
To find each of the points, the machine is moved with the joystick until the
cutting torch is directly over the edge of the plate in the specified area. Use a
low speed when approaching the edge for exact positioning.
The control prompts the operator for each of the points. When the point is
reached, press Confirm (FI) to adopt the current location of the torch as the
requested point. The control will then prompt for the next point.
Adopt points.
VISION 500
Point Adoption for Plate Alignment
The screen for plate alignment will show the three symbols described below to
indicate to which of the three points the machine should be moved. Once at the
point, the position is stored when Confirm (FI) is pressed.
Once the third point is adopted, the measurements are complete and the
calculation of the angle and position of the plate are performed.
m Adopt point at the top right edge.
Adopt point at the bottom right edge.

Dl
Adopt point at the front left edge.
I
Zero Point Adoption
If the Program Start key is pressed right after the third point is adopted, the
machine automatically will move to the bottom right corner of the plate. This
point will then also be the program zero point when processing is started. After
the movement is completed, the control switches back to the automatic setup
screen, and the calculated plate rotation angle will have been added to the
screen. (page 112)
10 If the backpage key is pressed after the third point is adopted, the
current position of the machine will be the program zero point when the
program is started. The control will return to the automatic setup
screen. (page 112)
VISION 500
Step and Repeat
This feature allows a single program to be cut multiple times automatically.
When step and repeat is selected from the automatic setup screen, a box
appears which prompts the operator to enter four values. Values must be
entered for the number of rows of parts to cut, the number of parts per row, and
the distance (offset) between parts.
In order to define the distance between the repetitions, the control assumes a
rectangular area around the given program. This rectangle is called a container
and it encompasses the furthest extents of the program, including lead-ins and
lead-outs. The offset distance entered is the distance between the containers.
With a zero offset, the containers will be right next to each other. With a
negative offset, they overlap. For oddly shaped parts, a negative offset may be
desired to nest the parts more closely together.
Once the four entries have been completed, press Confirm (FI) to accept the
input values and return to the automatic setup screen. Press Abort (F6) to
return to the automatic setup screen without using step and repeat.
PROGRAM
SPEED C
KERF CM
SCALE C
START A
PLATER0
PROGRAM
Confirm inputs and return to automatic setup screen. (page 112)
Abort, do not use step and repeat. (page 112)

VISION 500
Program Preparation and Kerf Calculation
If the Sectional Prekerf option has been installed there will be two menu keys on
the automatic setup screen for ending parameter input, F1 and F2. Both of
these menu keys complete the entry and trigger the calculations for program
execution.
The two keys lead to different ways of carrying out the program preparation. In
addition to the actual program path calculation, they also influence other factors
of program processing. F1 selects the standard method, "Total Preketf". F2
selects the optional feature, "Sectional Prekerf".
Total Prekerf means that all preparations, including the complete offset
calculation for the kerf, are done for the entire program
before execution is started. The calculated program path
data is completely stored in memory.
Sectional
Prekerf means that the preparation of the program path with kerf
offset calculation is done before and during processing.
The program is divided into sections. While one section is
being cut, the next sections of the program are calculated.
Path data from the sections already completed is discarded
from memory to make room for upcoming sections.
Each option has its advantages and disadvantages, as discussed below.
Total Prekerf Step and repeat can be used.
The control can recognize if the program will go outside of

the software limits prior to program start, allowing the
operator to reposition the machine as necessary.
There are no restrictions on reversing on path after a loss

of cut.
When the entire program execution is repeated, a new

calculation phase is not necessary.
The program length is limited to approximately 64 kBytes.
Sectional
Prekerf Program length is not restricted, since the program is
executed in sections.
VISION 500
Calculations are done simultaneously with program

execution, so the length of time for calculations is not
noticeable.
However, each time the program is run, calculations are

re-done.
Step and repeat is not possible.
There are restrictions with reverse movement. Normally,

however, they should not come into effect.
VISION 500
Automatic Program Execution
The program is automatically processed when the start key is pressed.
Switch between machine coordinates and program coordinates display
Interrupt program, manual jogging during automatic mode (page 121)
Switch between forward and backward
The coordinates of the X-axis and Y-axis as well as the kerf value (K) and the
current block number (N) are displayed on the left side of the screen. At any
time during processing, it is possible to switch the display between program
coordinates and machine coordinates.
For switching between forward and backward mode, the machine has to be
stopped with the stop key.
PI The execution of a program can be terminated with the backpage key

once the machine is in the stop state. All data that is necessary to
continue the program, will be stored. It will still be available even if the
machine power is switched off.
VISION 500
Program Interruption
A program can be stopped and interrupted at any point. After pressing the
interruption key, the machine can be operated the same as in the manual jog
mode. If the machine is jogged off of the program contour, there are two options
for continuing the program. The program may be continued in its original
location, by pressing backpage, or the program may be continued starting from
the current location of the torch, by pressing Resume (F4).
H Switch between machine coordinates and program coordinates display.
Resume program processing without retracing jog movement.

(page 120)
With the backpage key, program processing will be continued with a

return to the original contour location.
When the start key is pressed, the machine moves to the point of the contour
where the program was interrupted, and then stops. Now, cutting processes can
be manually started. Pressing start again will continue processing.
VISION 500
Fixed Point Movements
6.2 Fixed Point Movements
Fixed points are machine coordinate locations that are defined in the machine
constants. They should be set up at a point on the cutting table where most
programs will be started. The machine can easily be sent directly to one of the
fixpoints with the press of at button. Multiple fixpoints is an optional feature,
not installed in all machines.
To move to a fixpoint, press F3 from the main Movement window.
Automatic mode
Fixed point movements (page 123)
Reference point movement
Trace / Trace Record (page 127)

VISION 500
Fixed Point Movements Page 123
Selecting Fixed Points
The standard design of the control offers two automatic fixed point movements:
Movement to program zero point and
Movement to fixed point of working range.
Move to program zero point
Move to fixed point of first working range
The highlighted key indicates which working range is currently active.
Press the start key to start movement. After completing the movement, the
system will automatically return to the basic screen.
VISION 500
Page 124 Reference Point Movement
6.3 Reference Point Movement
The reference point (Home point) of the machine is defined by hardware limit
switches on the gantry and rail system. The machine must be referenced each
time the power is switched on, in order to enable features that require an
absolute machine coordinate system, including fixpoints, software limits, and
resuming programs after power fail.
Referencing the machine is done by pressing F4 in the Movement window.
Automatic mode.
Fixed point movements
Reference point movement. (page 125)
Trace 1 Trace Record

VISION 500
Reference Point Movement Page 125
Reference Point Movement
The reference is lost when the machine power is switched off. Therefore, the
reference point has to be set by moving over the reference point of each axis
after switching on the machine. Depending on the design of the machine and
the control system, two different types of referencing are.
Adopt (only for machines without reference point system)

IJI
Manual Reference Point Movement
With the joystick, the operator selects the axis and pre-selects the direction
for the movement to the reference point of the axis. The current direction
is displayed in the top right corner of the screen. The movement is
launched with the start key. The machine stops automatically after
recognizing the reference point. The reference point of each axis is
detected when the limit switch for that axis reaches its cam, and the the
control then receives a zero pulse from the encoder. Therefore, the
reference point measurement is as accurate as one encoder pulse.
VISION 500
Page 126 Reference Point Movement
No Reference Point System
When the machine is not equipped with a reference switches and cams, the
reference point is defined manually. The axes are moved to a specific point
as accurately as possible. This position is adopted as reference point by
pressing the menu key adoption (FI).
VISION 500
Trace 1 Trace Record Page 127
6.4 Trace I Trace Record
If the VISION 500 is equipped with the optional opto-electronic tracing system,
the control can be used for copying (Trace) and for digitizing (Trace Record)
graphical patterns.
The tracer system moves the machine such that the tracer follows a line or an
edge on a graphical pattern.
In the Trace Record mode, the control continuously records points along the
contour in very short intervals. Some of them are then chosen and stored as
scanning points.
While scanning, the control calculates an artificial line connecting the two most
recent recorded points. The system then checks each following measuring point
to see if it deviates to either side of the line by more than a preset tolerance, or
if the distance since the last recorded point exceeds a preset limit. The last
recorded point that meets both requirements is stored as contour point.
With this collected data, the control calculates a complete main program which
can be processed in automatic mode.
In order to understand the following instructions, it is useful to know just a little

about the tracer's behavior. The following discussion refers to a line movement.
The same procedure applies for an edge movement.
In the Trace mode, the machine starts by moving in a preselected direction

towards the line until the "eye" of the tracer recognizes the line.
The "eye" is the photo-electric sensor in the tracer. The area under the tracer
eye is illuminated by a floodlight. The floodlight counteracts the influence of
external lights and shadows.
When the tracer has recognized the line, the machine motion begins to follow the
line according to the preselected direction, either turning to the left or to the
right.
In trace mode, the machine movement stops at the end of the line. If the line
has is a closed contour, tracing will continue indefinetely.
In the Trace Record mode, the system automatically recognizes the point at
which the line was initially recognized and it ends the contour there.
VISION 500
Paae 128 Trace I Trace Record
Selecting the Function: Trace I Trace Record.
To select either Trace or Trace Record mode, press F6 from the main menu in
the Movement window. The tracer system is an optional feature, so this icon will
not appear on machines without the tracer system.
Automatic mode
Fixed point movement
Reference point movement
Trace I Trace Record. (page 129)

VISION 500
Selecting Trace 1 Trace Record
m
FI
Trace (Tracing the contour without recording) (page 130)
Trace Record (Tracing the contour with recording) (page 133)

VISION 500
Page 130 Trace / Trace Record
6.4.1 Trace
Prior to tracing, set the tracing speed, kerf offset, and lineledge option.
SPEED CMMPMI:
KERF CMMI:
m Confirm parameters and prepare to trace (page 131)
I@ma Toggle selection between line I edge
Feed: is the feed rate at which the contour is scanned. During

scanning, the feed rate can only be altered via the feed
potentiometer.
Kerf: The kerf value causes an offset of the machine to the side
in relation to the scanning point in order to compensate for
the width of the cutting tool.
Line / Edge If the line width of the pattern is more than 1 mm, "edge"
mode must be used.
VISION 500
Start Tracing
Prior to starting tracing, the machine can be moved with the joystick in order to
position the tracer or torches at the correct starting point. Press F1 to toggle
between manual mode for joystick movement, or tracing mode.
Also prior to starting the trace, check the Trace RightlTrace Left toggle (F5) to
make sure that the correct turn in direction is selected.
To start tracing, press F1 to toggle into the Trace mode. Press the joystick in
the direction of the pattern to define the search direction. Press the start button
to begin searching for the contour.
W Switch between manual control and tracing
%1 Enter to the left Ito the right

VISION 500
Page 132 Trace 1 Trace Record
Status displays during the tracing process:
El Searching contour
I Found contour. Scanning active.
The symbol "Searching contour" is displayed while the machine is moving in the
search direction looking for the contour. During the search process, the axes
are moved at half of the preset speed.
When the line has been found, the symbol "Found contour" is displayed. The
machine will begin to move at the preset speed. Furthermore, the symbol for
"forwards/backwards - switch" is displayed in the menu.
VISION 500
Trace ITrace Record Page 133
6.4.2 Trace Record Setup
The set up procedure for Trace Record requires several additional selections.
First, a program name must be entered for the main program that will be
generated by the control once the contour is traced. Selection must also be
made for the tracing speed, lead-inllead-out definition, point-to-point distance,
and line edge mode. When finished entering parameters, press Confirm (FI).
I ZCDEFGHI JKLMNOPQRSTUVWXYZ
IJI Confirm parameters, proceed to the Trace Record mode (page 136)
E l
IGI
Select lead-in type, straight or curved
Select lead-out type, straight or curved
Enter lengths and angles for the lead-in (page 134)
Enter point-to-point distances (page 135)
Toggle selection between line 1 edge
Program: Name of the program under which the scanned contour

should be stored. If a program with this name already
exists, the newly scanned contour is added to it.
Feed: The feed rate at which the contour is scanned. During

scanning, the feed rate can only be altered via the feed
rate potentiometer.
Line Iedge: If the line width is more than 1 mm, "edge" mode must be
used.
VISION 500
Page 134 Trace / Trace Record
Entering lengths and angles for the lead-in generation
The lead-in and lead-out for the generated program must be entered before
tracing is done. These values will be used by the control after the contour has
been recorded, and a lead-in and lead-out will be added to the program
automatically.
Enter values for the length and angle of lead-in and lead-out in the inquiry box,
as shown below. When finished entering, press Confirm (FI) to complete the
entries and return to the Trace Record setup screen.
LEAD IN LENGTH
LEAD-IN CMMI: 000010.0
LEAD-OUT CMMI: 000003.0
ANGLE
LEAD-IN CDEGREE1:845
LEAD-OUT CDEGREEl045
Confirm entries and return to Trace Record setup (page 133)
No function.
VISION 500
Trace / Trace Record Page 135
Entering the Minimum Point-to-Point Distance
The minimum point-to-point distance is used by the control during tracing to

determine when to record points. The larger the minimum point-to-point
distance, the larger the smallest line sections. This is important because it will
affect the quality of the playback when the generated main program is run. If the
program is going to be run at high speed, longer point-to-point distances should
be used. High speed cutting cannot be done if the recorded line sections are tos
small. However, the contour is recorded with slightly
- higher precision with small
line sections.
1 PROGRAM :
SPEED CMMPMI :
MIN POINTDISTANCE CMMI: 000.6
Confirm parameters and return to setup screen (page 133)
No function.
VISION 500
Pane 136 Trace I Trace Record
Trace Record Mode
Once all the parameters have been entered, the trace record mode is entered.
At this screen, the machine may be jogged to the starting location, turn-in
direction is selected, an index point for the recorded program may be defined,
and tracing may be started.
F1 allows the operator to switch to manual mode for jogging the machine into
position to trace. This can be used in conjunction with F6 to record an index
point for the generated main program. F5 is used to toggle between Turn-In Left
and Turn-In Right. When ready to trace, press the joystick in the direction of the
pattern to select a search direction, then press start.
m Switch between manual jog mode and Trace Record
1 Toggle selection between turn-in left I turn-in right
Record program index point
When Record Index Point (F6) is pressed, the control will add a straight
movement from that point to the first point of the line recognized by the tracer.
This allows the operator to record an index point, such as a point at the corner
of the plate, from which the generated main program will be started.
VISION 500
Status displays during the Trace Record mode
Searching contour
Found contour. Scanning active.
Lost contour
Completed contour
If the Trace Record process has not yet been started, the machine can be moved
with the joystick as in normal manual control.
Prior to starting tracing, the search direction must be defined with the joystick.
The tracing process may then be started by pressing the start key. The symbol
"Searching contour" will be displayed. During the search process, the machine
is moved at half of the preset speed.
When the line has been found, the symbol "Found contour" is displayed. The
machine will then move at the preset speed.
The contour will be scanned and recorded until the machine recognizes that it
has returned to the starting point of the scanning process. When the contour is
completed the Trace Record process is automatically terminated and the
recorded contour is stored as a main program in internal memory.
VISION 500
Page 138 Process Window
7 Process Window
The process window is used for controlling the cutting and marking processes.
Once the 24 volt power has been turned on, the process window may be
accessed. The menu for each different cutting or marking process that is
present on a machine will have a main level, and one or more option levels. Not
all of the functions discussed in this chapter are available on every machine.
Only processes that are actually available on the machine are displayed.
In all levels of the process window, the main portion of the screen will display
the XIY-coordinates and a the active and inactive stations.
The process menu that appears depends on which station is selected. If no

stations are selected, the general options menu will be shown. If a station is
selected, the process menu for the type of cutting tool on that station will be
displayed. Pressing the Backpage key will access the General Options menu.
Within the process window, the currently selected process is always displayed in
the top left corner next to the symbol for the process window. Below are the
symbols for each process.
F
I Plasma (page 140)
m Oxy-Fuel (page 142)
m Punch Marker (page 145)
rn Plasma Marker (page 147)

VISION 500
Process Window Page 139
The General Options Level
The General Options Level is used for additional process options. No other
options are implemented at this time.
I7 Return to the currently selected process screen.

VISION 500
Page 140 Plasma Process
7.1 Plasma Process
Main Level of the Plasma Process
Go to option level (page 141)

AHC allow
AHC onloff
Preflow onloff (test preflow)

Y
I _8_ I Plasma startlstop
If a process timer is running, it is displayed as graphical bar indicator.

VISION 500
Page 142 Oxy Fuel P r o c e ~ s
7.2 Oxy Fuel Process
Main Level of the Oxy Fuel Process
Go to option level. (page 143)
M71 Process Stop
Edge Start
Oxy Fuel Cutting
Oxy Fuel High Preheat
Oxy Fuel Ignite
If a process timer is running, it is displayed as graphical bar indicator.

VISION 500
Oxy Fuel Process Page 143
-
Oxy Fuel Option Levels
Go to additional option levels (page 144).
AHC allow
AHC onloff
M73. Process Stop
Travel
M70. Process Start

VISION 500
Page 144 Oxy Fuel Process
Oxy-Fuel Additional Option Levels
Water table low
Water table medium
Water table high
Punch AHC allow
Punch AHC onloff
Manual Punch Mark (for marker mounted on the Oxy-Fuel station)

VISION 500
Punch Mark Process Page 145
7.3 Punch Mark Process
Main Level of the Punch Mark Process
m Go to option level (page 146).
AHC allow
AHC onloff
If the process timer is on, it is displayed as graphical bar indicator.

VISION 500
Page 146 Punch Mark Process
Punch Mark - Option Levels
R
Water table low
Water table medium
1 Water table high

VISION 500
Plasma Mark Process Page 147
7.4 Plasma Marker Process
Main Level of the Plasma Marker Process
Go to option level. (page148)
AHC allow
AHC onloff
Plasma Marker startlstop
If a process timer is running, it is displayed as graphical bar indicator

VISION 500
Page 148 Plasma Mark Process
Plasma Marker - Option Levels
R
Water table low
Water table medium
1 1 Water table high

VISION 500
Station Control Window Page 149
8 Station Control Window

The Station Control window consists of two menus: station selection and station
lift control.
The X/Y coordinates and the active and inactive stations are displayed in the
station control window.
The number of displayed stations depends on the machine. The following

screens show a machine with four cutting stations.
8.1 Station Selection
The stations are selected and cancelled by pressing the keys F1 through F6.
Select or cancel station 1.

