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Programming of the

Plasma Chamfering Unit


For NC Controller NCE 520

Contents
Introduction
Layout of the Manual
Abbreviations used

Plasma Chamfering Unit Overview


Inputs / Settings by the User
Capabilities of the Unit

6
6
7

Examples for Programming

Example 1: Right Angle, Constant


Angle, Light Beam Sensor
Programming of the Cutting Contour
Example 1a: Constant Chamfer
Angle, Sensor-Sensor
Example 1b: Variable Chamfer
Angle per Section
Example 2: Circle, Constant Angle

Rules for Programming


Programming Sequences
Variable Chamfering Angle
Variable Chamfer Angle Over
Multiple Sections (Over Curves) or
an Arc up to a Maximum of 90
List of Rules

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5
5

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

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23
25
29
36
42
42
45

47
48

Contents

Help Functions
Organisation Program for
Plasma Chamfering Unit with
NCE 520 NC Controller
Layout of an organisation program
Basic layout of an organisation
program with sample values

55

60
60
62

Annexes
List of valid pages

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Programming of the Plasma Chamfering Unit


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Z-1

Introduction
The Plasma Chamfering Unit is used to produce
vertical and chamfered edges for the assembly of
large components in, for example, shipbuilding.
The chamfering of the edges can be varied. This
means that it can cut not only to fixed set angles, but
it is also possible to vary them continuously during
cutting.
Various kinds of materials, alloyed and unalloyed
steels, can thus be processed with a high cutting
speed without affecting the required cutting and
angle accuracy.
The automation of many sequences which the
Plasma Chamfering Unit offers makes handling of
the machine considerably easier for the user. As a
rule, it is only necessary to take the values for
vertical cutting from a table. The controller adapts
itself to the angle that has been input. This means
that the user does not need to calculate those values.
The Plasma Chamfering Unit is operated together
with the NCE 520 Controller. It is assumed therefore
that the operator has a basic knowledge of this type
of controller. In addition the reader should
understand ESSI programming and the main
terminology of plasma cutting.

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Programming of the Plasma Chamfering Unit


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Introduction

Layout of the Manual


A summary connected to this section states which
details must be input in order to produce a program
for the Plasma Chamfering Unit, and what the
Plasma Chamfering Unit will then be capable of.
In general, this manual has been laid out in such a
way that the user can obtain the required knowledge
for the programming of the Plasma Chamfering Unit
through examples, step by step, and he will be able
to produce his own programs as quickly as possible
without having to read through the entire manual.
Explanations for the individual steps should thus
make it much easier to understand the examples.
The reader is also put in a position where he is able
to program parts with differing inputs.
Tables for cutting speed and the stand-off distance
from the jet to the plate, the organisation table, etc.,
follow after these examples. In addition, the
technical connections which were only touched on
briefly in the examples are explained at this point
with the help of geometrical illustrations.

Abbreviations used
HF

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Help Functions

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

Plasma Chamfering UnitOverview


Inputs / Settings by the User
+

In the case of a chamfered cut, there are always two contours of different
sizes in a component. The user should program the larger contour (visual
edge), regardless of whether this is located on the upper or the lower side
of the plate.

There is also the chamfering angle

and the location of the cut joint.

In the case of a variable chamfering angle, it is necessary to input a start


angle and an end angle.

The values for cutting speed,

the width of the cut joint

and the stand-off distance between the burner and the tool are the
same as for a vertical cut.

It is also necessary to input the thickness of the sheet.


In order to maintain sharp corners when cutting, it is necessary to
program the so-called corner routines: one should cut approximately
10 mm beyond the contour in the same direction as the latter and,
together with a bevel, return to the next contour line in the form of a
triangle.

Corrective values for any necessary deviations in angle and size are
given in an organisation program, which the user can produce or modify
according to his own requirements.