E
lal Select or cancel station 2.
Select or cancel station 3.
R Select or cancel station 4.
Select or cancel station 5 (if available).
Select or cancel station 6 (if available)

VISION 500
Page 150 Station Control Window
8.2 Station Lift Control
This feature is only applicable to machines equipped with motorized torch lifters.
Station lift control is used to manually raise and lower the stations. The station
to be moved is preselected with the keys F1 through F6. Pressing the key a
second time cancels the preselection. The actual movement is done by pushing
the joystick. Pushing the joystick down moves the preselected station down.
Pushing the joystick up moves it up. Multiple stations can be selected and
moved up or down at the same time. The sensitivity of the torch lifter to the
movement of the joystick can be set with the MIP constant 34.
m Preselect station 1 for Iiftingllowering
2
f
I
El
Preselect station 2 for liftingllowering
Preselect station 3 for liftingllowering
1 ~ 1 Preselect station 4 for liftingllowering
H
Preselect station 5 for Iiftingllowering (if available)
Preselect station 6 for Iiftingllowering (if available)

VISION 500
Timer Window Page 151
9 Timer Window
The Timer window is accessed at any time by pressing <SHIFT-Process
Window>.
The Timer window allows the operator to set various timers used by the machine
processes. The changes remain valid until another process is selected.
The current setting of each timer indicated by the bar indicator. The feed rate
potentiometer and the joystick are used to scroll vertically within the display.
Placing the cursor to the left of the bar indicator, marks the item selected to be
changed. Changing the value is done by turning the feed rate potentiometer and
SIMULTANEOUSLY pressing the F1 key. Turning to the right increases the
value, to the left reduces the value. Some of the timers cannot be changed.
TIME
DELAY
UP
TIME
TIME
Press and hold, then turn the feed rate potentiometer to change a timer
setting.
VISION 500
Page 152 Error Status Display
10 Error - Status Display

The Error-Status Display is accessed at any time by pressing <SHIFT-F6>.
This screen displays any Errors that have occurred and, if possible, additional
information.
The name of the current or last processed program is indicated with PRG. BLC
indicates the current block number of the processed program.
PRG BLC 0000
Delete error
Switch to status display (page 153)

VISION 500
Error - Status Display Page 153
Status Display
I I
yfl Port reset
El Time setting (page 156)
+ screen when the 24 Volt power has been switched on. The voltage is
The 24 Volt power may be manually switched off with the key combination
shiftlstop. It is also switched off any time the machine's E-Stop string is
broken, or the machine power is turned off.
b has already been referenced.
VISION 500


axis.

be processed.

Feedhold. Motion is disabled. The machine cannot be operated.
Memory Reset. For clearing resetting the battery backed up

memory.
0 Time. For setting the time kept by the system clock.

1
01 active.
VISION 500
Auxiliary function. Highlighted symbol indicates that a process M-

code is being executed, such as torch ignition.
Feed rate reduction. Highlighted symbol indicates that feed

reduction is active.
Emergency stop. Highlighted symbol indicates that emergency stop

is active.
X-axis Motion blocked. Highlighted symbol indicates that movement


of Y-axis is blocked.
VISION 500
Time Setting
Setting the time. The adjustment is done with the joystick and feed rate
potentiometer.
No adoption
VISION 500
Display of Version Number
I SERIENNUMMER
SYSTEM
ALFE VERSION
0999
U2.52C
----
HIP VERSION LTEC-2 V.14.03.95
8031 OS 2.66A
8031 BOOT 1.0
Serial number: Control number

Svstem: Version number of the basic system (ANC41.EXE)
A~FE Version: Version number of optional tracer system
MIP version: Version number of the MIP program (MIP41.MIP)
8031 0 s : Operating system number of the sub system
(NOS8031.BIN)
8031 Boot: Version number of the boot loader of the sub system
(BOOT8031.HEX)
VISION 500
Page 158 Index
11 lndex
24 Volt power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16. 153
Auxiliary function
replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Backpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Block number
search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
setting start block in auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Boxes
information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
inquiry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Break in E-stop chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Computer Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Controller release ; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16. 154
Data window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 66
Delete
editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
main programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Letter line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
End function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Error Status Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6, 152
Feed rate
setting in automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Feed release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 154
Fixed point movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Floppy Disk Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Frequency Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Graphics
standard shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Homing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Individual screen description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Information boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Input boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inquiry boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Internal memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Kerf
setting in automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Key
menu extension . . .. 4
VISION 500
Index Page 159
shiftlbackpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lead-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Letterline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Line Iedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
LoopError . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Main programs
delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Manual control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Mark (program lines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Maximum radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Minimum point-to-point distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Movement Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 107
OxyFuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
activating options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
AHC allow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143, 148
AHC onloff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143, 148
Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Edgestart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
High Preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Ignite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
M70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
M71 Process Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
M73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
mainlevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142, 147
Process Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Process Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Parameter
automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
standard shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Parameter window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Plasma
activating options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
AHC (Automatic hight control) allow . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
AHConIoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
option levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Preflow onloff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
startlstop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
test preflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Plasma Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
activating options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147, 148
AHC onloff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
startlstop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
water table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Plate alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112, 115
Point-to-point distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Powerfailure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Prekerf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Process control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Process main level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Process values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Process Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 138
Processing
automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Program Dimension Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Program editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Program input-output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
UDL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Program interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Program line length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Program zero point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Programs
directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Punch Mark
Activating options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
AHConIoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Reference point movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Release
controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 154
feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 154
SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 154
Repetitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Rotation
setting in automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Running programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Scale
Screen description
general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
individual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Search direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
ServiceWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Servicing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Shapelibrary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Speed
SPS release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 154
Standard shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Station Selection W~ndow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 149
Station UpIDown Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 150
Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Step and repeat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Symbol overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Time setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
VISION 500
Index Page 161
Timer Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 151

Trace ITrace Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Trace Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Turn voltage on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Type of lead-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
UDL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Voltage. turning on 24 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16. 153
Watchdog Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Water Table
high level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141. 144. 146
low level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141. 144. 146
medium level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141. 144. 146
Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 5. 66
error status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Function range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 5. 107. 122
process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 5. 138
service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 5
station selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 6. 149
station upldown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 6. 150
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . 5 . 151
VISION 500
Diagnostic and Service Windows
SECTION 2:
DIAGNOSTIC
AND SERVICE
WINDOWS
SERVICE MODE
DIAGNOSTIC CAPABILIT1ES
CONSTANT DESCRIPTIONS
VISION 500
Contents
Contents
1 Symbol Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
1.1 Service window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 LCDTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 MIP Signal Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 AFIKF Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Synchronization Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Mini Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Service Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Constant Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Station Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Speed Measurement and Rotational Speed Display . . . . . . . . . . . . . 18
2.4 Creating a Copy of the System Floppy . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Formatting a Floppy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Diagnostic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Loop Error Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 LCD Contrast Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 MIP Signal Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4 AF-KF Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5 Display of Synchronization Errors . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6 Mini Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4 Error .Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5 Operating System Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1 Files of the system floppy disk . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2 System Constants (SYS.KON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 Machine constants (MASKON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4 MIP Constants (MIP.KON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.5 Device constants (DEV.KON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6 Station constants (STATxx.KON) . . . . . . . . . . . . . . . . , ........ 66
5.6.1 Station constants (STATxx.KON)/ATHC 2 . . . . . . . . . . . . . . 66
5.6.2 Station constants (STATxx.KON)/AMAD . . . . . . . . . . . . . . . 77
5.6.3 Station constants (STATxx.KON)/ASIOMB3 . . . . . . . . . . . . 84
5.7 Configuration file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
VISION 500
1 Symbol Overview
II Service window

-- constants, as well as, displaying the configuration.
Station parameters. For editing station parameters, as well as,

sending the parameters.
u Speed Measurement. For determining the velocity of the axes.
Rotational speed display. For displaying the revolutional speed per

axis with adjustable voltage supply.
Impulse. Clocked voltage supply for drive optimization.

M
System floppy disk. For creating a second system floppy disk
H+U
Formatting. For formatting a floppy disk in drive B.
H55
Insert floppy disk. Request for confirmation with the functions that
create system floppy disks and format floppy disks. Insert floppy disk in
drive B.
VISION 500
I Symbol Overview
1.I Service window

-- constants, as well as, displaying the configuration.
Station parameters. For editing station parameters, as well as,

sending the parameters.
u Speed Measurement. For determining the velocity of the axes.
Rotational speed display. For displaying the revolutional speed per

axis with adjustable voltage supply.
m Impulse. Clocked voltage supply for drive optimization.
System floppy disk. For creating a second system floppy disk

B.8
Formatting. For formatting a floppy disk in drive B.
B5
n.1 Insert floppy disk. Request for confirmation with the functions that
create system floppy disks and format floppy disks. Insert floppy disk in
drive B.
VISION 500
1.2 LCD Test (ShiftIFl)
LCD Test. Contrast minus.
(# + LCD Test. Contrast plus.
LCD Test. Display of basic font. All black, all white.

VISION 500
1.3 MIP Signal Display (ShiftIF2)
Signal display window. This symbol is displayed in the top left corner
of the screen when the window of the MIP signal display is the active
window.
Display of the data bus input signals.

BIT1
Display of the data bus output signals.
BIT0
Display of static input and output.
APEP
Display of internal MIP signals.
USER
Display of MIP signals higher than 512.
512..
c0
11111111
Force. For forcing value 0.
C -1 Force. For forcing value 1.

11111111
1111mrm1 Force off. For cancelling the force instruction.

)I
VISION 500
1.4 AFIKF Control (ShiftlF3)
AFIKF. Display of the last 16 auxiliary and key functions. This

symbol is displayed in the top left corner of the screen when the
AFIKF control window is the active window.
AF. For displaying the last 16 Auxiliary Functions sent to the MIP.
1-
KF. For displaying the last 16 Key Functions sent to the MIP
IL
VISION 500
I.5 Synchronization Display (ShiftlF4)
Synchronization control. This symbol is displayed in the top left

corner of the screen when the window of synchronization control is
the active window.
ASIOB. For deleting the display of maximum value.

%*
Panel. For deleting the display of maximum value.
%P
VISION 500
I.6 Mini Operating System (ShiftlF5)
Mini operating system. For displaying internal M M addresses. This

symbol is displayed in the top left corner of the screen when the
window of the mini operating system is the active window.
Mini operating system. For switching between the displays of byte,

word, long.
Mini operating system. For switching to absolute addresses.
Mini operating system. For changing the value.

VISION 500
Service Window Page 7
2 Service Window
The Service Window is accessed by pressing <SHIFT-DATA WINDOW>. This
window provides access to the machine constants, the speed measurement
tests, the system disk copy utility, and floppy disk formatting utility.
Constant editor.
Speed measurement.
F
13
( Create system floppy disk.
p///1 Format floppy disk.

Constant Editor
For editing machine constants (page 8)

For editing device constants (page 8)
For editing system constants (page 8)
For editing MIP constants (page 8)
For editing the configuration (page 8)
For editing station constants (page 13)
Speed Measurement
For determining the axis speed (page 18)

Rotational speed display (page 20)
Creating A System Floppy
For creating a backup copy of the system floppy disk (page 21)
Formatting A Floppy (page 23)

VISION 500
Page 8 Editing Constants
2.1 Constant Editor
The control is adapted to the machine and it's environment by means of various
constants and parameters. Constants and parameters are stored in the internal
memory.
Constants should be set up once during the installation of the machine, but may
require changing in order to adapt to changing demands on the machine.
Descriptions of the each of the constants and their meanings start on page 41.
To access the constants, press <SHIFT-DATA WINDOW. This will bring you to
the Service Screen shown below. The constants editor is then accessed by
pressing F1.
Constant editor. (page 9)
Speed measurement.
Create system floppy disk.
Format floppy disk.

VISION 500
Editing Constants Page 9
Selecting Constants
The constants are divided into six groups:
- Machine constants for moving the machine

- Device constants for external devices
- System adaption
- MIP constants
- System - configuration constants (only display)
- Parameters of the stations (does not apply to all machines)
After selecting the Constants Editor, select from one of the categories as listed
below by pressing F1 through F6. Refer to the page numbers shown below for
descriptions of the constants.
MK CON SYS MIP

+ ~g
Machine constants (page 41)
Device constants (page 61)
System constants (page 48)
MIP constants (page 57)
Additional constants
Station parameters (page 13)

VISION 500
Configuration constants
The Configuration Constants may be displayed, but cannot be changed.
FIG
1
Fl configuration constants - cannot be changed - (page 88)
VISION 50'0
Editing Constants Page 11
Editing Constants - Machine Constants: An Example

All constants and parameters are treated the same way. The example below
shows the screen as it appears while editing the machine constants. Device,
system, and MIP constants are treated the same way. The configuration
constants cannot be changed.
X EXIST
Y EXIST
FREE
P EXIST
X +,-ROTAT ION
Y +/-ROTAT ION
FREE
P +,-ROTAT ION
YES
End editing procedure. If changes have been made, the changes will be
saved automatically.
The identification character is in the top line, indicating which constants are
being displayed. The symbols are carried over from the preceding menu.
The following eight lines list, in extracts, eight of the constants at a time.
The first number at the left is the number of the constants. In some cases, the
constants are displayed in a different order.
The colon is followed by the actually value stored in that parameter. The
meaning of the digits can be defined differently for each constant.
The remaining part of the line is the description of the parameter. The
description does not have any effect, it is only displayed for identification
purposes.
Use the F1 and F2 keys to page up and down through the list by one page (8
lines) at a time. Use the ENTER key to move down through the list one line at a
time.
VISION 500
The bottom line shows the type of values that are acceptable for each constant.
Text Character Set
O=NO / I=YES 0 and 1

Decimal entry from <n> to en>, with signs 0 to 9, +/-
Positive entry from <n> to <n> 0 to 9
Hexadecimal entry 0 to F
Binary entry 0 and 1
No entry
Every entry is checked to verify that it is within the correct scope. If necessary,
it is limited to the maximum value. No entry indicates that these constants
cannot be changed.
VISION 500
Setting Station Parameters Page 13
2.2 Station Parameters
Stations are adapted to their tasks by means of parameters. The station

parameters are stored on the system disk, and loaded into memory for each
station.
To initialize the stations, select the Service Screen by pressing <SHIFT-DATA

WINDOW>. From the Service Screen, select the Constants Editor, as shown
below.
Constant editor (page 14)
Speed measurement
b+d Create system floppy disk.

1 Format floppy disk
VISION 500
Page 14 Setting Station Parameters
Selecting Constant Editor
From the Constant Editor screen, select F6 for the Station Parameters.
Machine constants
Device constants
System constants
MIP constants
Additional constants
Station parameters (page 15)

VISION 500
Setting Station Parameters Page 15
Station Parameters
Highlight each station that is installed on the machine, then press F l to store
that station's parameters.
The control is designed to handle a maximum of six torch stations. The "stations"
13, 14 and 15 are actually not real stations, but may be used to store additional
process parameters.
w u u w u u uuu
E l 2 3 4 5 6 l3 1) l5
Send parameters to selected station (page 16)
Edit parameters of selected station (page 17)

VISION 500
Page 16 Setting Station Parameters
Sending Parameters To Selected Station
Parameters are only sent to a station if this station supports a process, i.e. the
first station constant (SYSTEM CONFIG LIFTSTATION) indicates whether or not
the station supports a process, and if yes, which process the corresponding
station supports. If the value is 0, the station does not support a process.
In case of successful sending (positive station response), a so-called derivation

for this station takes place. The station is added to the process screens. The
process that the station supports is activated so that it can be preselected and
launched.
If this function is executed for a station that does not support any process (first
station constant = 0,or no constant file is available for this station) only the
above mentioned derivation (no sending) will take place. If the station was
visible on the screen. it is made invisible. If the process that the station
supported, is not available on any other station, it is deactivated (the process
can no longer be preselected and launched).
VISION 500
Settina Station Parameters Page 17
Editing Parameters
The description of the constants regarding content starts on page 41.
SYSTEM-CONFIG LIFTSTAT
KU SENSOR 1 € 8-39)
KU SENSOR 2 < 8-93>
KU ARC-UOLTAGE € 8-99)
KU ANALOGSENSOR < 8-99>
MIN. STANDOFF SENS1
MIN. STANDOFF SENSZ
.MIN. STANDOFF ARC UOLT
End editing procedure
The bottom line shows the type of entry and the scope per constant.
Text Character Set

O=NO 1 1=YES 0 and 1
Decimal entry from <n> to <n> +, -, 0 to 9
Positive entry from <n> to <n> 0 to 9
Hexadecimal entry 0 to F
Binary entry 0 and 1
No entry
The constant that is to be edited in this window, can be selected with the joystick
and feed potentiometer.
Every entry is checked to find out whether the value is within the scope. If
necessary, it is limited to the maximum value.
When the changes have been adopted, the data is stored and then sent
automatically to the corresponding station.
VISION 500
Page 18 Speed Measurement And Rotational Speed Display
2.3 Speed Measurement and Rotational Speed Display
These two displays can be used to assist in adjusting the machine's drive
speeds. Proper adjustment of the drive speeds is very important for proper
operation of the position control system. These displays provide accurate
measurement and display of the drive speeds, with either fully automatic or fully
manual speed measurement.
To access the Speed Measurement or Rotational Speed Displays, begin at the

Service Screen by pressing <SHIFT-DATA WINDOW>. From the Service Screen,
press F2 as shown-below.
Constant editor
R
@
Speed measurement (page 19)
Create system floppy disk
Format floppy disk

VISION 500
Speed Measurement And Rotational Speed Display Page 19
Speed Measurement Display
The Speed Measurement Display appears, as shown below. This display allows
automatic measurement of the axis speeds.
Press F1 to automatically measure and display the speed setting of the X axis
Press F2 to automatically measure and display the speed setting of the Y axis.
CAUTION: The machine will move all by itself as soon as these buttons are
pressed. Take precautions to avoid injury. Make sure no one is touching or
working on the machine prior to accessing this display.
When these buttons are pressed, the machine will move approximately 2 inches
in the positive direction, then approximately 2 inches in the negative direction. It
will then stop and display the maximum drive speed for that axis. The test may
be repeated as necessary when adjusting the drive speeds.
mu +02602
m Measure speed of X-axis
Measure speed of Y-axis
1 1 Rotational Speed Display (page 20)
FI Press the backpage key to store the measured speed values in the
machine constants.
VISION 500
Page 20 Speed Measurement And Rotational Speed Display
Rotational Speed Display
The Rotational Speed Display allows for completely manual measurement of the
drive speeds. This display allows the operator to set a desired output voltage to
be sent directly to the drives. The control then displays the actual drive speed,
based on the encoder feedback. This test does not stop automatically, and must
be run with the drives disengaged.
To access this test, press F6 from the Speed Measurement Display. The screen
below will appear.
R
Select X-axis
Select Y-axis
Output square-wave-signal
Press F1 to test the X axis, press F2 to select the Y axis. The voltage that is
output to the drives is adjusted by the speed potentiometer. It is advisable to
start the test with the voltage set to zero, to avoid a hard start when the button
is pressed. The current speed is displayed on the screen, based on the actual
encoder feedback. The accuracy of this speed depends on the correct value
being entered in the machine constants for the axis encoder count. Voltage
output is stopped by deselecting an axis. A square wave output is provided for
drive optimization. The voltage level is variable. The frequency amounts to
approx. 1Hz. This feature should only be used by a technician.
VISION 500
Copying The System Floppy Page 21
2.4 Creating a Copy of the System Floppy
The service window provides a utility for making copies of the system disk, if the
secondary floppy disk drive was purchased.
Press <SHIFT-DATA WINDOW> to select the Service Window. From this window
press F5, as shown below, to select the disk copy utility.
FI Constant editor
1 ~ 1 Speed measurement
Create system floppy disk (page 22)
Format floppy disk

VISION 500
Page 22 Copy The System Floppy
Copying the System Floppy
Insert 1.44 MB floppy disk in drive 2. Press F1 to start the copying process.
ESAB
fTf
Start copying process
Do not start copying process
Since the floppy disk is formatted during the copying process, it is not possible
to cancel the process after it has been started. If the disk is removed from the
drive during copying, an error message will be displayed and the disk will not
contain usable data.
VISION 500
Copying The System Floppy Page 23
2.5 Formatting a Floppy
To access the formatting utility, press <SHIFT-DATA WINDOW> to access the

Service Window. Press F6 from the menu shown below to format a floppy disk.
Constant editor
Speed measurement
Create system floppy disk
Format floppy disk (page 24)

VISION 500
Page 24 Copy The System Floppy
Formatting a Floppy
Insert 1.44 MB floppy disk in drive 2, then press F? to start the formatting
process.
ESAB
7'7
11
Start formatting process
'%f
Do not start formatting process
Do not cancel formatting process. Do not remove disk from drive during
formatting process. Otherwise the disk cannot be used.
VISION 500
Diagnostic Features Page 25
3 Diagnostic Features
The diagnostic windows provide support for fault location in the case of service,
as well as a system status display. These modes should normally be operated
only by a service technician.
The following functions are available:
SHIFTIF1 Loop Error Display (page 26)

LCD contrast adjustment (page 27)
SHIFTIF2 MIP signal display (page 28)
SHIFTIF3 AF IKF control (page 30)
SHI FTlF4 Display synchronization error (page 31)
SHI FTlF5 Mini operating system (page 32)
SHI FTIFG Error Istatus display (page 34)

VISION 500
Page 26 Diagnostic Features
3.1 Loop Error Display
This display shows the current following error in encoder pulses, as well as the
maximum error per axis. The maximum value is stored until cleared by pressing
F4. This allows measurement of the maximum loop error that was reached over
a period of time.
RJli 88388
LOUP ERROR MAX UALUE
x 8000 1 Br3B43
*
\
i 08008 80c?83
F' 8c3088 88838
I 4 Delete display of maximum value
m Switch to LCD contrast setting (page 27)

VISION 500
LCD-Test Page 27
3.2 LCD Contrast Adjustment
The contrast of the LCD screen can be adjusted in the <SHIFT/FI> diagnostic
window. In addition, it is possible to test the screen operation.
Increase contrast
Reduce contrast
Test screen (FONT,BLACK,WHITE)
Return to deviation display (page 26)
CAUTION: It is possible to adjust contrast to the point that nothing is visible on

the screen. The setting remains even after the machine has been switched off.
Be sure not to adjust the contrast to the point that the screen is not visible.
VISION 500
Page 28 MIP Signal Display
3.3 MIP Signal Display
The MIP signal display is for checking the MIP behavior. Input and output can
be monitored and the signals that correspond with the control can be seen. It is
possible to force signals (value forcing).
Positioning the cursor is done with the joystick and the feed rate potentiometer.
The inverse key indicates which of the signal groups is displayed.
ASlOB output
ASlOB input
Static input and output
Force value 0 at cursor position
Cancel forced value
If the value for a signal is forced, this value is displayed inverse.

VISION 500
MIP Signal Display Page 29
More Key of the MIP Signal Display
MIP signal
MIP signal higher than 512
Cancel forced value

VISION 500
Page 30 AK-KF Display
3.4 AF-KF Display
Display of the last 16 Auxiliary Functions and Key Functions that were sent to
the MIP. The Key Functions (KF) are displayed on the left side of the screen.
The Auxiliary Functions (AF) are displayed on the right side of the screen. Error
messages of the ATHC are displayed in the far right column of the screen in
form of auxiliary functions to the MIP.
The arrow on the left side of a column indicates that the function is included in
the internal list. The arrow on the right side of the column indicates that the
function has been excluded from the internal list for the MIP.
If both arrows point away from the column, the MIP does not take anymore key
or auxiliary fun.ctions. .
F
1Send a key function to the MIP
Send an auxiliary function to the MIP
Return to previous window

Dl
VISION 500
Synchronization Error Page 31
3.5 Display of Synchronization Errors
This display should only be used by a service technician.
Percentage display (0-100) of ASlOB or panel synchronization errors

(interferences, etc..). Interferences with more than 30 percent are indicated by
an additional error message.
Next to the bar display, there is a display of the maximum value.
1m
Delete display of ASlOB maximum value
Delete display of panel maximum value

VISION 500
Page 32 Mini Operating System
3.6 Mini Operating System
Individual data areas of the control can be monitored and changed by means of
the mini operating system.
In this case, detailed knowledge of the RAM distribution is necessary. This

function is only for use by a service technician.
In two independent lines, memory addresses can be entered. The step size for
incrementing and decrementing is always entered in bytes.
If addresses outside of the data segment are to be displayed, then the address
of the data segment has to be entered in the column "MAP DS", and the segment
address of the memory in the first column of the display line. Addresses are to
be taken from the ANC41 .MAP file.
For a display within the data segment these two values have to be kept on
ZERO.
I HAP CIS: BOB8 STEP

I
Switch to word, long or byte display
Decrement address by step size
Increment address by step size
Set value
Switch to absolute addresses (hardware)

VISION 500
Mini Operating System Page 33
Certain memory addresses can be accessed directly via an index. For this, enter
"F000" in the first column (segment address). In the second column (offset)
enter the index of the desired memory address according to the following list.
The "MAP DS'value is not relevant for this display. Switching to absolute
addresses does not have any effect, either.
Description
Deviation in encoder units (32 bit)

X-axis
Y-axis
P-axis
Voltage of deviation share 7FFF = 10 volt (16 bit)

X-axis
Y-axis
P-axis
Voltage of speed pick-up Vmax axis (MC) = 8 volt (16 bit)

X-axis
Y-axis
P-axis
Total voltage output of deviation share and speed pick-up (16 bit)
X-axis
Y-axis
P-axis
Actual values in encoder units (32 bit)

X-axis
Y-axis
P-axis
Tool path feed rate in [mil] (32 bit)

X-axis
Y-axis
VISION 500
Page 34 Error - Status Display
4 Error - Status Display

The Error-Status Display is accessed at any time by pressing <SHIFT-F6>.
This screen displays any Errors that have occurred and, if possible, additional
information.
The name of the current or last processed program is indicated with PRG. BLC
indicates the current block number of the processed program.
I FtRG BLC 0000 I
Delete error
Switch to status display (page 35)
Switch to version number display (page 38)

VISION 500
Status Display
I I
F~ Port reset
El Time setting (page 37)
] screen when the 24 Volt power has been switched on. The voltage is
The 24 Volt power may be manually switched off with the key combination
shiftlstop. It is also switched off any time the machine's E-Stop string is
broken, or the machine power is turned off.
b has already been referenced.
Drive Enable X. Indicator for drive enable in the X-axis. If this

@ symbol is not displayed, the drive is not enabled. The machine cannot
VISION 500
Drive Enable Y. Indicator for drive enable in the Y-axis. If this

A,
'LC symbol is not displayed, the machine cannot be operated along the Y-
axis.

@ If this symbol is not displayed, no program codes or key functions will
be processed.

@ the machine interface.
r7 Feedhold. Motion is disabled. The machine cannot be operated.
Memory Reset. For clearing and resetting the battery backed up

memory.
{T
C
Time. For setting the time kept by the system clock.

F I active.
Auxiliary function. Highlighted symbol indicates that a process M-

WI code is being executed, such as torch ignition.
Feed rate reduction. Highlighted symbol indicates that feed

I/MIPI reduction is active.
Emergency stop. Highlighted symbol indicates that emergency stop

1[5TOPlJ is active.
X-axis Motion blocked. Highlighted symbol indicates that movement


ofY-axisis blocked.
VISION 500
Time Setting
Setting the time. The adjustment is done with the joystick and feed rate
potentiometer.
Adopt time
No adoption
VISION 500
Display of Version Number
SERIENNUMMER 0999
SYSTEM U2 .52C
ALFE UERS ION ----
M I P VERSION LTEC-2 U.14.03.95
Serial number: Control number

System: Version number of the basic system (ANC41.EXE)
ALFE Version: Version number of the optional tracing system
MIP version: Version number of the MIP program (MIP41.MIP)
8031 0 s : Operating system number of the sub system
(NOS8031.BIN)
8031 Boot: Version number of the boot loader of the sub system
(BOOT8031.HEX)
VISION 500
Constant Descriptions Page 39
5 Operating System Software

The operating system software of the VISION 500 is on a floppy disk with the
format 3.5", High Density, 1.44MB.
The system programs occupy approximately 400KB so that there is

approximately I M B available for processing the customer's part programs. The
customer's programs are written on the disk by the control. However, it is also
possible to write such programs on the system floppy disk under DOS (MS DOS
or others) with a compatible PC.
5.1 Files of the system floppy disk
The following is a listing of the files that reside on the operating system disk.
Name Ext Type Description
ATAS SYS B Boot loader for ANC

ANC41 EXE B System file VISION 500
BOOT8031 HEX B Boot loader for 8031
BOS8031 BIN B Subsystem 8031 (ABIMBO)
NOS8031 BIN B Subsystem 8031 (ATHC 2)
LCD GOM B System user interface
LCDMlP GOM B Process user interface
MIP41 MIP B Machine interface program
ALL SHP B Standard shape library
ANCDEF KON A/B Add-ons configuration

DEV KON A Device constants
SYS KON A System constants
MAS KON A Machine constants
MIP KON A MIP constants
MAKROS DEF A Macro key definitions
DEF TEC A Technology definitions
PARAM CUT A Technology data
STAT01 KON A Constants station 1

STAT13 KON A Constants central station 1
EIA ESSl DEF BIA EIA definition file

ALL- BUG A Character generator library
VISION 500
Page 40 Constant Descriptions
In the list above, Type B indicates a binary file and Type A an ASCll file. ASCll
files can be read with any ASCll text editor.
Constants are located on the system floppy only for those stations that are
actually installed on the machine. This is also true for add-ons that need a data
record.
The file ANCDEF.KON determines the expansion of the control with add-ons.
This file should not be altered. Doing so could disrupt the functioning of the
control.
The remaining files with the extension "KON", as well as the files MACROS.DEF,
DEF.TEC and PARAM.CUT contain constants and settings that are defined
during the installation of the machine. They cannot be altered during operation.
Exceptions are marked and, if necessary, they can be adapted by the user of the
machine.
VISION 500
5.2 System Constants (SYS.KON)
List of system constants
DECIMAL POINT SPEED

TYPE KERF CALCULATION
ENCODER SIMULATION
MIP SIMULATION
CIRCLE MODE
DECIMAL POINT NIY 011
MM OR INCH 011
EIA KEYS
PROCESS HANDLING
CUTTING PACKAGE RESET
STANDARD SHAPE IN EIA
BASETEXT
LUBRICATION [MI
PANELPOSITION
ESABILTEC LOGO (011)
DOWNLOAD CONFIGURATION
ERROR WAITING TIME
STEP AND REPEAT DIRECTION
CUSTOMER
BUS VERSION
EMERGENCY STOP
PANEL
ASlOB
WATCHDOG
NOlSC2685 (011)
NO1NTllNTOlINT5 (01112)
NOIDIOITEST (01112)
405 (011)
VISION 500
Description o f the system constants
1 Decimal point speed
In Europe speed is programmed and displayed in millimeter per minute. In USA

speed unit is inch per minute. For lower speed it is possible to set a decimal
point for the speed input. If this constant is "I", speed input gets a decimal point
and the smallest value is 1/10 inch per minute.
3 Type of kerf calculation
The procedure of the kerf calculation can be controlled with this constant. The
following input values can be entered in form of a sum in order to combine
characteristics.
Enables collision checking.
Small segments of arcs with a height smaller than 1/10 mm are interpreted as
a line. This measure prevents collision of the offset contours with the
programmed segment for small arcs.
Forces a linear movement from the last point with disabled kerf compensation
to the first point with enabled kerf compensation. A jump in form of a line with
half of the kerf value will not be generated.
Movement proceeds from the last kerf calculated point of a contour directly to
the following first point without kerf if kerf is not enabled. Here again, no line
with half of the kerf length from the corrected point to the same point
uncorrected will be generated.
Encoder simulation
For testing purposes, control functions can be simulated without encoders. The
target point of a contour is taken as actual point. Position control as well as
reference point movement are not relevant.
5 MIP simulation
In order to override certain actions of the existing MIP program enter the
following settings.
1 MIP is not able to cancel the feed release.
2 Error messages generated by MIP are not displayed.
In order to enable both settings, add the values.

VISION 500
6 Circle mode
The interpretation of circle center point coordinates for EIA programs is set with
this constant.
0 Standard interpretation. Circle center point coordinates are programmed

absolute or incremental to the starting point in dependence of the path
conditions.
1 Circle center points coordinates are always incremental to the starting point
independent of path conditions.
2 Missing circle center point coordinates are supplemented, assuming that the
arc is always within a quadrant.
7 Decimal point
Programming decimal points in EIA format.
0 No decimal point in EIA format is expected. Coordinate values are interpreted

according to machine constant 49 as IIlOmm, 11100mm or 111000 inch.
1 A decimal point in EIA format is expected. For a missing point, all values are
interpreted in millimeter or inch units.
8 MM or INCH
In certain texts, mm, mmlmin or in, inlmin is displayed. In the system, these
texts exist only once. The dimension is only entered alternatively. The constant
controls the insertion of the dimension.
0 mm or mmlmin text displays.
1 in or inlmin text displays.

VISION 500
9 ElA - Keys
In Europe normal programming format is ESSI. Therefore (+) - Key is more used
then (.) - Key. In EIA format (.) - Key is more used than the (+) - Key.
Input Keys
10 Process handling
Whenever the control is switched on, the process used last is activated and the
corresponding stations are selected.
0 At system start, activate stations and process automatically / switch on turn-

on voltage.
1 No process active after system start (American version)
11 Cutting package reset
To ignore the last loaded cutting package file (SDP) and the changed cutting
package values stored in battery RAM, set parameter to "1".
28 Representation of standard shapes in ESSIIEIA
Standard shapes are processed in ESSl format. Usually, they also generate
programs in ESSl format. If the add-on "EIA format" is installed, main programs
can also be evaluated in EIA format.
0 Program evaluation in ESSl format.
1 Program evaluation in EIA format.

VISION 500
Constant Descri~tions Page 45
29 Basetext
If there are many languages available on the numeric control, you choose one
by using this parameter.
30 Lubrication
If the machine is equipped with an automatic lubrication, the control adds up the
distances, which all axes are moving. If one axis reaches the limit, the MIP is
informed to do a automatic lubrication.
48 Panelposition
0 Panel is fixed on the left side of the machine.
1 Panel is fixed on the right side of the machine
The order of the stations on the screen is changed.
49 ESABIL-TEC LOGO
0 The used logo of the control is "ESAB".
1 The used logo of the control is "L-TEC".
Function is only active for customer "L-TEC".
50 Download configuration
0 Control is waiting for an answer of the station after sending statxx.Kon file.
1 Control not waiting for an answer of the station after sending statxx.kon file.
Parameter is hexadecimal (e.g. "000F"= stations one to four no answer

expected).
51 Error waiting time
When an error has been displayed and its elimination confirmed by the operator,
the system tries to eliminate the error. Whether an error can be deleted or not,
depends on the type of error and its generation, for example, on the reaction of
the hardware. In some cases, an error will be generated again immediately after
VISION 500
the system has tried to eliminate the error. Then, there will not be a further
message to the operator, but the error indicator will remain in the background.
The waiting time (in units of 16 ms) prevents the display of the same error within
this time period.
52 Step and Repeat direction
0 Repetitions are left next to each other
1 Repetitions are right next to each other.
54 Customer
0 ESAB-HANCOCK
1 L-TEC
55 BUS version
Information on the hardware connected to ASIOB.
0 ATHC-2 card (intelligent station) at the ASIOB.
1 ABIMBO connected to the ASIOB (American version).
57 Emergency stop simulation
For testing purposes, the emergency stop effect in the program system of the
control can be blocked with this constant. This constant does not have any
influence on the emergency stop behavior of the hardware.
58 Panel simulation
A missing or defective control panel does not allow further operation of the
control. All movements are prevented immediately (value zero). For testing
purposes, the control can also be operated by a regular PC keyboard. Error
messages and their effects on a missing control panel are suppressed with a "1"
in this constant.
59 ASIOB simulation
1 Error messages in hardware are ignored.

VISION 500
60 Watchdog Simulation
For testing purposes, dead man messages of the hardware are not taken into
account.
Setting for simulating the D l 0 card.
0 D l 0 card does not exist. All access to the D l 0 data area (battery RAM, dual
port) is prevented. All corresponding functions are replaced as far as possible
(the work of the 8031 processor CANNOT be taken on.).
1 D l 0 card exists.
2 At system start, the system checks whether a D l 0 exists or is set

correspondingly. This option requires that no other card/ RAM is located in
the address area D000:0000 to D000:FFFF.
This constant must be 1.