Inputs for the ESSI Program


x

Inputs, settings for the controller

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Programming of the Plasma Chamfering Unit


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Plasma Chamfering Unit- Overview

Capabilities of the Unit


The controller recognises from the position of the
cut joint and the signed value of the input
chamfering angle whether the programmed
contour is on the upper side or the lower side of
the plate and travels automatically for the required
amount of sideways offset of the unit.
The cutting speed that was input will be reduced
as the chamfering angle increases.
In the same way, the width of the cut joint is
adjusted with regard to the angle.
As the angle increases, and the bevelling angle of
the burner increases likewise, the Plasma
Chamfering Unit is raised and offset sideways to
avoid a possible collision between the jet cap and
the material.
Execution of the corner routine likewise depends
on the angle and on the thickness of the sheet.
The cutting speed is reduced to the extent that the
Plasma Chamfering Unit can turn in the new
direction while it is executing the corner routine. In
doing this the Plasma Chamfering Unit does not
follow the contour line with the rotation but turns
directly from the direction of the most recently cut
contour into the direction of the following contour
of the part to be cut. This is achieved via a special
ESSI help function (HF 118).
A special corner technology achieves correct
execution of the corner routine even with minimal
or maximum sheet thickness or chamfering
angles.

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Plasma Chamfering Unit- Overview

The user merely needs to ensure that he has


included the corner routine when setting the
stand-off distance from the edge of the plate or
from a neighbouring part.
Through the use of an organisation program, the
controller corrects for any possible inaccuracies in
angle and size which could be caused by the
cutting process or by the Plasma Chamfering Unit.

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Programming of the Plasma Chamfering Unit


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Examples for
Programming
The following examples are intended to illustrate the
previous details and help the user to produce his
own programs.
The solutions selected do not necessarily represent
the only option (see the list of ESSI help functions in
the help functions section), they are intended rather
to make the program sequences consistent to a
large extent so that the user is confronted with only a
small number of different cases. The programs
should in the main be produced with a(n) (ESAB)
programming system or directly at the controller.

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Programming of the Plasma Chamfering Unit


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Examples for Programming

Example 1: Right Angle,


Constant Angle, Light Beam
Sensor
Geometry:

right angle, first side with chamfer,


all other sides are vertical

Size:

150 x 100 mm

Thickness:

10 mm

Chamfer
angle:

-20, constant angle,


negative chamfer

The tangential controller remains switched on in


order to make a transition from a height
measurement with a sensor (at the chamfer) to light
beam measurement.

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Examples for Programming

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Examples for Programming

3
000014000
4
5
+200+100
6
39+3175
29
51
76
53
122+200
++50
118
++50
++300
48
77
++700
++100
118
122+0
-100-100
+50+
47
+50+
+800+
48
+700+
+100+
118
-100+100
+-50
47
+-50
+-300
48
+-700
+-100
118
+100+100
-50+
47
-50+
-500+
(48)
(77)
-1000+
(117)
-100+
54
52
38
122+0
0
(63)

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Program number

Start sequence

Start

Start

+ 1st Side

Corner routine

+ (2nd side)

(Corner routine)

+ (3rd side)

(Corner routine)

+ 4th side

Exit
End sequence

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12

Examples for Programming

Cutting of the parts begins after rapid traverse.


Before starting the actual contour cutting, the burner
which was still vertical for hole punching, places
itself diagonally to the set angle for the following
chamfer. Then the corner routine begins.
The burner sets itself upright again while carrying
out this routine. The remaining sides are cut
vertically. In detail, this is shown as follows:

Start sequence

5
+200+100
6
39+3175
29
51
76
53
122+200
++50
118

++50

++300

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Examples for Programming

Point 1
39 + 3175
The cutting speed can be taken from the tables.
Always start on the basis of a normal vertical cut.
This gives a cutting speed of 3175 mm/minute for a
thickness of 10 mm. The details in the table are to
be taken as guidelines, and other values may be
necessary according to the type of material.
The controller reduces the cutting speed
proportionally as the chamfering angle increases or
decreases, since the actual cutting length for a
chamfer is larger than that for a vertical cut.
This means that a vertical cut will be carried out at
the cutting speed that had been input, while the
Plasma Chamfering Unit operates as if one was
using thicker material when cutting chamfers.
29
The cut joint is located to the left of the contour.
Cutting is done in a clockwise direction (this involves
an external contour). HF 29 is also used in all further
examples. The location (direction) of the cut joint
affects the input of the chamfer angle (+ or -).
51
The tangential controller is switched on. This insures
that the Plasma Chamfering Unit always follows the
contour and the set angle will always be maintained,
even in the event of a change of direction and also
for an arc-shaped contour.