VISION 500
5.3 Machine constants (MAS.KON)
List of machine constants.
X EXISTENT I10
Y EXISTENT I10
P EXISTENT I10
X ENCODER ROTATION DIRECTION 011
Y ENCODER ROTATION DIRECTION 011
P ENCODER ROTATION DIRECTION 011
X LA [IISEC]
Y LA [IISEC]
P LA [IISEC]
X SPEEDl8V [MMIMIN]
Y SPEEDl8V [MMIMIN]
P SPEEDl8V [MMIMIN]
X PULSES11000 MM
Y PULSES11000 MM
P PULSES11000 MM
REFERENCE X [ I11OOOMM]
REFERENCE Y [ I11OOOMM]
HOME POSITION 1 X [MM]
HOME POSITION 1 Y [MM]
SOFT LlMlT 1 +X [MM]
SOFT LlMlT 1 -X [MM]
SOFT LlMlT 1 +Y [MM]
SOFT LlMlT 1 -Y [MM]
MAX SPEED [MMIMIN]
ACCELERATION TIME [MS]
MANUAL FAST MOTION [MMIMIN)
MANUAL FEED [MMIMIN]
TEACH TRACE KV [IISEC]
TEACH QUER KV [I110 SEC]
PORTAL DEVIATION [ I l l OMM]
VISION 500
SMOOTH FACTOR
MACHINE UNIT 0111213
SUPP CABLE ERROR 011
REFERENCE YIN 110
LOOP ;MODE
TI PPILATCH
THREE-PHASE CURRENT DRIVES
SPEED PUNCHMARKER [IPM]
SPEED POWDER MARKER [IPM]
SECOND ACCELERATION SPEED [IPM]
TOOL OFFSET 1 X[1/1OOOMM]
TOOL OFFSET 1 Y[1/1000MM]
TOOL OFFSET 2 X[111OOOMM]
TOOL OFFSET 2 Y[1/1000MM]
TOOL OFFSET 3 X[111000MM]
TOOL OFFSET 3 Y[111000MM]
TOOL OFFSET 4 Y[111OOOMM]
TOOL OFFSET 5 Y[111000MM]
SECOND ACCELERATION TlME
EMERGENCY DECCELERATION
X BACK LASH COMPENSATION [1/1000 mm]
Y BACK LASH COMPENSATION [111000 mm]
P BACK LASH COMPENSATION [111000 mm]
TlME ON EDGE
MINIMUM ANGLE STOP ON EDGE [DEGREE]
VISION 500
Description of the machine constants
12 Axis definitions
Enter whether X-axis and Y-axis exist. Usually both constants are 1.
4 Portal axis
Machines with a portal can be moved along the X-axis via two separate drives.
These drives, however, have to be synchronized. Such portal control is an
additional function to the VISION 500. When this function is installed, this
constant can be set to 1. The following axis constants have to be entered
separately (from the X-axis) also for the P-axis.
5,6,8 Rotation direction

After mounting and cabling, the encoders on the machine will not always produce
positive actual values with positive axis direction. This matter is checked during
the automatic speed measurement test and, if necessary, a 1 is entered
automatically during measurement in order to correct the rotation direction of the
encoder.
In case of a wrong entry in this constant, the position control cannot work. Loop
errors can also occur in case of axis standstill.
9,10,12 Amplifying factor (LA) of control loop
The value given in this constant defines the amplifying factor of the position
control loop as a ratio of speed and positional deviation. It is indicated in [llsec].
In case of portal axes, all amplification factors have to be the same. In order to
reduce feed path errors during acceleration, the amplifying factor for the X-axis
and Y-axis should be the same. Among others, the amplifying factor and the
maximum speed of an axis define the maximum deviation. Exceeding this value
leads to a deviation error.
For testing purposes, the position control can be disabled with a zero LA value.
VISION 500
13,14,16 Maximum axis speed
The maximum axis speed indicates the speed and, thus, indirectly the rotational
speed of the drive that the axis can reach with a presetting of 8V. These values
have to be precise and are, therefore, determined and entered by the automatic
startup of the axes. These speed values are the basis for a compensation of the
deviation mentioned above that, at least at constant speeds, should not occur.
A wrong adaption due to incorrect values can lead to instable moving behavior
and over-travelling when moving in the predefined position. This is why the
constants cannot be used for limiting the maximum axes speeds.
17,18,20 Encoder pulses
The constants indicate how many pulses are generated by the encoders on a
certain distance ( I m). In practical operation, these specifications will deviate
from theoretically calculated values if steering rack and gearing errors are
included in the specification of pulses.
The values of the portal axes do not have to be exactly the same.
When comparing actually generated pulses with the nominal values of the
encoder, please consider that the nominal values in the control have been
quadrupled.
21,22 Actual values at the reference point
The reference point cam on the machine and the encoder zero pulse define a
machine zero point that can be reproduced any time with the accuracy of one
measuring unit. This way machine coordinates are reproduced uniquely even
after the voltage has been switched off.
In most cases, it is desirable that the coordinate zero point of an axis is located
at the end of the traversing range of this axis and not at the point where the
reference cam happens to be mounted. This can be done by modification so that
the actual value at the reference point is not zero but a value that moves the
zero coordinate value to the end of the traversing path.
23,24 Home position 1
Any point within the traversing range of the machine can be declared home
position. Certain operating instructions (point movements) move the axes to the
defined home position. This point can also be reached in automatic mode without
the coordinate values being programmed. This point is of special importance
when more than one working range is in use (add-on).
VISION 500
25 - 28 Software Limits
In connection with the reference system an absolute coordinate system is

installed on the machine. This way it is possible to define "soft limits" that cannot
be exceeded in manual or automatic mode. Trying to exceed these limits leads to
a "Limit switch error".
41 Maximum speed
This constant is the reference value for several functions.
All manual and automatic movements are limited to the maximum speed. Higher
speed requirements are not admitted, not even by forcing via override.
The maximum speed is used as fast motion speed during automatic process
execution.
The maximum speed is used as reference value for the calculation of

acceleration based on the acceleration time (see acceleration time).
The maximum speed should not be set higher than the lowest of the axis speeds
since no control takes place during automatic processing.
42 Acceleration time
The period of time in which the machine should or can accelerate to maximum
speed (see constant 41) is entered here. Machine acceleration for all operating
situations is based on this value.
43 Manual fast motion
Maximum speed for manual control in fast motion.
44 Manual feed
Maximum speed for manual control without fast motion.
45,46 Teach trace KVITeach quer KV
Higher numbers cause a more precise contour. The teach quer KV should be 25
per cent of the teach trace KV. The final result depends on the KV of the
machine.
VISION 500
47 Portal deviation
The control of a portal with two separate drives is designed as add-on. Both
portal axes are controlled separately. However, the position of the two axes to
one another is constantly monitored and the deviation is compared with the value
preset in this machine constant. If the limit has been exceeded, a "deviation
error P" is displayed and both drives are deactivated via the controller release.
48 Smoothing factor
Acceleration of the individual axes is "smoothed" with the smoothing factor, i.e.
the starting and stopping procedure is.carried out softer. The smoothing factor
cannot be indefinitely big in order to avoid contour inaccuracies with circles.
Depending on machine and application, values between 1 and 3 are
recommended.
49 Machine unit
Independent of the measuring resolution of the individual axes that was defined
in the constants of the encoder pulses (17 - 20), programming of the axes and
coordinate display follow the rule that all values should be allocated fast and
securely by the programmer or user.
In Europe, constants are programmed and displayed in the metric system. In

cutting operation, the smallest unit for programming and displaying is 1/10 mm.
In this case, the value 1 is entered in the machine constant so that one digit
after the decimal point is displayed. At the same time, program coordinates with
missing decimal points (ESSI) are interpreted in units of 1/10 mm.
In special cases programming and display is done in units of 11100 mm. In this
case, the value 2 has to be entered.
In the USA, the machine unit 1/1000 inch is used. In this case, all specifications
refer to inches. The machine constant has to be set to 3 so that 1/1000 in is
displayed as the smallest unit.
51 Cable error suppression
It might be useful to relax monitoring of the encoder and cabling to the control
during startup. In this special case, a "1" can be entered in this constant so that
cable errors are suppressed. For safety reasons, however, a zero must be
entered here during regular operation.
VISION 500
52 Reference
This constant value set to 1 indicates that a reference point system has been
installed.
Small machines are sometimes not equipped with a reference point cam. In order
to deactivate controls of the controlling system in this case, a 0 (= no reference
point system) can be entered here. Nevertheless, soft limit monitoring can be
activated, if the reference point adoption is simulated by the operator at an
appropriate point of the table.
53 Loop behavior
This constant controls the behavior of the control loop.
0 The position control loop is enabled in automatic as well as in manual mode.

The control loops will only be disabled in case of errors or interrupted voltage
supply.
1 In manual mode, the position control loops are only enabled when a moving
command has been given.
The control loops are always enabled when using the hand wheel.
54 TippILatch (operation)
This constant controls the type of manual traversing.
0 Tipp operation. In manual mode, the drives are moved only as long as the
joystick is pushed. Start and stop are generated by the control according to
the position (initial or pushed) of the joystick.
An exception in tipp operation is the reference point movement when the

direction is preselected and the movement is triggered with start, as well as
the hand wheel control when only the axes are preselected.
1 Latch operation. Traversing directions are preselected with the joystick. The
movement is triggered with the start key.
55 Three-phase current drives
0 DC-Drives, no reference point movement after power failure.
1 AC-Drives, reference point movement after power failure.

VISION 500
60,61 Speed punchmarker /Speed powder marker
Different speeds for different processes.
62,78 Second Acceleration
A second ramp of acceleration can be defined by using MC 62 and MC 78. This

ramp can be used for fast motion and other motions.
68 - 77 Tool offsets
These constants define the mechanical distance of the individual tools to the
main cutting tool. Actually, the program does not need to know the position of
the individual tools to one another in order to generate a geometrically unified
work piece. These distances are calculated independently by the control when an
offset is required by the program..
155 Emergency brake
This constant defines the time, which passes until the machine stops, when the
emergency button is pressed.
156 X back lash compensation
The measured back lash of X - axis 1st compensated.
157 Y back lash compensation
The measured back lash of Y - axis 1st compensated.
159 P back lash compensation
The measured back lash of P - axis 1st compensated.

VISION 500
160 Time on edge
This constant defines the time, which passes during a stop at an edge.
161 Minimum angle stop on edge
Minimum angle between straight on line and the edge of material, which causes
a stop.
VISION 500
5.4 MIP Constants (MIP.KON)
List of MIP constants
DISTANCE BEFORE LlNE [1/1000 mm]

DISTANCE AFTER LlNE [1/1000 mm]
LOGICAL PROCESS NUMBER
IN-THE-FLY AF 1
IN-THE-FLY AF 2
IN-THE-FLY AF 3
IN-THE-FLY AF 4
IN-THE-FLY AF 5
IN-THE-FLY AF 6
IN-THE-FLY AF 7
IN-THE-FLY AF 8
AF ilN EXCHANGE FOR AF 7 AT TT
AF IN EXCHANGE FOR AF 8 AT TT
MIP OVERRIDE 1
MIP OVERRIDE 2
MlP OVERRIDE 3
INFORMATION FIELD 1
INFORMATION FIELD 2
INFORMATION FlELD 3
INFORMATION FlELD 4
INFORMATION FlELD 5
INFORMATION FlELD 6
INFORMATION FlELD 7
INFORMATION FlELD 8
INFORMATION FlELD 9
INFORMATION FlELD 10
lNFORMATION FlELD 14
VISION 500
INFORMATION FIELD 15
INFORMATION FIELD 16
MIP SETTING 1
MIP SETTING 2
MIP SETTING 3
MlP SETTING 4
MIP SETTING 5
MIP SETTING 6
MlP SETTING 7
MlP SETTING 8
MIP SETTING 9
MIP SETTING 10
MIP SETTING 11
MIP SETTING 12
MIP SETTlNG 13
MIP SETTING 14
MIP SETTING 15
MIP SETTING 16
VISION 500
Description of the MIP Constants
17,18 Distance beforelafter line
These constants define the distance, which is relevant for the calculation of an
edge.
22 Logical process number
The processes are given in this constant in hexadecimal form. The number of
possible processes is extended up to 16. On the VISION 500 the maximum
number of processes is limited to three. Each combination of three processes is
possible (1+2+5 e.g.).
23 - 30 Auxiliary functions without machine stop
Usually, auxiliary functions are let out when the machine has stopped. In some
cases this is not the desired procedure. Then certain auxiliary functions are let
out in-the-fly. These are, for example, instructions to the height control when the
active cutting process should not be interrupted by a machine standstill.
ESSl functions that are let out without machine stop, are entered in the machine
constants in random order.
31 - 32 AF in exchange for AF 7,8 at Teach Trace
If the Teach Trace mode is active, the auxiliary functions, which are given in
MC31 and MC32, override the auxiliary functions AF7 and AF8.
35,36,37 MIP override 1,2,3
If one of markers for speed reduction is passed by the program, the machine
speed is reduced to the percentage, which is given by the constant.
40 - 55 Information field
16 constants to pass data to the MIP. Each constant defines 16 signals in a

hexadecimal form. So a maximum number of 256 signals can be given to MIP.
The meaning of the signals will be fixed by MIP. It can be e.g. "which station has
which process" and so on.
VISION 500
57 - 72 MIP setting
The machine interface program MIP can be parameterized with these eight
constants so that alternative forms of behavior can be selected in dependence of
the machine constellation. The meaning of the individual constants is, thus,
defined by the installed MIP. Only 0 and 1 can be entered in the constants.
VISION 500
5.5 Device constants (DEV.KON)
List of constants for serial interfaces.

01 COMlDEVlCE
02 BAUD RATE
03 PARITY NIOIE 011I 2
04 DATA BITS
05 STARTISTOP BITS
06 HSK NOIXON-XOFF 011
07 TI MEOUT (SEC)
09 COM2 DEVICE
10 BAUD RATE
11 PARITY NIOIE 01112
12 DATA BITS
13 STARTISTOP BITS
15 TIMEOUT (SEC)
17 COM3 DEVICE
18 BAUD RATE
20 DATA BITS
21 STARTISTOP BITS
23 TIMEOUT (SEC)
24 RS232 IRS485 (011)
25 COM4 DEVICE
26 BAUD RATE
28 DATA BITS
29 STARTISTOP BITS
31 TIMEOUT (SEC)
33 UDUCOLUMBUS 011
34 ENDCHARACTER
35 NUMBEROFENDCHARACTERS
VISION 500
Description of the Device Constants
The VISION 500 supports a maximum of four serial interfaces. The interfaces
COM3 and COM4 are part of the basic equipment of the control. Interfaces
COMl and COM2 have to be added on to the hardware of the control.
1,9,17,25 Device
With these constants, an interface is allocated to the used driver in the system of
the VISION 500.
Data transfer from the paper tape reader
Serial data transfer without protocol. The connected device should support
transfer control with XON 1 XOFF. See below.
UDL (Up Down Load). UDL enables a secured data transfer between the
control and a computer. An appropriate UDL host program is necessary on
the computer. Data transfer to the host computer is controlled with UDL by
the control.
ASOD (ATAS Serial Online Debugger). ASOD is a tool integrated especially

for testing and startup purposes.
Terminal
12 Serial data transfer of part programs without protocol .
2,10,18,26 Baud rate
The transfer speed of a serial connection is defined by the baud rate. The baud
rate has to be set to the same value on both sides. All serial interfaces in the
control support the following baud rates:
300 baud
1200 baud
2400 baud
4800 baud
9600 baud
VISION 500
3,11,19,27 Parity
Individual characters can be protected by a parity bit during transmission. As for

the baud rate, both partners, control and data device, must have the same
setting. The following three settings are possible:
0 No parity supplement
1 Odd parity supplement
2 Even parity supplement
4,l2,20,28 Data bits
This constant defines the number of data bits for a character. Seven bits are
sufficient for program data since only the ASCII data record is being used and no
special characters or graphics are transmitted. The number of transferred bits
per character have to be identical between the control and the connected device
or computer. The control admits the following two values:
7 Seven data bits

8 Eight data bits
5,13,21,29 Number of stop bits
Each character in serial transfer is completed with a stop bit. For the control, the
two valid values are:
1 One stop bit

2 Two stop bits
In most cases, the choice of stop bits depends on the setting of the connected
device. Remember that the sum of data bits, parity bits and stop bits per
character may not exceed eleven.
VISION 500
6,14,22,30 Handshake
During transfer of a serial data flow, it might be necessary to give both partners
the time to process or store the received characters. In many cases, the time
necessary is longer than the transmission time of an individual character so that
transfer has to be interrupted for the processing mentioned above. The control
characters XON and XOFF are provided for this control.
Examples: During transfer, the control system informs the sending device by
sending the XOFF character that the data received before, has to be written from
a temporary storage in the internal memory (floppy disk) first. During this time
more than five following characters cannot be buffered. After completing the
storage procedure, the control sends XON. The connected device must,
therefore, interrupt the transfer in the time period between receiving XOFF and
XON.
0 No handshake possible
1 Handshake XON / XOFF available
If handshake is not available, tests must determine the maximum baud rate that
can be used for transfer without losing data. This baud rate may not be
exceeded. The DOS command COPY does not support the control with XON /
XOFF!
7,lS,23,3l Timeout
This constant defines the period of time, the system waits if a UDL connection
could not be established. It then sends an error message.
With serial transfer, this time is used in order to determine a transmission end.
(see also constants 33/34).
24 Interface switching (RS232lRS485)
Switching between electrical transmissions.
0 RS232 transmission
1 RS485 transmission
VlSlON 500
33 UDL Setting
In general, the UDL system in the VlSlON 500 is compatible with the preceding
version SERIES 2000. There is a difference in the representation and treatment
of the display of data records (files) that are available on the host computer.
Therefore, it is necessary to specify to which of the available UDL host systems
the VlSlON 500 will be connected.
0 UDL host system version 3 1 4

1 UDL host system in connection with the programming station Columbus
34,35 End character, number of end characters
The end of the serial data transfer with the driver 3 (XON / XOFF) cannot be
specified unambiguously.
- The data flow ends with CTRL Z, coding IAH. The control interprets this
character as data end and completely ends the transmission in the control.
- It is not possible to add the character CTRL Z as end of transmission in
existing data records. So the procedure used with punched tape has
established itself here, too: For identification of the data end, a certain
number of characters (ZERO or BLANK) is added to the end of the
information. The character itself is defined with constant 34 and the minimum
number of characters is defined with constant 35.
VISION 500
5.6 Station constants (STATxx.KON)
There are three types of distributors:
- ATHC 2 (page 66)

- AMAD (complete box with ASIOB-MB00) (page 77)
- ASIOMB3 (page 84).
The different use of the station constants, which depends on the installed
distributor card, is described below.
5.6.1 Station constants (STATxx.KON)IATHC 2
List of station constants
SYSTEM CONFIGURATION STATION

LA C- SENSOR 1 (0-99)
LA C-SENSOR 2 (0-99)
LA ARC VOLTAGE (0-99)
LA ANALOG SENSOR (0-99)
MIN. STANDOFF SENSOR 1 (0-99)
MIN. STANDOFF SENSOR 2 (0-99)
MIN. STANDOFF ARC VOLTAGE (0-99)
MIN. STANDOFF ANALOG SENSOR (0-99)
MANUAL SPEED BHC MODE O(0-99)
MANUAL SPEED BHC MODE l(0-99)
DWELL TIME
IHS-MODE 110
IHS-MODE 312
DELAY LIFT CYLINDER 1U=8MS
PATH /TIME WITH IHS
IHS SENSOR HEIGHT 0 (not used)
ANALOG OUTPUT (PRCA 1)
ADDITIONAL INPUT PORTS (PRCA 3)
VISION 500
l NPUT X713 AND X712

lNPUT X614 AND X812
PRC-A OUTPUT 0
PRC-A OUTPUT 1
PRC-A OUTPUT 2
PRC-A OUTPUT 3
PRC-A OUTPUT 4
PRC-A OUTPUT 5
PRC-A OUTPUT 6
PRC-A OUTPUT 7
PRC-B OUTPUT 0
PRC-B OUTPUT 1
PRC-B OUTPUT 2
PRC-B OUTPUT 3
PRC-B OUTPUT 4
PRC-B OUTPUT 5
PRC-B OUTPUT 6
PRC-B OUTPUT 7
VISION 500
Description of station constants
Parts of the constants parameterize the sensor control of the station. Which
sensor mode is active is defined by the ASIOB signal BIT0+61 and BIT0+62.
Sensor mode BIT0+62 BIT0+61
Depending on the sensor mode, only parts of the constants are relevant. In the
following, this is indicated with "sensor mode <n>".
01 System configuration
Allocation of the processes available on the station. The entry is binary. A

combination of different processes is possible.
Process I Plasma
Process 2 Oxy - Fuel
Process 3 Punch Marking
Process 4 not allocated
Process 5 Plasma marking
VISION 500
02 - 05 LA (Loop amplification)
The value entered in this constant defines the amplifying factor of the position
control loop as a ratio of speed and positional deviation. It is specified in [llsec].
Constants are selected in dependence of the sensor mode.
02 "C-Sensor 1" Sensor mode 0

04 "ARC voltage" (arc control) Sensor mode 2
05 "Analog sensor" (eg. drag foot X5) Sensor mode 3
06 - 09 Minimum standoff
Defines the minimum distance of the sensor to the surface. A measuring unit
cannot be given. Depending on the hardware of the station, a number value can
be interpreted as different distances. Constants are selected in dependence of
the sensor mode.

08 "ARC voltage" Sensor mode 2
09 "Analog sensor" Sensor mode 3
VISION 500
14 - 15 Manual speed BHC mode
The manual burner height control is executed at this speed. In dependence of

the ASlOB signal BIT0+59 one or the other of the two constants is activated.
14 "BHC mode 0nBIT0+59 = 0

15 "BHC mode InBIT0+59 = 1
16 Dwell time
Put in the duration, which the machine needs or should need to reach the
manual speed (Mc 14, 15). The acceleration is calculated by using the MC 16.
The real dwell time is the result of the formula below.
Hochlaufieit = -
n * 8mec
MC16
Put in MC14 or MC15 instead of "n".

VISION 500
17 - 18 IHS cycle
Definition of the IHS cycle for each sensor mode. Constant 17 contains the value
for sensor mode 0 and 1. Constant 18 contains the value for sensor mode 2 and
3.
Values for IHS cycle.
0 no function (no IHS)

1 IHS sensor digital with lifting cy
2 IHS sensor digital without lifting cylinder
3 not used
4 Analog sensor input with lifting cylinder
5 Analog sensor input without lifting cylinder
6 Tooltip with collision sensor
The entry "42" in constant 17 thus indicates:
- The IHS cycle "Analog sensor input with lifting cylinder" has been entered
for sensor mode 1 (described by the left digit of the number).
- The IHS cycle "IHS sensor digital without lifting cylinder'" has been
entered for sensor mode 0 (described by the right digit of the number).
19 Delay lifting cylinder
One unit amounts to eight milliseconds. This constant describes the period of
time from activating the lifting cylinder until it is completely lifted. This constant
is only effective for lifting cylinders without limit switches.
VISION 500
21 Pathltime with IHS
Calibration value for IHS standoff. The preset standoff for all stations is the
same in the parameter record of the process parameter. Depending on the
hardware of the station, the number value can be interpreted as different
distances Constant 21 serves as multiplier for the standoff, so that each station
has the same distance to the surface.
29 Analog output
PRCA 1 is not available
10/01010101110/01PRCA 1 is available
The input must be done in binary format.
The four analog outputs of the PRCA 1 have fixed channel-numbers:
Analog I Analog
1 output 1 channel
I I number
VISION 500
Constant Descri~tions Page 73
30 Additional input ports
The eight additional input ports of the PRCA 3 have to be separately enabled.
x x x x x x x x plug meaning
I I I I I I I I
I I I I I I I * - - X50 Pin 2 carriage collision
I I I I I I *---- X50 Pin 3 Lift cylinder down
I I I I I *------ X50 Pin 4 Drag foot down
I I I I *-------- X51 Pin 2 Pilot ARC on
I I I *---------- X51 Pin 3 Main ARC on
I I *------------ X52 Pin 2 Station change
I *-------------- X52 Pin 3 Burner collision
*---------------- X53 Pin 2 IHS-Sensor
31 - 32 Input
Four digital inputs of the ATHC2 basic card can be variably used with different
input signals. The additional allocation of the input number to each input is done
with constants 31 and 32 (hexadecimal format).
input No. Description

0 Reserved
1 MESS0 (BIT1+16 + station)
5 Reflection
6 Toolholder external off
7 Switch burner
8 Collision burner
9 Lifting cylinder limit switch
VISION 500
A Drag foot limit switch

B IHS sensor
C Stylus manual down
D Stylus manual up
E Pilot arc
F Main arc
The entry "E6" in constant 31 thus indicates:
- Message at input X713 (described by the left digit of the number) with the
signal "Pilot arc".
- Message at input X712 (described by the right digit of the number) with
signal "Toolholder external off'.
The entry "9B" in constant 32 thus indicates:
- Message at input X812 (describes by the left digit of the number) with
signal "Collision burner".
- Message at input X614 (describes by the right digit of the number) with
signal "IHS sensor"..
VISION 500
33 - 48 Process output card

Single-signal:
v=== single-signal number

single-signal
W process output
1matrix-signal
exceptions:
"zero"
"one"
VISION 500
lifting cylinder IHS

VISION 500
5.6.2 Station constants (STATxx.KON)/AMAD

LA OXY - FUEL STATION +O
LA OXY - FUEL STATION + I
LA OXY - FUEL STATION +2
LA OXY - FUEL STATION +3
LA PLASMA STATION +O
LA PLASMA STATION + I
LA PLASMA STATION +2
LA PLASMA STATION +3
PRC-B OUTPUT 0
PRC-B OUTPUT 1
PRC-B OUTPUT 2
PRC-B OUTPUT 3
PRC-B OUTPUT 4
PRC-B OUTPUT 5
PRC-B OUTPUT 6
PRC-B OUTPUT 7
PRC-C OUTPUT 0
PRC-C OUTPUT 1
PRC-C OUTPUT 2
PRC-C OUTPUT 3
PRC-C OUTPUT 4
PRC-C OUTPUT 5
PRC-C OUTPUT 6
PRC-C OUTPUT 7
PRC-A INPUT 1
PRC-A NPUT 2
PRC-A NPUT 3
PRC-A NPUT 4
PRC-A NPUT 5
PRC-A NPUT 6
VISION 500
55 PRC-A INPUT 7
56 PRC-A INPUT 8
57 SYSCON STATION +O
58 SYSCON STATION + I
59 SYSCON STATION +2
60 SYSCON STATION +3
Parts of the constants parameterize the sensor control of the station. Which
sensor mode is active is defined by the ASlOB signal BIT0+61 and BIT0+62.
Sensor mode BIT0+62 Description
0 C-Sensor 1
1 ARC Voltage
Depending on the sensor mode, only parts of the constants are relevant. In the
following, this is indicated with "sensor mode <n>".

X X X X
I I I I
I I I *-- Process 1 Plasma
I I *---- Process 2 Oxy - Fuel
I *------ Process 3 Punch Marking
* - - - - - - - - Process 4 not allocated
VISION 500
02 - 05 LA (Loop amplification) Oxy - Fuel

02 "Oxy - Fuel Station +ON Oxy - Fuel Station +O

03 "Oxy - Fuel Station + I " Oxy - Fuel Station 91
04 "Oxy - Fuel Station +2" Oxy - Fuel Station +2
05 "Oxy - Fuel Station +3" Oxy - Fuel Station +3
06 - 09 LA (Loop amplification) Plasma
06 "Plasma Station +OM Plasma Station +O

07 "Plasma Station +I" Plasma Station + I
08 "Plasma Station +2" Plasma Station +2
09 "Plasma Station +3" Plasma Station +3
VISION 500
Single-signal:
PJJJ=-
1
single-signal number
single-signal
w
I
I
aprocess
matrix-signal
process output
exceptions:
"zero"
"one"
VISION 500

VISION 500
Values for process output
input No. Description
1 plasma start
2 lift cylinder down
3 not used
4 center burner on (oxy - fuel process)
5 center burner, pre-heat gas (oxy - fuel process)
6 center burner, pre-heat 0, (oxy - fuel process)
7 ignite (oxy - fuel process)
8 punch on 1 off
9 not used
10 TANAKA heating on (punch process)
11 pre-heat gas on (punch process)
12 TANAKA whirl on (punch process)
13 TANAKA guidance (punch process)
14 TANAKA ignite (punch process)
49 - 56 Process input card
R'F= list below

station offset (+o to +3)
not used

VISION 500
lnput list
lnput No. Description

0-3 not used
4 exchangeable support
5 carriage collision
6 Pilot arc
7 Main arc
57 - 60 System-Constant
The four station are individually assigned to one available process. The available
process number are discribed above (constant 01).
57 "SYSCON Station +Ow Process of Station +O

58 "SYSCON Station +I"
Process of Station + I
59 "SYSCON Station +2" Process of Station +2
60 "SYSCON Station + 3 Process of Station +3

VISION 500
5.6.3 Station constants (STATxx.KON)/ASlOMB3

ADDITIONAL INPUT PORTS (PRCA 3)
PRC-A OUTPUT 0
PRC-A OUTPUT 1
PRC-A OUTPUT 2
PRC-A OUTPUT 3
PRC-A OUTPUT 4
PRC-A OUTPUT 5
PRC-A OUTPUT 6
PRC-A OUTPUT 7
PRC-B OUTPUT 0
PRC-B OUTPUT 1
PRC-B OUTPUT 2
PRC-B OUTPUT 3
PRC-B OUTPUT 4
PRC-B OUTPUT 5
PRC-B OUTPUT 6
PRC-B OUTPUT 7
PRCA-C1 ASSIGNMENT
PRCA-C2 ASSIGNMENT
PRCA-C3 ASSIGNMENT
PRCA-C4 ASSIGNMENT
PRCA-Dl ASSIGNMENT
PRCA-D2 ASSIGNMENT
PRCA-D3 ASSIGNMENT
PRCA-D4 ASSIGNMENT
PRCA-C1 ENABLE
PRCA-C2 ENABLE
PRCA-C3 ENABLE
PRCA-C4 ENABLE
PRCA-Dl ENABLE
VISION 500
62 PRCA-D2 ENABLE
63 PRCA-D3 ENABLE
64 PRCA-D4 ENABLE

X X X X X X X X
I I I I I I I I
I I I I I I I * - - Process I Plasma
I I I I I I *---- Process 2 Oxy - Fuel
I I I I I *------ Process 3 Punch Marking
I I I I *-------- Process 4 not allocated
Process 5 Plasma Marking
30 Additional input ports
The eight additional input ports of the PRCA 3 have to be separatly enabled. The
input must be done in binary format.
X X X X X X X X meaning
I I I I I I I I
I I I I I I I * - - X50 Pin 2 carriage collision
I I I I I I *---- not used
I I I I I *------ not used
I I I I *-------- X51 Pin 2 Pilot ARC on
1 I I *---------- not used
X52 Pin 2 Station change
not used
X53 Pin 2 .IHS-Sensor
Caution: The PRCA3 card have to be connected on the PRC-D slot.
VISION 500
Single-signal:
PJJJJJ-
/
single-signal
TwQJ- process output
/ matrix-signal
exceptions:
"zero"
"one"
VISION 500
5.7 Configuration file (ANCDEF.KON)
PORTAL AXIS
PLATE ALIGNMENT
NOT USED
STRAP BRIDGE
JOG STROKE
SECOND ACCELERATION
TEACH TRACE, TRACE
ADJUSTABLE PROGRAM ZERO POINT
PROGRAM ROTATION
EIA FORMAT
KEY - PAD MACROS
TAPEREADER
FLOPPY
XONIXOFF
UDL
NOT USED
RS 491
C-LI NK
PROGRAMMABLE PROCESS PARAMETER
PROGRAMMABLE CUTTING DATA
ADDITIONAL COM - PORTS
COMMISSION
CHECKSUM
VISION 500
49 - 56 Assignment of analog outputs
The four PRCA-C and four PRCA-D analog outputs are assigned to the ASIOB-
channels 0-63. The entry is binary.
57 - 64 Enable of the analog outputs
The four PRCA-C and four PRCA-D analog outputs, which have been assigned,
are enabled.
7lJJJ==
I
single-signal
matrix-signal

VISION 500
lndex Page 89
6 Index
24 Volt power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
AF-KF Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ASlOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ASOD
ATAS Serial Online Debugger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Auxiliary function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Configuration constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. 88
Constant descriptions
device constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
machine constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
MIP constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
station constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
system constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Constant types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Constants editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Contrast adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Device constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. 61. 66
Diagnostic Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Drive enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Drives
adjusting speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Editor
constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Enable
drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
system processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Error status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Feedhold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Floppy disk
copying the system disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
LCD contrast adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Limit switch error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Machine constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. 4%
Mini operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
MIP constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. 57
MIP signal display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Motion enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operating System Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2%
Pixeltest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Release
controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
VISION 500
Page 90 Index
Rotational speed display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ServiceWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Servo adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Signal display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Software
operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Software limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Speed measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Station constants
AMAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
ASIOMB3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
ATHC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Station Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Station setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Step and repeat setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Synchronization error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
System constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. 41
System floppy
making a copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
System processing enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
System software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Time setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Voltage. turning on 24 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Window
diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
error-status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
NOTES:
F 14 - 081 1/96 Printed in U.S.A.
February, 1996
VISION CNC
PART PROGRAMMING INSTRUCTIONS

@ ESAB Cutting Systems, 1996
This manual is ESAB Part Number F14082
This manual is intended for the convenience and use of the

cutting machine purchaser. It is not a contract or other
obligation on the part of ESA6.
Printed In U.S.A.
VISION PROGRAMMING
Preface
The Vision Computer Numerical Control System is a cutting machine CNC manufactured by
ATAS GmbH of Seligenstadt, Germany exclusively for ESAB Cutting Systems. The Vision
CNC may be used on various machines and may utilize numerous different cutting
processes. The Vision CNC is designed for ease of operation, flexibility, and precise control
of cutting processes.
Part programs for the Vision CNC may be manually entered, programmed off-line,
generated from a library of shapes, or digitized from traceable patterns.
This manual discusses creation of part programs for the Vision Computer Numerical Control
system, including the Vision 500, Vision 1000, Vision 2000, Vision 2000C, and Vision 3000.
For information regarding the operation of one of these specific controls, refer to the
appropriate Vision CNC manual.
There are numerous optional features which can be supported by the Vision CNC. For
completeness, all aspects of part programming have been covered in this manual. Not all
capabilities discussed in this manual will be present on all machines. In addition, more
capabilities and features may be added in the future, which are not covered in this manual.
ESAB Cutting Systems reserves the right to change or add programming features and
capabilities without notice.
VISION PROGRAMMING
Contents
1 General Information ........................................................................................... 1
1.1 File Format........................................................................................................ 1
1.2 Program Names.............................................................................................. 1
1.3 Program Format................................................................................................ 1
1.4 Units Of Measurement................................................................................... 1
1.5 Decimal Points .................................................................................................. 2
1.6 Programming Method ....................................................................................... 2
1.7 Axis Orientation............................................................................................... 3
1.8 Programming Limits...................................................... ..................................3
Standard EIA Codes ......................................................................................... 4
2.1 G-Codes ............................................................................................................ 4
2.2 M-Codes............................................................................................................ 6
2.3 . . Codes ............................................................................................... 10
Aux~l~ary
Programming Techniques ............................................................................... 1 1
3.1 Programming A Straight Line .................................................................... 1 1
3.2 Programming An Arc ...................................................................................... 12
3.3 Programming A Circle .................................................................................... 13
4 General Rules Of Programming...................................................................14
5 Programming Examples................................................................................... 16
5.1 Program Example 1 ........................................................................................ 16
5.2 Program Example 2 ........................................................................................18
5.3 Program Example 3 ........................................................................................ 20
6 Index ......................................................................................................................... 22
VISION PROGRAMMING
General Information - Page 1
1 General Information ?
1.I File Format

Part programs are simple text files written in ASCII format. Any IBM compatible Personal
Computer may be used with a simple text editor to create and edit part programs. Programs
may be stored on hard disk, copied to a floppy disk, or transmitted via serial cable.
1.2 Program Names

Part programs are named using the standard DOS file name format. This format allows file
names of up to 8 characters in length, with a file name extension of up to 3 characters. The
Vision CNC requires the file name extension ".MPGu to denote part programs. The 8
character file name may include both letters and numbers, but not symbols.
EXAMPLE FILE NAMES:
1.3 Program Format

Standard Vision programming format is EIA Format. EIA format (Electronic Industries
Association) provides programming conventions for contouring/positioning numerical
controlled machines which comply with the standard practices of the industry.
1.4 Units Of Measurement

The Vision control can accept programs written in either inch or metric. The standard mode
is inch. To use a program written with metric dimensions, the G71 code must appear at the
beginning of the program. The G71 is not supported in all versions.
VISION PROGRAMMING
Page 2 General Information
1.5 Decimal Points

Decimal points may be included with the part program, or they may be omitted. System
Constant #7 tells the control whether or not it should expect decimal points to be included in
the program.
Ser System Constant 7 accordingly:
0 = NO decimal points will appear in the program.
1 = decimal points are included in the program.
If System Constant 7 is set to 0, then Machine Constant #49 is used to tell the control how
many decimal places to assume. The standard setting is 3, which means that the far right
hand digit in any number will be assumed to mean 111000 inch.
If System Constant 7 is set to 1, then the control expects to see a decimal point in each
dimensional value. If no decimal point is included in a value, then the value is assumed to
be a whole number of inches.
- EXAMPLES:
System Constant 7 ='?,.and Machine Constant 49 = 3,
X I 4875 Y21031 will be read as X14.875 Y21.031
System Constant 7 = 0, and Machine Constant 49 = 2,
X14875 Y21031 will be read as Xl48.75 Y210.31
System Constant 7 = 1,
X12 5 Y2.50 will be read as X1.250 Y2.500

d. '
X125 Y250 will be read as X125.000 Y250.000
1.6 Programming Method

Part programs can be written in either absolute or incremental modes. The default mode is
absolute. To switch to incremental mode, a G91 code must be entered. Programs that are
written entirely in incremental mode should have a G91 at the very beginning of the
program.
VISION PROGRAMMING
General Information Page 3
1.7 Axis Orientation

The X and Y axes of the cutting machine are oriented as shown below. The X axis is the
longitudinal axis, down the length of the rails. The Y axis is the transverse axis, across the
beam of the machine. When facing the machine's control console, positive X is away from
the machine operator, negative X is toward the machine operator. Positive Y is to the left,
negative Y is to the right.
1.8 Programming Limits

The following limitations should be taken into account during programming.
The length of each program line is limited to 80 characters. A line with more than 80
characters will cause an error at run time.
The maximum radius length for arcs is 1.3 miles, or 1 x lo6 inches.
The tolerance for arc endpoints is 10 programming units. When using 3 decimal point
precision, this means 10 thousandths of an inch. If the distance from the start point to
the center point and the distance from the end point to the center point are different by
more than this amount, a Circle Error will occur.
VISION PROGRAMMING
Page 4 Standard EIA Codes
Standard EIA Codes ?
EIA format uses G-Codes (Geometry Codes) to program motion, and M-Codes
(Miscellaneous Codes) to program processes. This section describes the standard
programming codes supported by the Vision CNC.
G-Codes indicate movement or motion commands.
Motion Codes
The motion codes are used to define programmed motions of the machine. These codes
are modal; once they have been read, the control assumes the following lines to be the
same type of motion, until a different G-Code is encountered. When entering actual
program dimension values, the plus sign (+) is optional. The control will assume all values
to be positive unless a negative sign (-) is present.
GOO Rapid Motion. For programming linear movement at rapid speed. This is used for
traversing between parts. The machine will execute this movement at the maximum
feed rate for that machine. The control will stay in rapid mode until a different G-
Code is encountered. Required values: X, Y. See also: "R" on page 10.
FORMAT: GOO Xnnnn.nnn Y nnnn.nnn
GO1 Linear Motion. For programming linear cutting movements. Cancels rapid motion.
Required values: X, Y.
FORMAT: GO1 Xnnnn.nnn Y nnnn.nnn
GO2 -
Circular Motion Clockwise. For programming circles or arc motions in a
clockwise direction. Cancels rapid motion. Required values: XI Y, I,
J. Iand J
define the position of the center point.
FORMAT: GO2 Xnnnn.nnn Ynnnn.nnn 1nnnn.nnn Jnnnn.nnn
GO3 -
Circular Motion Counterclockwise. For programming circles or arc motions in a
J. I
counter-clockwise direction. Cancels rapid motion. Required values: X, Y, I,
and J define the position of the center point.
FORMAT: GO3 Xnnnn.nnn Ynnnn.nnn 1nnnn.nnn Jnnnn.nnn