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14

Examples for Programming

76
A sensor is used for automatic height control when
cutting chamfers. This is done either by a feeler foot
or by an inductive sensor. The sensor senses at a
short distance from the jet (approx. 60 mm) from the
plate and ensures that the set stand-off distance
between the plate and the jet will be maintained in
the event of unevenness.
53
The plasma cycle is switched on and cutting can be
carried out.
122 + 200
A chamfering angle is input with this help function,
and the signed value affects the direction of the
angle (positive / negative angle).
Warning:
It is necessary to distinguish between input of
the angle (programmed angle) for the Plasma
Chamfering Unit and the chamfering angle of the
(finished) work piece.
In the case of a work piece, a positive angle means
that the contour at the upper side is smaller than the
contour on the lower side of the sheet. The opposite
applies in the case of a negative angle.
Always enter the direction of the angle on the
Plasma Chamfering Unit with HF 122. In order to
determine this, you require the location of the cut
joint in addition to the chamfering angle of the work
piece: if the cut joint is to the left of the contour
(HF 29), the chamfering angle to be input is the
opposite of the angle direction of the work piece.
You produce a positive angle at the work piece when
you program a negative angle for the Plasma

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15

Examples for Programming

Chamfering Unit. This assumes that the correct


cutting direction was taken into consideration when
programming the contour.
In the example, the positive angle (+200) that was
input takes effect, since a negative chamfer (-20)
was cut on the work piece.
If the cut joint is located to the right of the contour
(HF 30), the signed value of the chamfering angle at
the Plasma Chamfering Unit and the work piece are
identical. You must input a negative angle if you
wish to cut a negative chamfer.

Point 1a
118
The Plasma Chamfering Unit does not, as is usual,
turn in the direction of the section which follows
directly after HF 118 but turns instead in the
direction of the subsequent section.
In the example, the directions of the first section of
the chamfering and the subsequent first contour
element are identical. Help function HF 118 has no
effect in this case.

Point 2
The start is over, and the actual geometry will be cut.

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16

Examples for Programming

Corner routine
Since the plasma jet always lags behind underneath
to some extent in the case of thicker sheets, the
corner of a part will already have been reached on
the upper side, while cutting has not yet reached the
corner on the lower side. A change of direction at
this point would produce a cutting-off or a
rounding-off of the lower corner. It is thus essential
for right-angled or acute angled corners, at least, to
be cut beyond the corner. This is done with a corner
routine. This is not (absolutely) essential for obtuse
angles (e.g. 120 and more). This depends on the
thickness of the sheet and the desired accuracy of
the corner.

5
7
48

77
++700

++100
118

122+0
-100-100
+50+
47
+50+

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Examples for Programming

Point 3
48
Automatic height setting is switched off 70 mm
before the new corner. This is essential when cutting
chamfers with the sensor travelling ahead, since it
can already be ahead of the edge of the plate before
the burner head reaches the corner. The stand-off
distance is a function of the distance between the
burner and the sensor, plus an additional margin for
safety.
77
The feeler system with the sensor is turned off. It is
raised. In fact, HF 77 selects height measurement
with a light beam, but this only becomes active once
the automatic height setting has been switched on
again.