VISION PROGRAMMING
Standard EIA Codes Page 5
2.1.2 Special Purpose G-Codes

Inch mode. lnforms the control that all programmed dimensions are in inches.
When used, this code must appear at the beginning of the program. This is the
default mode. If neither a G70 nor a G71 is programmed, the control will assume
inch mode.
Metric mode. lnforms the control that all programmed dimensions are in mm.
When used, this code should appear at the beginning of the program.
Absolute Programming. lnforms the control that all programmed dimensions are
absolute coordinates, referenced from an absolute zero point. When used, this code
must appear at the beginning of the program. This is the default mode. If neither a
G90 nor a G91 is programmed, the control will assume absolute mode.
Incremental Programming. lnforms the control that all programmed dimensions

are relative distances, referenced from the start of each block. When used, this code
must appear at the beginning of the program.
Absolute Zero Point. Defines the position of the absolute zero point for absolute
programming mode. The format of this code allows the user to define the zero point
anywhere in the coordinate system. If no X or Y value is included, then the control
assumes that the current machine position is the absolute zero point. Otherwise, the
value programmed for X and Y is taken as the distance that the machine is currently
offset from the absolute zero point. Those values are loaded into the control's
Program Coordinates register, and all absolute programming movements are
referenced to the new zero point.
FORMAT: G92 Xnnnn.nnn Ynnnn.nnn

VISION PROGRAMMING
Paae 6 Standard EIA Codes
MO PROGRAM STOP. This code may be used to stop program execution at a specific
point in the program, such as at the start of cutting operations. To continue program
execution, the operator must press PROGRAM START.
M21-M28 SHAPE ORIENTATION. These codes interchange or rotate the coordinate axis
in 90 degree intervals or mirror image positions. These codes can be useful for
orientation or nesting of parts.
M21 NORMAL MODE. This is the default mode. This code only needs to be .
programmed if returning to normal orientation after using M22 through M28.
M22 MIRROR X AXIS. (X=-X, Y=+Y)
M23 ROTATE 90" CCW FROM NORMAL. (X=+Y, Y=-X)
M24 MIRROR IMAGE OF M23 (X=-Y, Y=-X)
M25 ROTATE 90" CW FROM NORMAL. (X=-Y, Y=+X)
M26 MIRROR IMAGE OF M25 (X=+Y, Y=+X)
M27 ROTATE 180" FROM NORMAL (X=-X, Y=-Y)
M28 MIRROR IMAGE OF M27. (X=+X, Y=-Y)
M45 MARKER OFFSET # I ON. Moves the marker to the location previously occupied by
the torch. Automatic Height Control is initiated so the marker unit will lower to the
plate. Direction and amount of offset are determined by the Machine Constants.
Either this code or an M47 must precede any marking or scribing. After one of these
offset codes has been programmed, actual marking is done by programming an
-
M60, scribing is done with the M74 and M75.
.VISION PROGRAMMING
Standard EIA Codes Page 7
MARKER OFFSET #2 ON. Moves the marker to the location previously occupied by
the torch. Automatic Height Control is initiated so the marker unit will lower to the
plate. Direction and amount of offset are determined by the Machine Constants.
MARKER OFFSET #I OFF. Cancels the offset initiated by M45, turns off Automatic
Height Control and raises the marker unit. The marker offset off codes M46 and M48
should only be used after all marking and scribing in the program is completed.
MARKER OFFSET #2 OFF. Cancels the offset initiated by M47, turns off Automatic
Height Control and raises the marker unit.
M57 AUTOMATIC HEIGHT CONTROL BLOCK. This code freezes the Plasma AHC
until an M58 code is received.
M58 AUTO HEIGHT CONTROL RELEASE. This command re-enables Plasma AHC
after having been disabled by an M57.
M60 PUNCHIMARK. This code momentarily enersizes the marking unit to make a mark
on the plate. Marker Offset On must be programmed first to enable height control
and to properly offset the marker unit, either M45 or M47. All punching or marking
should be done prior to cutting the part, since parts may shift or drop away after
being cut, and the vibration from the marker can cause cut parts to move.
M65 PLASMA ON. This code causes the following sequence of events:
1. Automatic Height Control is initiated, torches find initial height.
2. The Plasma process is initiated.
3. When all arcs are established, the Travel Delay and Pierce Timers begin.
4. After the Travel Delay Timer ends travel is initiated.
5. During the Pierce Timer, the Master Up output is on.
M66 PLASMA OFF. This code stops all arcs and raises the brches for the amount of
time in the MASTER UP TIMER.
VISION PROGRAMMING
Page 8 Standard EIA Codes
M67 KERF LEFT. This code turns on kerf compensation offsetting to the left of the path.
To determine the desired direction of kerf offset, it is necessary to envision the cut
direction. Kerf Left will offset the cut path to the left, when facing the cut direction.
The programmer need only consider the kerf direction. The machine operator will
enter the kerf amount, which needs to be determined by measurement of the actual
cut width, and will change with every thickness of material and type of cutting. The
controller will automatically offset the cut path by 112 of the entered amount. This
puts the edge of the cut along the actual programmed path.
EXAMPLE: KERF LEFT

Actual tool
path
\ Cut direction
I ~ e r f ~ f f s e t~ r o ~ r a m d Path
ed
Kerf Width
M68 KERF RIGHT. This code turns on kerf compensation to the right of the programmed
path. See M67 abeve for other details.
EXAMPLE: KERF RIGHT

Kerf Width Kerf-Offset Programmed Path
I
/
Actual tool Cut direction
path
M69 KERF OFF. This code turns off the kerf compensation after being turned on by an
M67 or M68. It is not necessary to program M69 before changing from kerf offset on
one side to the other, however, this should not be done when the torch is lit.
VISION PROGRAMMING
Standard EIA Codes Paae 9
OXY FUEL CUTTING CYCLE START. This code causes the following sequence of
events to occur: I
1. The Automatic Height Control is initiated and selected torches lower to the plate.
The ignitors on all torches turn on.
2. The ignitors turn off automatically after five seconds of operation.
3. High preheat gases turn on and PREHEAT timer starts.
4. When the preheat timer has completed its timing, the cutting oxygen is turned
on, and the preheat gases are switched to "low preheat".
5. Machine travel is initiated.
If a Plasma station is selected, the M70 is the same as an M65.
CUTTING CYCLE STOP. This code shuts off all gases and causes the torches to
raise for the amount of time in the MASTER UP TIMER. The machine will be in
feedhold while the torches are being raised. If a Plasma station is selected, the M71
functions the same as an M66.
CUT STOP. This code shuts off the cutting oxygen, but leaves preheat oxygentfuel
gas on, and raises the torches for the amount of time in the MASTER UP TIMER.
This function is used primarily to end the cutting process between multiple oxy-fuel
cuts. If a plasma station is selected, the M73 functions the same as the M66.
..-
SCRIBE ON. This code energizes the marking unit in order to mark a scribed path.
The markers remain energized until an M75 is programmed. This code should be
followed immediately with a motion block.
The M74 should only be used after a marker offset code has been programmed,
either M45 or M47. The scribe on code begins marking, and assumes that the
marker has already been moved into the correct position and that the height control
has been turned on.
M75 SCRIBE OFF. This code de-energizes the marking units to end a scribed path.
After all marking or scribing has been finished, a marker offset off code should be
issued to turn off the marker offset and the marker height control, either M46 or M48.
VISION PROGRAMMING
Paae 10 Standard EIA Codes
2.3 Auxiliary Codes

- The Vision has added capabilities that allow for special functions. ~ h e s special
e capabilities
are not critical to the function of the CNC but allow for easier more convenient programming.
R RAPID FEED RATE. When placed at the end of a G01, G02, or GO3 motion code,
that line will be executed at Rapid speed. The 'R" is not modal, the speed will return
to normal after this line is executed.
FORMAT: GO1 Xnnnn.nnn Ynnnn-nnn R
Knnn KERF OFFSET. Programmed Kerf Offset allows for changes in Kerf settings within
the part program. A programmed kerf value overrides any kerf value entered by the
machine operator. "K" followed by the kerf value in thousandths of an inch will load
the kerf value into the control's kerf register.
EXAMPLE: K.250
Fnnn FEED RATE. Programmed Feedrate provides feedrate changes during automatic
program execution. 'F" followed by the feedrate in inches per minute will cause a
feedrate change upon execution of this block. Operator override of feedrate is still
functional.
EXAMPLE:
The following program cuts a 10 x 10 inch square with a 4 inch hole in the
center. The hole is cut at 75 inches per minute, the square is cut at 100
inches per minute.
G91 INCREMENTAL MODE

GOO X5.0 Y-6.5 RAPID MOVE TO 1ST PIERCE POINT
F75 SET FEED RATE AT 75 IPM
M65 CUTTING PROCESS ON
GO3 J-.25 LEAD IN
GO3 J2.0 CUT CIRCLE
GO3 J.25 LEAD OUT
M66 CUT PROCESS OFF
GOO X-5.5 Y6.5 RAPID MOVE TO 2ND PIERCE POINT
F100 SET FEED RATE AT 100 IPM
M65 CUT PROCESS ON
GO1 X10.5 CUT SQUARE
Y-10.0
X-10.0
Y 10.5
M66 CUT PROCESS OFF
VISION PROGRAMMING
ProgrammingTechniques Page 11
3 Programming Techniques
3.1 Programming A Straight Line

A straight line is programmed by specifying the endpoint of the line. Normally, a straight line
is programmed with a G01. However, if the movement is to be at rapid speed, then a GOO is
used.
3.1.1 Incremental
In incremental, the dimension specified is the displacement from the start point of the line. If
there is motion only in one axis, then other axis dimension need not be programmed.
EXAMPLE: GO1 X+10.0 Y-5.0
3.1.2 Absolute
In absolute, the dimension specified is the absolute coordinate of the endpoint. If a
dimension is omitted, it is assumed that the endpoint in that axis is a the same absolute
dimension as the start point.
EXAMPLE: GO1 X+14.0 Y-6.0

VISION PROGRAMMING
Page 12 Programming Techniques
3.2 Programming An Arc

An arc is programmed by specifying the endpoint and center point of th6 arc.
3.2.1 Incremental
In incremental, both the endpoint and center point dimensions are specified as the
displacement from the start point.
- EXAMPLE: GO2 X1O.O Y-10.0 I 0 J-10.0
3.2.2 Absolute
In absolute, both the endpoint and center point dimensions are specified as the absolute
coordinates of those points. If a dimension is omitted, then it is assumed that the absolute
position of that point is the same as the start point.
EXAMPLE: GO2 X14.0 Y-11.0 14.0 J-11.0

VISION PROGRAMMING
ProgrammingTechniques Page 13
3.3 Programmlng A Circle

A complete circle is programmed by specifying the center p ~ i nof
t the circle.
3.3.1 Incremental
In incremental, center point dimensions are specified as the displacement from the start
point. The endpoint need not be specified, since the displacement is zero.
EXAMPLE: GO2 17.0
3.3.2 Absolute
In absolute, the center point dimensions are specified as the absolute coordinates of that
point. The endpoint need not be specified, since the control will assume the X and Y
dimension to be unchanged from the current position.
EXAMPLE: GO2 I1 1.0

VISION PROGRAMMING
Page 14 General Rules Of Programming
4 General Rules Of Programming

Below are some general rules of programming as demonstrated in the example programs.
Cut direction should generally be clockwise on the outside perimeter of a part,

counter clockwise on any inner perimeter. This is due to the assumption that any
part program may be used for plasma cutting. When plasma cutting, the physics of
the arc result in a straighter part edge on the right side of the cut then on the left.
Therefore, the good part should always be kept to the right of the cut, the scrap to
the left. This also allows the use of Kerf Left (M67) for both the ID and OD.
Cut direction:
Clockwise on outer perimeter.
Counter-clockwise on inner perimeters.
Parts should generally have their index point in the lower right corner, with the pierce
point and lead-in point at the upper right corner. This is due to the general principle
that when oxy-fuel cutting, the last side of the part to be cut should be attached to the
largest part of the plate. Therefore, when cutting clockwise around the perimeter of a
square, the first cut would be down the right side, and the last cut would be from left
to right across the top. This assumes that the part is being cut near the end of the
plate closest to the operator.
PLATE
Cut order:
Last cut attached to the largest

part of the plate.
/PIERCE
0 INDEX
M-Codes may be on the same line as a programmed movement, but for clarity
should be placed on a separate line. If an M-Code is included on a line with a
programmed movement, the M-Code is always executed first.
VISION PROGRAMMING
General Rules Of Programming Page 15
Kerf On and Kerf Off M-Codes must always be done while the cutting process is
turned off. This means that you should program Kerf On before the process on code,
and program Kerf Off after the process off code. Failure to do so will cause the
machine to execute the kerf compensation movement while the process is on,
possibly damaging the part which is being cut.
An M71 code should only be used when you are sure that all cutting is finished. If a
part is going to be cut repeatedly, or used in a nest, the M73 code should be used
instead. Doing so will save time and gas by avoiding the unnecessary ignite cycle
for each pierce.
The Vision control interprets process M-Codes differently depending upon which
stations are tumed on. For example; on a machine with both plasma and oxy-fuel
process, if the plasma station is turned on, either an M65 or an M70 will start the
plasma pierce cycle. Because of this capability, the Vision control will only allow the
operator to turn on one type of station at a time.
If a program is going to be cut repeatedly, or in a nest, the return to index point may
be omitted. When nesting or doing repetitions on the Vision, the control will
automatically move the machine from the end point of one program to the start point
of the next program, regardless of where those points are located. Therefore,
eliminating the return to index point may save time in the cutting operation.
If machine motion needs to be stopped at a specific point during the program

execution, an MO may be programmed. This command halts machine motion.
Continuation of the program does not resume until the START button is pressed.
VISION PROGRAMMING .
Page 16 Programming Examples
5 Programming Examples
5.1 Program Example 1
?) - - -
3 CUT
PUNCH
MARK
.5 RAD. I I I I I
- 8.75 t I POINT
+Y (J)
VISION PROGRAMMING
Programming Examples Page 17
The following programs illustrate the use of common M-Codes and programming
techniques. Here is how it would be programmed:
1: G91 INCREMENTAL MODE

2: M47 PUNCH MARKER OFFSET ON
3: GOO X8.0 Y2.0 RAPlD MOVE TO 1ST PUNCH POlNT
4: M60 PUNCH MARK
5: X-5.25 Y2.0 RAPlD MOVE TO 2ND PUNCH POlNT
6: M60 PUNCH MARK
7: X-1.5 RAPlD MOVE TO 3RD PUNCH POlNT
8: M60 PUNCH MARK
9: Y1.O RAPID MOVE TO 4TH PUNCH POlNT
10: M60 PUNCH MARK
11: X1.5 RAPlD MOVE TO 5TH PUNCH POINT
12: M60 PUNCH MARK
13: X-.75 Y-2.0 RAPlD MOVE TO BEGINNING OF SCRIBE LlNE
14: M74 SCRIBE ON
15: Y4.0 SCRIBE LlNE
16: M75 SCRIBE OFF
17: X I .O Y-1.O RAPlD MOVE TO NEXT SCRIBE LlNE
18: M74 ., SCRIBE ON
19: X-2.0 SCRIBE LlNE
20: M75 SCRIBE OFF
21: M48 PUNCH MARKER OFFSET OFF
22: X5.75 Y-.75 RAPlD MOVE TO PIERCE POlNT
23: MO PROGRAM STOP AFTER PUNCH MARKING
24: F25 SET FEED RATE AT 25 INCH PER MINUTE
25: M67 KERF ON LEFT
26: M70 PIERCE CYCLE
27: GO1 Y-.75 LEAD IN
28: GO3 J-1.5 " CUT CIRCLE
29: GO1 Y.75 LEAD OUT
30: M73 CUTTING OXYGEN OFF, TORCHES STAY ON
31: M69 KERF OFF
32: GOO X5.0 Y-5.25 RAPlD MOVE TO NEXT PIERCE POlNT
33: M67 KERF ON LEFT
34: M70 PIERCE CYCLE START
35: GO1 X-8.75 LEAD IN
36: GO2 X-1.5 Y1.5 J+1.5 CUT DESIRED SHAPE
u
37: GO1 Y.75
H
38: GO2 X.50 Y.50 1+.50
n
39: GO1 X8.75
u
40: Y-9.75
41: M71 PROCESS OFF
42: M69 KERF OFF
43: GOO X-9.25 Y.50 RAPlD MOVE BACK TO INDEX POlNT
VISION PROGRAMMING

VISION PROGRAMMING
This program example, illustrates the difference between Incremental and Absolute
programming of the same shape.
Incremental Program Absolute Program

1: G91 1: G90
2: GOO X3.95 2: GOO X3.95
3: M67 3: M67
4: M70 4: M70
5: GO1 X-3.2 5: GO1 X.75
6: GO3 X-.75 Y.75 1+.75 6: GO3 X.75 YO 10 JO
7: GO1 Y1.O9 7: GO1 Y1.84
8: X50 Y.29 8: X50 Y2.13
9: GO3 X.37 Y.37 1+.5 J+.87 9: GO3 X.87 Y2.50 J3.0
10: GO1 X.29 Y.5 10: GO1 X I -16 Y3.0
11: X1.79 11: X2.95 Y3.0
12: X1.15 Y-1.15 12: GO1 X4.1 Y 1.85
13: GO2 Y-.7 1-.35 J-.35 13: GO2 X4.1 Y1.15 13.75 J1.5
14: GO1 X-1.65 Y-1.65 14: GO1 X2.45 Y-.5
15: GOO X-2.45 Y.5 15: M73
16: M73 16: M69
17: M69 17: GOO XO YO
VISION PROGRAMMING

The WES Test pattern (per WES 6601-1980) is used to check machine accuracy. This
program can be run while using a tracing pen mounted to one of the carriages in order to
trace the machine's movements on paper. The pattern produced is ideal for checking
machine squareness positioning accuracy, and repeatability.
VISION PROGRAMMING
Program:
VISION PROGRAMMING
Page 22 Index
Absolute ................................................................................................................................. 5
Absolute programming............................................................................................................ 2
AHC freeze............................................................................................................................. 7
Arcs ...................................................................................................................................... 12
Axis orientation ........................................................................................................................ 3
Circle Error ........................................................................................................................... 3
Circles .....................................................................................................................................13
Circular motion..........................................................................................................................4
Codes
format ................................................................................................................. ............ 1
Decimal point ....................................................................................................................... 2
Disk files
format ................................................................................................................................... 1
EIA format ............................................................................................................................. 1. 4
Endpoint tolerance ....................................................................................................................3
Feed rate programming ..................................................................................................... 10
File name extension............................................................................................................ 1
File names.....................;........................................................................................................ 1
Files
format .............................................................................................................................. 1
naming.............................................................................................................................. 1
G-Codes.................................................................................................................................... 4
Height Control freeze .......................................................................................................... 7
. Inch........................................................................................................................................ 1, 5
Incremental ............................................................................................................................... 5
Incremental programming......................................................................................................... 2
Index points............................................................................................................................. 15
Kerf
on and off codes ................................................................................................................... 8
programmed value .................................................................... '......................................10
e
when to program ............................................................................................................ 15