Point 4
Here begins the geometry for the actual corner
routine. As a rule, it is adequate if you program a
length of 10 mm for the sides of the triangle. This will
be adequate in most cases through automatic
off-setting of the Plasma Chamfering Unit,
corresponding matching of the cut joint and a special
corner technique. In the case of very thick material
and large chamfering angles, a larger corner routine
may be necessary.
The cutting speed is automatically matched to the
slower cutting speed when the Plasma Chamfering
Unit is turning or setting an angle. This ensures that
there is enough time for both operations while the
bevels of the corner routine are being cut.

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Examples for Programming

Point 5
118
HF 118 is used at this point to avoid unnecessary
changes of direction. This is done by ensuring that
the Plasma Chamfering Unit only follows the actual
contour of the part and does not exceed the
maximum possible rotation, which would be the case
if executing only a corner routine (plus geometry).
While the bevels of the corner routine are being cut,
the Plasma Chamfering Unit turns in the opposite
direction, i.e. from the direction of the section which
led up to the corner routine, directly into the direction
of the following section.
122 + 0
The burner is set to the new angle, which is vertical
in this case, and likewise while the bevel is being cut.

Point 7
47
Automatic height setting is switched on so that light
beam stand-off measurement (which had already
been selected) becomes active.

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Examples for Programming

End sequence

10
11
48

77
-1000+
117
-100+
54
52
38
122+0
0
63

Point 9
(48)
Automatic height setting is switched off before the
end of the section. This is done for the same
reasons as for the corner routine. It is thus
absolutely essential when the last section is to be
cut with a chamfer.
The safety stand-off distance of 100 mm, instead of
70 mm as is used at the corner, represents a value
that is adequate for practically all cases. (If the first
side of the right angle is to be cut with a positive

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20

Examples for Programming

chamfer, the section to be cut on the upper side of


the plate for the last section is in fact shorter than
that programmed.)
In the current example, HF 48 and the additional
stand-off distance are not essential. But
fundamentally you can operate with them for
simplicity.
(77)
The same applies for this function. It is essential if a
chamfer is to be cut, but in principle it can be used
for reasons of consistency. The sensor system is
switched off and light beam control is selected.

Point 10
(117)
This function ensures that the Plasma Chamfering
Unit maintains the direction of the last section, even
when the next section leads in another direction.
The reason for this application of HF 117 is the
same as the one for the use of HF 118 in the start
sequence and in the corner routine. An unnecessary
change of direction is avoided, and also the
possibility of exceeding the maximum possible
tangential rotation of the Plasma Chamfering Unit.
Since this ultimately only follows the exit path, the
Plasma Chamfering Unit can maintain the direction
without any danger. In the example, an exit is made
in the same direction as for the previous contour line
and HF 117 thus has no significance.
With the additional exit in connection with the
programmed contour, this ensures that the contour
is completely cut in every case, e.g., for each
chamfer (e.g., the first side vertical and the last side
with a negative chamfer), as in this case the plasma

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21

Examples for Programming

beam lags behind underneath and would not have


reached the programmed corner if the burner were
to stop at the corner.
An exit is made if the last side is to be cut vertically
here, and thus HF 177 is not absolutely essential but
is recommended.

Point 11
54
Plasma cutting is switched off.
52
Tangential control is switched off.
38
Cut joint compensation is switched off.
(122 + 0)
The angle is set to 0, i.e., the burner is set to
vertical. Since the last contour has already been cut
vertically, this input has no effect here.
0
This terminates the program and the machine stops.
63
Program end. This function is not absolutely
essential.

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22

Examples for Programming

Programming of the Cutting


Contour
When using the ESAB Plasma Chamfering Unit, the
user always programs the visual edge (larger
contour) for a part with a chamfer. He can thus
simply take the dimensional details from the
drawing, regardless of whether he wishes to produce
a positive or a negative chamfer.
In the case of a positive chamfer, the visual edge is
located on the lower side of the sheet. The controller
recognises this from the input by the user and is in a
position to take into account the difference in size
between the upper side of the sheet and the lower
side of the sheet by offsetting the plasma burner and
changing the cut joint.