Length. program lines ...........................................................................................................3
Limitations ............................................................................................................................. 3
Line length............................................................................................................................... 3
Linear motion ............................................................................................................................ 4
Marker offsets ........................................................................................................................6
Maximum
endpoint tolerance................................................................................................................ 3
line length ........................................................................................................................ 3
radius.................................................................................................................................... 3
M-Codes............................................................................................................................ 6. 14
Metric ......................................................................... ........................................................ 1.5
Mirror image.............................................................................................................................6
Motion codes ............................................................................................................................. 4
Naming programs ..................................................................................................................... 1
Orientation codes ...................................................................................................................... 6
Orientation of axes .................................................................................................................. 3
Oxy-Fuel codes.................................................................................................................... 9
Oxy-Fuel process off ............................................................................................................15
VISION PROGRAMMING
Index Page 23
Plasma codes ........................................................................................................................ 7

Process OnIOff Codes ............................................................................................................ 15
Program stop .........................................................................................................................15
Programming
codes ................................................................................................................................1. 4
feed rate .......................................................................................................................10
format .............................................................................................................................1
Programming Limits.................................................................................................................. 3
Punch Mark ............................................................................................................................... 7
Punch Marker............................................................................................................................ 6
Rapid................................................................................................................................... 4. 10
Rotation.................................................................................................... ............................... 6
Scribe codes ............................................................................................................................ 9
Speed ....................................................................................................................................... 10
Straight line ......................................................................................................................... 4. 11
Tolerance. endpoint ..................................................................................................................3
Units ......................................................................................................................................... 1
WES test .................................................................................................................................20
-
F 14 082 2/!% Printed in U.S.A.
VISION PROGRAMMING
Fage 6 Standard EIA Codes
2.1.3 Programmed Station Selection and Spacing

A set of G codes has been assigned for programming this optional feature for the Vision
Control system. These codes are described with regard to function and operation.
G83 and G87.
These codes are used in selection of stations to be activated and the clamp mode of
selected stations. G83 selects a station or multiple stations in the group of stations
1-9, G87 selects stations 10 and above. Follow The G code with an "I" parameter
and the station number (s) to be selected.
EXAMPLE
G831357 selects station numbers 3, 5 and 7
Stations 10 and above are selected by using G87. In this group of stations, station
10 is 1, station 11 is 2, station 12 is 3, etc.
EXAMPLE
G87ll 35 selects station numbers 10, 12 and 14
By including a 'J" parameter in the data block the clamping mode of the selected
stations can be specified. A data block with a "J"parameter will only cause the
station to be clamped as specified, it does not select the station for cutting. The
clamp mode can be either of four (4) choices.
JO Free stations (undamped)
J1 Clamp station(s) to beam
J2 Clamp station(s) in "like" image
J3 Clamp station(s) in 'mirror" image
EXAMPLES
G83ll23d1l Clamp stations 1,2, 3 and 4 to the beam
Clamp stations 2, 5 and 7 in "mirror" image
Clamp stations 10 and 11 in "like" image mode

VISION PROGRAMMING
Standard EIA Codes Pane 7
G84 and G88.
These two G-Codes are used to de-select stations. G84 de-selects stations 1-9,
G88 de-selects station 10 and up. An "I" parameter can be included to specify which
stations to de-select.
EXAMPLE
G8412468 De-selects station numbers 2,4,6 and 8
G8812 De-selects station number 11
If no station(s) are specified "All" will be assumed.
Programming Sequence
Since a G83 or G87 with a "J"parameter does not activate a station, all clamping
must be done prior to selecting which stations will be used for the cutting process. If
station spacing is changed during a program, it resets the station selection. Thus,
after re-spacing the stations, the appropriate stations must be selected prior to
starting the cutting process. A sample program using station selection and spacing
would look like this:
1: M89 MASH, releases all clamps and Mashes stations
2: GIY+100.0 Separate the Master carriage by 100 inches.
3: G8312J2 Clamp station #2 in the "Like" mode.
4: GIY+45.0 Move the station to the cutting area.
5: G83112 Select stations 1 and 2 for cutting.
6: M67 Begin cutting process.
7: M65
To change the station spacing in the middle of a program, start by de selecting all
stations using the G84 and G87. Next, clamp the slave stations to the beam as
required by using the G83 with a "J"parameter. Then, while the slave stations are
clamped to the beam, move the master carriage to the desired position relative to the
slaves. The actual minimum separation of the cutting torches will be different on
each machine and will have to be determined by measurement. Once the torches
are at the correct separation, clamp the slave stations as required using the G83 with
a "J"parameter. Finally, select the stations to be used for cutting by using a G83
code.
F14-114
March, 1997
lNSTALLATION INSTRUCTIONS for
PPT
Parallel Program Transfer Software

ESAB Cutting Systems, 1997
This manual is ESAB Part Number F l 4 114
This manual is intended for the convenience and use of the cutting
machine purchaser. It is not a contract or other obligation on the part of
ESAB.
Printed In U.S.A.
Contents
Contents
1 Introduction.......................
...
......................................................................................... 1
2 Setting Up the PPT Connection.................... . ................................................................. 2

2.1 Setting Up on the SERIES 2000................................................................................ 2
2.2 Connecting Cable for SERIES 2000 .IBM PC/XT/AT.............................................. 3
2.3 Setting Up on the VISION 1000, VISION 2000, VISION 2000C................................ 3
2.4 Connecting Cable For VISION 1000/2000/2000 C .IBM PC/XT/AT.........................4
2.5 Setting Up on the IBM-PCKVAT ............................................................................. 5
2.5.1 Changing the Configuration Parameters on the IBM-PC/XT/AT...................... 6
2.5.2 Starting Data Transfer on the IBM-PC/XT/AT .............................................. 8
2.5.3 Operation and Error Messages from the PC Side ............................................ 9
2.6 Operation of UDL and PPT on a Single RS-232 Port of the SERIES 2000............... 9
2.7 Setting Up VAX under VMS....................................................................................... 10
2.7.1 System-specific Information for PPT ........................... . . ............................. 10
2.7.2 Installation on the VAX .................................................................................. 11
2.7.3 Starting Data Transfer on the VAX ..................... . . . ................................... 12
3 Transfer Process ................................................................................................................. 13

3.1 Synchronization......................................................................................................... 13
3.2 Program Transfer from the HOST to the SERIES 2000NISION............................... 13
3.3 Errors......................................................................................................................... 13
4 Transfer Protocol ...................................... .......................................................................... 15

4.1 Protocol Handling .................................... .................................................................. 15
4.2 General Protocol Characters..................................................................................... 15
4.3 Data Transfer............................................................................................................. 16
4.4 Sample Protocols ...................................................................................................... 18
4.4.1 Synchronization of Host and SERIES 2000NISION by the Host ..................... 18
4.4.2 Transmission to the SERIES 2000NISlON..................................................... 18
4.4.3 Protocol Following Readiness Query............... . . ......................................... 18
lntroduction
Parallel Program Transfer (PPT) Page 1
1 Introduction
b
The computer connection 'Parallel Program Transfer,' referred to henceforth as PPT, is a
connection between the SERIES 2000NISION and a HOST computer.
One of the primary features of this connection is the possibility of transferring programs from
the host to the data memory of the SERIES 2000NISION at any time, without being
concerned about the operating state of the SERIES 2000NISION. No intervention is needed
by the operator with respect to the transfer.
PPT makes error-protected transmission of part programs from the host-computer to the
SERIES 2000NISION possible. The connection is controlled from the HOST side, making the
SERIES 2000NISION the passive partner. All activities are initiated by the HOST, and run in
the background, parallel to the events on the SERIES 2000NISION.
The host computer has to either be running under a multi-user operating system (such as
VAX-VMS, PDP-RSX), or else it must be available exclusively for the task of computer
connection (such as an IBM-PC under MS-DOS).
There must be a program installed on the host computer which carries on the communication
with the SERIES ZOOONISION in the specified form.
Such programs are made available by the manufacturer of the SERIES 2000NISION in
source form for various computers, so that installation by the user is possible.
b For the hardware connection, a serial port (RS232) is expected on the host, from which a
device such as a terminal can be operated.
Correspondence programs are available at the present time for the following systems:
I
IBM-PC/XT/AT under MS-DOS (in PASCAL)

VAX under VMS (in FORTRAN)
HOST computers under UNIXIAIX (in C)
Additional correspondence programs are in preparation.
Inquiries are welcome!
This paper includes more information than you need for the installation.
I For the installation, refer to Chapter 2.
Chapter 3 describes the sequence of transmission between the host computer and the
SERIES 2000NISION, and goes briefly into errors which may arise.
Chapter 4 describes the actual transfer protocol.

Setting Up the PPT Connection
Page 2 Parallel Program Transfer (PPT)

PPT communication is normally handled via a RS-232 connection.
A connection of the SERIES 2000NISION with the host computer through the current-loop
interface of the SERIES 2000NISION is also conceivable. The prerequisites for this should be
checked with the manufacturer.
Setting Up on the SERIES 2000
The two RS-232 ports have the following machine constants assigned to them:
MC098 - 105 Port 2 (X29)

MC106 - 113 Port 3 (X28)
Basic Settings Of the Port
The machine constants are normally set as follows,
Device identification 8
Baud rate 9600
Data bits 8 (no other input permitted)
Stop bits 1 (no other input permitted)
Parity 0 (no other input permitted)
XOWOFF 1
Abort type 011
Abort condition 0
The setting of the abort condition is of no significance here.
If the entry for abortion type is a 1, this indicates the joint operation of PPT and UDL
(Upload/Download) at a single RS-232 port (see section 2.6).
If there should be problems with data transfer, because of the length of the wiring for example,
the settings for the port - especially the baud rate - can be changed. It must be kept in mind
that any change in the interface parameters needs to be made on both sides of the
connection.
2.2 -
Connecting Cable for SERIES 2000 IBM PC/XT/AT
b The PC connector is connected to one of the RS-232 ports (X28/X29).
The pin assignments are as follows:
SERIES 2000 (RS-232) IBM PC/XT/AT25 pin

6 pin BLAG socket 25 pin Dconnection
PIN PIN
1 Rx 2 Tx
5 CTS
3 RTs
CTS 1 6 DSR
20 DTR
4 GND 7 GND
2 SHIELD 1
SERIES 2000 (RS-232) IBM PC/XT/AT 9 pin

6 pin BLAG socket 9 pin connector
PIN PIN
2 Rx
3 Tx
8 CTS
CTS 6 DSR
4 DTR
GND 5 GND
SHIELD 1
Setting Up on the VlSlON 1000, VlSlON 2000, VlSlON 2000C
The setup on the VlSlON 1000NISION 2000NISION 2000C is similar to the setup on the
VlSlON 2000C. Please refer to the operating instructions for the specific SERIES 2000 or
VlSlON CNC for additional information.
2.4 Connecting Cable For VISION 1000/2000/2000 C - IBM PC/XT/AT

The PC connector is connected to one of the RS-232 ports.
The pin assignments for the RS-232 port (X27/X28) are as follows:
VISION 1000/2000/2MXK= (RS-232) IBM PClXTlAT 25 pin
6 pin BLA6 socket 25 pin Pconnection
PIN PIN
1 Rx 2 Tx
3 RTs
CTS I 5
6
CTS
DSR
20 DTR
4 GND 7 GND
2 SHIEU) 1
VISION 100012000/2000C (RS-232) IBM PC/XT/AT 9 pin

6 pin BlA6 socket 9 pin connector
PIN PIN
1 Rx 3 Tx
8 CTS
*sDSR I
3
4
CTS
GND
E 6
4
5
DTR
GND
2 SHIELD 1
The pin assignments for the additional RS-232 ports are as follows:
VISION 100012000/2OOOC (RS-232) IBM PC/XTlAT 25 pin
25 pin Dconnector 25 pin Dconnection
PIN PIN
3 Rx 2 Tx
5 CIS
6 DSR
20 DTR 20 Dm
7 GND 7 GND
VISION 1000/2000/2000C(RS-232) IBM PCIXTIAT 9 pin

25 pin Dconnector 9 pin connector
PIN PIN
2 Tx 2 Rx
3 Rx 3 Tx
8 CTS
6 DSR
DTR 4 DTR
7 GND 5 GND
Parallel Program Transfer (PPT)
-- - -
Page 5
2.5 Setting Up on the IBM-PCIXWAT
For the PPT connection between the SERIES 2000 or VISION and an IBM-compatible
computer, ESAB supplies a diskette with the communication program.
This diskette contains the source files for the communication program, as well as a version of
the executable program (PPT.EXE).
To install the software, place the distribution diskette in one of your computer's disk drives.
Now follow the installation steps as indicated.
- Change to the drive in which you placed the diskette.

For example: A:cENTER>
- Enter the following command line at the keyboard
For example: INSTALL A: C:\PPT d
The parameters have the following meanings:
A: - Identification letter of the drive into which you placed

the diskette.
C:lPPT - Directory in which you wish to install the software.
d - Language preference; the options are:

d - for German, e - for English
Change the parameters in accordance with the existing

configuration of your computer. Note that a blank space was entered between
the individual parameters.
Now confirm the command with the return key.
All of the files on the distribution diskette are now copied into the directory
which you specified.
- Now change to the installation directory and enter the following command at
the keyboard.
For example: PPT/I=2,9600
Identifier to set the port parameters.
The serial port of the computer which will be used.
Separator character.
The transfer rate (baud rate) to be used
Confirm the input line with the <ENTER> key.

The port parameters are saved in the configuration file (CONFIG-PPT).
- The communication program is now completely installed and configured.
2.5.1 Changing the Configuration Parameters on the IBM-PC/XT/AT
The correspondence program initializes the serial port with the following setting:
COM1 , port COMl (from CONFIG-PPT)

9600 ,transfer rate (baud rate) (from CONFIG.PPT)
8 ,number of data bits (cannot be changed)
1 number of stop bits (cannot be changed)
N , parity (cannot be changed)
The initialization of the port is always performed using the current parameters from the
configuration file.
By means of the command line
PPT /I=c,baud
/I= - Identifierfor setting the port parameters.
c - The serial port of the computer. Possible values: 1 for COMI,2

for COM2.
I
- Separator character.
baud - The transfer rate (baud rate) to be used

Possible values: 3OO,6OO,l2OO,24OO,48OO and 9600 baud
Confirm the input line with the <ENTER> key. The port parameters are saved in the
configuration file (CONFIG-PPT).
Following the command:
PPT //=2,,4800cENTER>
PPT uses the COM2 port at 4800 baud.
In addition to the port parameters, the following parameters can be set on the PC by the user:
TIMEOUT : Monitors the data transfer time between SERIES 2000NISION

and PC. The TIMEOUT value is saved in the configuration file
and can be set with the command line
PPT /T=timeout.
timeout in seconds
NAK Number of data repetitions. When a transmission error has

been recognized, the other device is asked to send the packet
again. An internal counter is incremented, which stores the
number of repetitions. If this counter exceeds the defined
repetition rate, the connection is aborted.
The repetition rate is set by the command line
PPT Akcount .
count number of repetitions.
2.5.2 Starting Data Transfer on the IBM-PC/XT/AT
The correspondence program is started by entering
The program now waits for the name of a part program:
Filename:
The user enters the program name at the keyboard of the PC, and confirms the input with the
<ENTER> key. The correspondence program now establishes the connection with the
SERIES 2000NISION, and transfers the program data. The current operations are indicated
by operating and error messages displayed on the screen. After the transmission is
completed, the correspondence program ends.
The user can also pass the program name to the program in the input line (see examples).
I Examples for transferring:
PPT<ENTER>
Filename: 12345678 MPG
or
PPT 12345678.MfeENTER>
The program can be interrupted during the transfer with the key combination
<CTRb+cESC> (Press the <CTRL> key and the <ESC> key at the same time).
Operation and Error Messages from the PC Side
Operation messages: 01! Data ~ o dtost

t !
02 ! SERIES 2000 does not answer !
03 ! SERIES 2000 does not understand !
04 Transfer active
05 Transfer complete
06 ! 5meout !
07 Bytes transferred
08 Press Ctd+Esc to aboct the program
Error messages: 01 Program not present

02 Program already present
03 Internal memory enor
04 lntemal address book error
05 Memory is full
06 lntemal error 1
07 lntemal error 2
08 lntemal enor 3
09Intemalenor4
OA Format enor in geometry
08 Internal error 5
OC lntemal error 6
OD Internal enor 7
OE Format e m in auxiliary function
OF lntemalerror 8
10 Programaccess denied
11 unknrmncommand
12 Format error in program number
13 File read enw
Operation of UDL and PPT on a Single RS-232 Port of the SERIES 2000
A SERIES 2000 which is connected to a host computer by an RS-232 line can be operated in
both PPT and UDL (Up-Down-Load) modes.
For such operation the following conditions must be satisfied and the following settings made:
- the PPT port must be a RS-232 port (X28 or X29).
- the host computer must be connected to the PPT port.
- a "1" must be entered as the abort type in the machine constants of the PPT
port (MC96 and MC112).
- the UDL port is defined in the machine constants for one of the two remaining
free ports of the SERIES 2000. That can be either a RS-232 or a current-loop
port.
- the parameters for the PPT port and the UDL port must be identical with
respect to baud rate, data bit, stop bits and parity.
During data transfer from the host computer to the SERIES 2000 (PPT operation) the SERIES
2000 is blocked for UDL operation. In this case the error message "Data device not ready"
appears on the screen of the SERIES 2000.
2.7 Setting Up VAX under VMS
The source files for the host computer are furnished on a magnetic tape. A translation run and
installation is necessary as described below.
2.7.1 System-specific Information for PPT
To transfer a program from the host computer to the SERIES 2000NISION the following
information is needed:
- Directory for the files needed at run time
- Program name of the program to be transferred
- Name of the terminal channel to which the SERIES ZOOONISION is connected
In order to make this information accessible to the PPT, the logical names available under
VMS are used. Four logical names are defined:
PPTATA defines the path to the directory where the files which are needed at run
time are located. This path must contain at least one directory name
Additional information about logical or physical names of disks, etc., is
optional. The pathname must be set up in accordance with the VAX
configuration.
Example: SYS$SYSDRlVE:[PPT.SOURCE]
PmFlLE contains the program name of the program which is to be transferred.