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23

Examples for Programming

Inputs to the Controller


After starting the program, a number of values are
requested at the controller though a menu. The
following details are also required in addition to the
details already input in the program example:
sheet thickness
cut joint
As can be seen from the menu, it is possible at this
point to enter the cutting speed as well. Other values
(sheet thickness or cut joint width) can likewise be
entered in the program or at the menu.
Warning:
It is possible to enter values twice. In the event
of differing input values for the same parameter,
the programmed value must be deleted first,
meaning that a programmed value cannot be
corrected through a different value from the
menu. The programmed value must be deleted
first in this case.

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24

Examples for Programming

Example 1a: Constant Chamfer


Angle, Sensor-Sensor
Geometry:

right angle, 2 sides with chamfers

Size:

150 x 100 mm

Thickness:

10 mm

Chamfer
angle:

constant angle -20/+30


Side 1 - negative chamfer
Side 2 - positive chamfer

The sensor for height measurement will be used


when cutting the first two sides (with chamfer), in
which case maintenance of the necessary stand-off
distance between the jet and the sheet will be
controlled by the light beam voltage for the
subsequent vertical cuts. The angle changes from a
negative to a positive chamfer at the first corner after
the first cut. The tangential controller remains
switched on while the entire program runs.

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Examples for Programming

3
000014000
4
5
+200+100
6
39+3175
29
51
76
53
122+200
++50
118
++50
++300
48
77
++700
++100
118
122-300
-100-100
76
47
+100+
+800+
48
77
+700+
+100+
118
122+0
-100+100
+-50
47
+-50
+-300
48
+-700
+-100
118
+100+100
-50+
47
-50+
-500+
48
77
-1000+
177
-100+
54
52
38
122+0
0

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Program number

Start sequence

Start

Start
+ 1st side

Corner routine

+ (2nd side)

(Corner routine)

+ (3rd side)

(Corner routine)

+ 4th side

Exit

End sequence

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Examples for Programming

Except for some small changes, the program can be


taken from example 1.

Start sequence
This is exactly the same as the start sequence in
example 1.

Corner routine

5
6

Angle < 30

Angle > 30

48

48

77

77

++700

++700

++100

++100

118

118

122-300

-100-100

-100-100

76

76

47
122-400

47

+100+

+100+

Point 3
48
Automatic height setting is switched off.

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Examples for Programming

77
The sensor is raised.

Point 4
Beginning of the corner.

Punkt 5
118
The Plasma Chamfering Unit turns while the corner
routine is being executed in the direction of the next
right-angled side, and the rotation does not follow
the corner routine.
122 - 300
The burner sets itself to the new angle up to the end
of the next section. A positive chamfer (+30) is
produced at the work piece.

Point 6
76
The sensor is lowered. Unlike in example 1, height
measurement with the light beam is not selected,
since a chamfer is to be cut next.
47
Automatic height setting is switched on. As long as
the 5 mm (+50+) are being cut between points 6 and
7, the sensor has time to be lowered. This prevents
height measurement from being activated during this
process.
The second corner routine is identical to the first
corner routine from example 1:
transition from a chamfer to vertical cutting.

End sequence
This is exactly the same as the one from example 1.
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Examples for Programming

Example 1b: Variable Chamfer


Angle per Section
Geometry:

right angle, 2 sides with chamfers

Size:

150 x 100 mm

Thickness:

10 mm

Chamfer
angle:

variable angle from -10 to -20


and

from -20 to -10

Side 1 - negative chamfer


Side 2 - negative chamfer
The sensor for height measurement is used for the
first two sides, and then light beam control for the
vertical cuts.
As compared to examples 1 and 1a, the chamfer
angle changes while the section is being cut. A
chamfer that varies between -10 and -20 is
produced on the first side, and on the second side it
varies from -20 to -10.

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Examples for Programming

3
000014200
4
5
+200+100
6
39+3175
29
51
76
53
122+100
++50
118
++50
122+200+1
++300
48
77
++700
122
++100
118
122+200
-100-100
76
47
+100+
122+100+1
+800+
48
77
+700+
122
+100+
118
122+0
-100+100
+-50
47
+-50
+-300
48
+-700
+-100
118
+100+100
-50+
47
-50+
-500+
48
77
-1000+
117
-100+
54
52
38
122+0
0

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Program number

Start sequence

Start

Start

+ 1st side

Corner routine

+ (2nd side)

(Corner routine)

+ (3rd side)

(Corner routine

+ 4th side

Exit

End sequence

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Examples for Programming

In this case, the program is also almost exactly the


same as examples 1 and 1a. The main difference is
that a start angle and an end angle must be input for
the variable angles.

Start sequence

5
+200+100
6
39+3175
29
51
76
53
122+100
++50
118

++50
122+200+1
++300

Point 1
The same inputs as in example 1 will be required,
except for the angles.
39 - 3175
The cutting speed to be as per the table.

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Examples for Programming

29
The cut joint to the left of the contour (cutting in a
clockwise direction).
51
The tangential controller is switched on.
76
The sensor for automatic height control is lowered.
53
Begin the plasma cycle.
122 + 100
The start angle is set to +10 for the Plasma
Chamfering Unit (this produces a negative angle at
the work piece).

Point 1a
118
The Plasma Chamfering Unit turns in the direction of
the first section of the cutting path, and not in the
direction of the start which follows immediately after
HF 118.

Point 2
122 + 200 + 1
The end angle is to be entered in this form, i.e., the
angle that is to be reached after cutting off one or
more sections. The angle will vary equally from this
point up to an end point that is still to be determined:
the Plasma Chamfering Unit changes its angle
during cutting via linear interpolation from +10 to
+20. The result is a work piece with a negative
chamfer that begins with -10 and increases to -20.

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32

Examples for Programming

Corner routine

5
8
6

Angle < 30

Angle > 30

48

48

77

77

++700

++700

122

122

++100

++100

118

118
-100-100

122+200

76

-100-100

47

76

122+350
+100+

47

122+100+1

+100+
122+100+1

Point 3
48
Switch off automatic height setting.
77
Raise the sensor.

Point 4
122
HF 122 without an angle being input shows the end
of the variable angle. The burner reaches the
previously input end angle (20) at this point. The
angle thus varies in the example from Point 2, with
the start of the first right-angled side over the

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

33

Examples for Programming

sections that were input (++300, ++700 / giving a


total of 100 mm) up to Point 4, which is the end of
this work piece side.
The Plasma Chamfering Unit maintains this angle.
Points 5, 6 and 7 are identical to the same points
from Example 1 up to angle input.

Point 5
118
Counter-rotation of the Plasma Chamfering Unit in
the direction of the following section of the piece
being cut.
122 + 200
The burner is reset to an angle of +20. Since the
starting angle of this section is the same as the end
angle of the last section, this input would not be
necessary here. The angle is still processed here for
reasons of consistency.

Point 6
76
The sensor is lowered.
47
Automatic height setting becomes active.

Point 8
122 + 100 + 1
The end angle for the following right angle side is
input. The angle varies again from the start of the
right-angled side up to the end of the work piece
side.
In this case the Plasma Chamfering Unit changes
the angle setting from +20 to +10, and a negative
chamfer (from -20 to -10) is produced at the work
piece.
Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

34

Examples for Programming

The end of the chamfer is shown at the next corner


(second corner routine). The program sequence up
to this point is as follows:
:
:
+800+
48
77
+700+
122
:
:
This corner routine is identical to the corner routine
from example 1 up to the angle inputs of HF 122 ...
Changeover over from chamfer cutting (height
measurement with sensor) to vertical cutting (light
beam measurement).
The Plasma Chamfering Unit maintains the angle
with HF 122. Angle inputs 122 + 0 are thus required
for Point 5. The program sequence is as follows:
:
122
+100+
118
122+0
-100+100
+-50
47
+-50

End sequence
This is identical to the end sequence from example 1.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

35

Examples for Programming

Example 2: Circle, Constant


Angle
Geometry:

circle as inner contour,


outer contour

Diameter:

200 mm/300 mm

Thickness:

10 mm

Chamfer
angle:

constant angle, negative


chamfer: -20

A program for a ring with a constant chamfer is


explained. The same negative chamfer is produced
for the inner contour and the outer contour. The
sensor is used for height measurement for both
contours.
Apart from the missing corner routine, the execution
of the help functions only differs slightly from the
function sequence for a right angle with constant
chamfer (see example 1).