Additional pathnames are noted.
Example: UMAO:[USERI]TRANSFIL.UCT
NCEDEV defines the logical or physical name of the terminal channel on the VAX
to which the SERIES 2000NISION is connected.
Example: TXB3:
PPTTEST defines the test option. If this logical name has the value "TEST", the
correspondence between VAX and SERIES 2000NISION is output in
addition on the terminal.
Two command procedures are needed to define this logical name:
defines PPTATA and NCEDEV. PPTINI.COFJI must be carried

out before the first PPT run.
defines PPTFILE and PPITEST. PPTCOM calls the

executable program PPTSYS.EXE, using the pathname defined
in PPTATA.
2.7.2 Installation on the VAX
2.7.2.1 Creating the Executable Program PPTSYS.EXE
All of the files from the magnetic tape must be copied into one directory. The FORTRAN77
compiler must be accessible from this directory with the command "FOR file". The supplied
magnetic tape must contain the following files:
PPTSYS.FOR PPTSUBS.FOR
PPTSUBIO.FOR PPTCOMSNC
DIATUCT.PPT PPTINS.COM
PPTCOM
After the source files have been copied successfully, the installation is started with the
command @PPTINS.COM. The following files are created:
PPTPAR-INC Parameter file for the name convention of the SERIES

2000NISlON
ALTKON=TRUE Numerical program names
ALTKON=FALSE Alphanumeric program names
PPTSYSEXE Executable program
PPTINI.COM Command procedure. Contains the logical name definition as

specified.
2.7.2.2 Preparation for Muttiple-user Access
Following the successful completion of PPTINS (the installation procedure), all of the files
needed at run time are available. In order to have access to PPT via the logical name
PPTATA, all of the files needed at run time must now be copied into the directory pointed to
by PPTATA. (PPTATA was defined during installation PPTINS by the "pathname" input).
The files needed at run time are:
PPTSYS.EXE DIATUCT.PPT PPXCOM
In order to make PPTATA available to all users, the command procedure PPTINI.COM must
be called at each login. This can also take place directly in the login procedure.
If only one SERIES 2000NlSION is to be supplied with programs via the PPT, every user
uses the same terminal channel, which is defined with NCEDEV. For this reason PPTINI.COM
should be copied into the directory with the files needed at run time, and be called from the
login procedure with the appropriate path designation.
When several SERIES 2000NISION machines are to be supplied, each user can only supply
one machine. In this case PPTINI.COM must be copied directly into each user directory.
PPTINI.COM must then be edited for each user's machine. Here the terminal channel defined
through NCEDEV must be modified.
2.7.3 Starting Data Transfer on the VAX
PPT is started with the command:
PPT path:file-ext
Example: PPT PARTOI.MPG
PPT DISK:[USER]PART02.MPG
For diagnostic purposes, "TEST" can be specified as a second parameter. In this case the
entire correspondence between the VAX and the SERIES 2000NlSION is output on the
terminal channel.
Example: PPT P1234.MPG TEST
Information about name conventions and cable connections may be found in the PC-
installation manual.
Transfer Process
3 Transfer Process
3-1 Synchronization
I
When the SERIES 2000NISION is switched on, the driver interface to the host computer is
also activated and released in the course of system initialization. From this point on the
SERIES 2000NISION is ready to be controlled by the host.
To open the message interchange the host sends a tilde (-) to the SERIES 2000NISION. If
this is acknowledged in the affirmative with ACK (>), the transfer of data can begin.
3.2 Program Transfer from the HOST t o the SERIES 2000NISION
Process:
The host initiates program transfer by sending the identifier for this type of order and the
program number of the program part to be transferred. The SERIES 2000NISION thereupon
opens this program in its program memory.
If a program of the same name is already present in the control system, it is automatically
deleted (without notewingthe operator of the SERIES 2000NISION), if this program is not
called to execute at this time.
The SERIES 2000NISION acknowledges the open order with a message whose content is
dependent on the success or outcome of the opening procedure. The host then sends blocks
of data, which the SERIES 2000NISION stores in its program memory.
At the conclusion the host sends an end identifier. The SERIES 2000NISION closes the
transferred program.
I 3.3 Errors
Only the host can react to errors, because it is the active partner in the connection. The
normal reaction to an error state is to abort transfer or attempt to repeat it.
Depending on the nature of the error, however, the host may have the possibility of
responding to the error (by repeating a message, for example) and thereby maintaining the
connection and transfer.
Transfer Process
These basic types of errors can be distinguished:
- Checksum error
Each data block transferred is secured by a checksum. If a checksum is
recognized as erroneous, the transfer of the data block is repeated.
- Timeout
The host monitors the response time of the SERIES 2000NISION. If no
response comes, it sends a query to determine the status of the recipient and
starts a new transfer of the data block if necessary.
- Format error
Logical errors in a data block which are recognized by the SERIES
2000NISION are reported to the host by an appropriate error message.
Transfer Protocol
Transfer Protocol
The following explanations and information are only of interest to users who write the
correspondence program for host computers or who wish to learn about the protocol.
Protocol Handling
A contiguous sequence of characters sent by the host or the control system is known as a
block. It consists of a variable number of ASCll characters and concludes with a <CR>
carriage return.
Between the host and the control system, blocks are always sent alternately; in other words,
the host does not send a new block until a block has been received from the SERIES
2000NISION.
General Protocol Characters
All of the valid protocol characters are explained in the next section.
The character <-> underline is used in the present text only as a visual aid to mark a space
character. During transfer, a space (20 hexadecimal) must be sent.
Universally valid protocol characters are:
- Tilde
This character is used to establish 'initial contact' (synchronization). Transfers
which are still open or which have been aborted are closed on the SERIES
2000NISION side.
? Question mark
This character is sent only by the host to the control system, thereby inquiring
about the status of a transmission. This is necessary whenever the host has
recognized a time error (TIMEOUT).
The control system responds to this character by repeating the transmission of
its last block (ACK, NAK or an error message).
%% 2 Percent Signs
used by the SERIES 2000NISION to nottfy the host of an error. After the
character string '%%' an ASCll error number INN' is reported.
! Exclamation point
used as a separator between the individual ESSI or EIA program records in the
data block. It replaces the <LF> or <CR/LF> as the symbol for the end of a
record, in order to avoid conflicts with the operating system of the host
computer.
Transfer Protocol
> Greater than

stands for ACK, and is sent in order to inform the other side that the preceding
data transmission was carried out correctly. The ACK also has a counter '0'..'3'
appended to it so that the sequence of the acknowledgments can be
monitored.
< Less than

stands for NAK. If one of the sides receives this character, then the last block
needs to be sent again. If there are a number of erroneous tries, the host
should abort the current transfer and attempt to begin transmission again.
1 Closed bracket
identifies the end of a program transmission.
& Ampersand
sent by the host in order to inform the SERIES 2000NISION that the next two
characters are a command.
4.3 Data Transfer
- Start of data transfer, program name

The data transfer is initiated by the host with the string
&FH represents the command From Host, just as it is used in transferring with
Upload/Download. The program number of the program to be transferred is represented by
nnnnnnnnn.
The program number is governed by the rules of the specific SERIES 2000NISlON:
Main program no. 9 digits

Program nest no. 5 digits
Standard shape no. 4 digits
Macro no. 3 digits
Depending upon machine constant 74 of the SERIES 2000, the main programs may also
contain capital letters and trailing spaces. In any case, the program numbers must always be
given with all of their digits, with spaces for padding if necessary.
Transfer Protocol
- Data block
This contains part of a numerical control part program, and is a block secured for correct
transfer. It is made up of:
- 2 characters to indicate length, in the range from 00 to FF hexadezimal,

represented by ASCII '01..'9'and 'A'..'F'
- a maximum of 250 characters of data including the end-of-record characters

<!>
-
- 2 characters for checksum (same format as the length indicator)
The checksum is generated by an XOR over all of the data characters. The
result is sent as two hexadecimal digits.
- End-of-block character <CR>.
Example:
Data Block
/ Data
Characters indicating length
~
Transfer Protocol
4.4 Sample Protocols
4.4.1 Synchronization of Host and SERIES 2000NISlON by the Host
All lines which are sent are terminated by a <CR>character.
Host: -
SERIES 2000NISION: >O
4.4.2 Transmission to the SERIES 2000NISION
All lines which are sent are terminated by a <CR>character.

Anything between parentheses ( ) is a comment, and serves only as an explanation for the
corresponding line of the protocol
Host: &FHJESTO1 (main program TESTOI)

SERIES 2000NISION: >1
Host: Data block 1
Host: Data block 2
SERIES ZOOONISION: >3
Host: Data block 3
SERIES 2000NISION: < (error)
Host: Data block 3
SERIES 2000NISION: >o
Host: I
4.4.3 Protocol Following Readiness Query
All lines which are sent are concluded by a <CR> character.

Anything between parentheses ( ) is a comment, and serves only as an explanation for the
corresponding line of the protocol
Host: ?
or
SERIES 2000NISION: <
or
SERIES 2000NISION: %%-01

411 S Ebenezer Road
To: Mike Featherstone

Company: Samuel Plate
Phone:
Fax: 905-664-741 6
Pages including this 8
cover page:
Mike,
I hope you didn't hear the phone crashing down at the end of our conversation.
It fell out of my hand as I was placing it down.
Here is the UDL protocol that you requested. If you should try to implement this
protocol, the udl feature will have to be enabled on your control if it is not
already. Let me know if you need for this to be done.
Have a good day,

Jim Johnson
Basic X O W F F serial communication allowing DOS copy command to download
from PC to Series 2000. Download timing must be coordinated between the Series
2000 operator and the host computer operabor. This capability is built in to the Series
2000 and requires no additional saftware.
Software package for the PC allowing downloading of programs to the Series 2000 in
"Parallel" with any operation of the cutting machine. Makes use of the Series 2OWs
multi-tasking capabilities, cutting machine operabor is not aware of download taking
place. Download is controlled by the host PCs operabor.
and messages bskwaen the Series 2000 and a host computer, espaddly
suited for very remote machine locations. Dawnloadsand Uploads are controlled by the
cutting machine operabr. Current versions of UDL are not TSRs(Terminate and Stay
Resident) nor do they run in background.
Once both ends of the communications link have been set up with the proper
parameters, PFT is ready a run. The only requirement at the Series 2000 is that the
power be turned on.
To transmit a prugram, at the FCs keyboard type:
then press R E N R N .
The PCs display will shaw the following:
At the prompt, type in the name of the part program that you wish to transmit, and press
RETURN.
Or simpfy type PPTfollowed by the filename. then press RRURN.
The part program must have the .MFG extension. The part program does nat need tn
be in the same di-ry as the PPT program. If it is n a in the same directory then you
must enter the full name to the part pmgrarn. The pmgram will be transmitted. and
PPT will terminate. A transfer status message will be displayed during and after
transmission. If there is any pmblem with transmission. an emr message will be
dislplayed.
B- 223691 1 T H I S D R n U l N G C O N T A I N E S P R O P R I E T A R Y Z O N F I D E N l I 4 L ! N F O R M A l I O N OF L - T E C
"LENLANDCUTTING SYSTEMS A N D E L O A N E C "T+ THE C X F R " ~ ~ A a G n r E W i T
T H A T T H l S D R & U I N G ( 1 ) W I L L NOT B E R E P R O W C L D OR C O P I E D . ( 2 ) U l L L NOT BE
USED OTHER THAN I N WORK FOR L - T E C . 4 N D 13) ' S I L L NOT BE D I S C L O S E D L X C E P l Q U A N T I T I E S ARE I N U/M E S T A B L i S H E D B Y INVENTORY
TO EMPLOYEES DF 1ME P A R T Y TO WHOM T H l S 3 R A d I N G I S L O A N E D AND ON A
CONFIDEYTIAL BASIS UNIT
TEM 1 OTY OF DESCRIPTION
JO
CODE N o MEAS
1 IP-2061210 1 JEA I CONNECTOR. 25 PIN
2 IP-2018145 1 i::,1 ,:::, / CABLE, 4 COND , 2 0 AWG. SHIELDED
3 P-2060495 I Ea 2 5 O!N D HEAD
SEE NOTE 1
25 P I N
1; ill NOTES
i X28. 8 P O S I T I O N CONNECTOR TO BE S U P P L I E D WITH
THE ATAS CONNECTOR PACKAGE AND
ATTACHED A T THE F I N A L ASS'Y
FOR M I N I F I L E X 2 8 - 5 = RED WIRE

@ 2
X 2 8 - 7 = WHITE V I R E
25 P I N
SOCKET
kiii%dF
RELEASED FOR
FLORENCE,
T 1T L E
SOUTH CAROLINA
CABLE ASS'Y
M I N I F I L E RS232 ( V I S I L
F I R S T MADE FOR
Computer Interface
Parallel Program Transfer
4. Transfer protocol
The f o l l d n g statements are interesting only for those customers who want to develop
comrnunlcation software of their own or who just want to gel informed of how the proto-
col Is structured.
4.1 Protocol processing

Throughout this chapter a block Is defined as a character string which is sent at a time. 11
conslsts of a variable number of ASCIl-charactors and ends with the code for carriage
return 'CR'.
Blocks are sent alternating between HOST and NCE570. This means that the HOST-
system will send a second block not before it received a block from NCESI0.
4.2 General protocol codes
In thls chapter all valid protocol codes are described. The underscore symbol '-' Is used
here to mark blanks. A Mock must contah a blank slgn @OH) at these IocaOons lor trans-
fer.
Generally valid protocol codes:
This code Is used for a first handshake (synchronlsation). NCE510 will then close eventu-
ally open or aborted transfers. .
- Question mark 7
Thls code is only sen1 by the HOST-system as n status request. This will always happen if
a tlme-out error is dofocted.
NCE510 afmvers Ulis request by repeatedly sending Its last block (ACK, NAK or error
code).
- 2 percent signs %%
Thls code precedes a two dlgit ASCII number which encodes an error detectec by
NCESI 0.
- Exclamation mark I
This code separates h e single ESSI-IEIA-program records. It replaces the normally used
end of recard code LF or LF CR in order to avoid difficulties with the HOST-operatlng
system.
Page 8
Computer Interface
3. Transfer process
3.1 Synchronlmtlon
NCE510 Is automatically booted alter power-on. This lncludes acthtim and unblocking
of the interface driver. NCESIO is ready then to receive programs from the HOST-system.
The HOST-system sends a single tilde in order to open the communication. Program
transfer can start then if NCES10 acknowledges with ACK.
3.2 Program-transfer from Host to NCE610

Process
Program transfer is started by the HOST-system by sending an inslructioncode together

with the number of the part-program that is to be transferred. NCE510 then opens lhls
program In It's program storage.
An already existing program will be superseded without Informing the NCESlO's operator
if it is not just activated for processing.
NGESlO repiys to tho opening telegram with a telegram wtltch contains Information of
success or faflure of processing the opening instruction.
Transfer will normally end with an and of transfer telegram. NCES10 then closes the
transferred program.
3.3 Error type8

All detected errors can onty be handled by the HOST-system because it is the acthe
partner of the connection. It will normally stop transfer and retry agaln.
Depending on the error the HOST-system trys to keep the connoction a c t i by

~ repeating
transfer of an actual telegram.
The following three types of errors can occur;

Checksum error
All data blocks are protected against data loss by cheokwmming.
A telegram will be repeatedty sent H checksumming fall$.
nw-~ul artor
The HOST-system controls the delay time within which NCE510 must
acknowledge a telegram. A status request will be sent If a time out occurrs.
The actual telegram will be sent again iftlm status request is sathfactofily
answered.
Format errors
Logical errors within data Mocks can only be detected by NCES10.
In tMs case an ercoc te(egram is sent back to the HOST-system.
Computec Interface
ParaUel Program Transfer
This code is used for ackno4edgement that means the sender of It understood the re-
ceived block and processed it correctly. This sign is fdlbwed by a counter ('0' '3')..
wMch serves for controlling of correct sequencing.
- Less sign <
This code means no acknowledgement. In this case the last block must be sent agaln. If
transfer of a block multiply fails, the HOST-system must abort the entire transfer process
and restart It.
- Right bracket ]
End of transfec code.
- Ampersand &
This code precedes a two character instruction code and is sont from HOST lo NCE510.
Page 9
Computer InteHace
4.3 Data transfer

- Start of data transfer, program name
Data transfer is Initiated by the HOST by sendlng a Mock of the form:
BFH k the instruction 'from host' and Is also used with UDL. 'nnnnnnnnn' is the program
Identlflcation.
The following rules of NCES10 for progcam identifications are valid:

Main pcogram number 9diglls
Program chain number 5digits
Standard shape number 4diglls
Macro number 3digits
Depending on machine constant 74 of NCE510 main program numbers may also contain
upper case letters and trailing blanks. In each case rriain program names must consist of
9 characters within this block. Trailing blanks must be added if necessary.
- Data block
A data block contains subsequent rocords of an NC-part program together with code
that ensures correct transfer. The structure of it is:
- 2 characters length information. valid length is 00 through FF hexadecimal,

represented by ASCII '0'..'9'and *A'..'F'.
- a maxlrnurn of 250 chractors includlng the erld of record character 'I'
- 2 characters for checksum (encoded corresponding to length Information)

Checksumming is done by XOR-ing all data characters.
- End of block code CR.
Exampte:
Data Mock
1E+100+!++100!-loo+!+-1001-+100!16 CR
Length Information Data characters Checksum
Page 10
Computer Interlace
4.4 Examplae tor correspondence
-
4.4.1 Synchronlsatlon Host NCE510 by Host
Host: "(CR)
NCESI0: >O(CR)
4.4.2 Transfer to NCES10
Host:BFH-TESTOl(CRJ Main program TEST01

NCESIO: > 1(CR)
Host:Date block 1
NCE510: >2(CR)
Host:Data block 2
NCESIO: >3(CR)
Hos1:Data block 3
NCE61O: < (GR) Error
Host:](CR)
NCES10: > 1(CR)
4.4.3 Correspondece with status request
Page 11

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Esab Vision 500 Manual

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January, I996

INSTRUCTION MANUAL FOR THE

41 1 South Ebenezer Road

This manual is ESA6 Part Number F 1408 1

This manual is intended for the convenience and use of the

2 General Description of Screens . . . . . . . . . . . . . . . . . . . . . . . 9

6 Movement Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1.1 The Control Panel of the VISION 500

A multi-tasking operating system supports the "simultaneous" access to different

1.1 The Control Panel of the VlSlON 500

8 Station Control Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

9 Timer Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

Window and Function Keys

Shiftifunction keys lead to additional, independent service windows. When a

The combination of shiftlbackpage switches back directly to the basic screen of

A standard format is followed with the layout of the LCD screen.

1.3 Functions of the Windows

Service: (SHIFT-Data Input)

- Preparation for program execution

Station UplDown: (SHIFT-Station Selection)

- Raising and lowering motorized stations

Character and Number Block

Character block Number block Station UpIDown keys

EmergencyStop Stop Start

- 2 General Description of Screens

The top line on the screen is used to display general information.

The symbols in the top left corner mark main

The symbol at the far left shows which main

The symbols to the right of the window symbol

Whenever branching down in the menu is

The top right corner displays the current speed,

The bottom line of the screen displays the menu,

Whenever a key branches down in the menu

If pressing a function key does not lead to further

change of a control or machine function. When a

When a symbol is not highlighted, it means that

Boxes for Information, Selection, Input and Inquiry

The current menu line above the function keys

The current menu line above the function keys of

Again, the actual menu line of the current picture

The required data is entered with the letter and

Again, the menu line is overlaid with the symbol

If the F1 key is pressed, the requested action will

The cursor is positioned on the individual letters

Arrangement of This Manual

This manual consists of pages of screen descriptions. Each of these page

- a picture of the screen

Confirm. This symbol is used to prompt the operator to confirm an

4 Defining a macro. This symbol is displayed in the bottom left corner

ng Cancel. For cancelling or quitting a function, for example, of an

Save. This symbol appears in an inquiry box. It is displayed after data

Delete. This symbol indicates clearing errors or deleting programs,

Direction indicator. Indicates the current direction of

3.2 Error Status Windows

Status lnformation window. For switching to the status information

Version Information window. For switching to the version

Drive Enable X. lndicator for drive enable in the X-axis. If this

Drive Enable Y. lndicator for drive enable in the Y-axis. If this

System Processing Enable. lndicator for System Processing Enable.

Motion Enable. lndicator for motion enable. Motion Enable is set by

Direction indicator. Indicates the current direction of

3.2 Error Status Windows

Status lnformation window. For switching to the status information

Version lnformation window. For switching to the version