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Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

36

Examples for Programming

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

37

Examples for Programming

3
000012800
Program number
4
5
+2500+1600
6
39+3175
29
Start sequence
51
76
53
122+200
+50+

Start
118
+50+

Start
++-1000++
Inner contour
48
77
117
-70-70
Exit
54
End sequence
52
38
122+0
5
+201-1061
6
29
51
76
Start sequence
53
122+200
-35+35
118
-36+36

Start
++-1061+1061- Outer contour
48
77
117
+-100
Exit
54
52
End sequence
38
122+0
0

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

38

Examples for Programming

Start sequence

Point 1
39 + 3175
The cutting speed (3175 mm/minute) can be taken
as usual from the table (vertical cutting is taken as a
basis). This is automatically reduced by the
controller according to the chamfering angle.
Above all, the maximum speed of rotation is to be
noted for small circles and thin sheet. While the
controller reduces the cutting speed to the extent
that the rotation can be completely carried out,
cutting quality will suffer under certain circumstances.
29
The cut joint is to the left of the contour, the direction
of cutting is anti-clockwise for the inner contour and
clockwise for the outer contour.
51
The tangential controller is switched off.
76
The sensor is lowered, automatic height setting
becomes active.
53
The plasma cycle begins.

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Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

39

Examples for Programming

122 + 200
The burner is set to an angle of 20. A negative
chamfer (-20) is produced at the inner contour and
at the outer contour.

Point 1a
118
The Plasma Chamfering Unit rotates during chamfer
cutting in a circle and not in the direction of the start.

Point 2
The start is ended. The ring contour begins.

End sequence

Point 3
48
Automatic height setting is switched off at the end of
the ring contour, before cutting the exit.
77
The sensor is raised.

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Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

40

Examples for Programming

117
The Plasma Chamfering Unit maintains the direction
that it had most recently followed when cutting the
ring contour, up to the following section (exit).

Point 4
54
Plasma cutting is switched off.
52
The tangential controller is switched off.
38
Cut joint thickness compensation is switched off.
122 + 0
The angle is set to 0, i.e. the burner is set to vertical.
0
The program comes to an end, the machine stops.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

41

Rules for Programming


Programming Sequences
Start sequence (constant angle)
5

Rapid traverse ON

Rapid traverse path

Rapid traverse OFF

39

Cutting speed in mm/min (100%)

29/30

Location of the cut joint

51

Tangential controller ON

76/77

Select light beam measurement/ select height


control with the sensor* and lower the sensor

** (122 angle)
53

Plasma cycle ON

122 angle

Angle setting of the Plasma Chamfering Unit in 1/10

| Start 1/2
118

The Plasma Chamfering Unit turns in the direction


of the next but one contour element

| Start 1/2
** (29/30)
|
| Parts geometry
|
*
**

Change index: 0

The sensor can be a feeler foot or an inductive sensor


The details in brackets are alternative programming, please see the
section List of Rules for an explanation. Only the alternatives without
brackets were included in the section Examples for Programming.

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

42

Rules for Programming

Corner routine

a = 70 mm
3
2
6
1/2

Point 1
48

Height setting OFF

77

1. Select light beam measurement


2. Lift the sensor if HF 76 already applies

|a

Length = stand-off distance from sensor to jet +


safety margin

Point 3
118

The Plasma Chamfering Unit turns in the direction


of the next but one contour element
(from Point 4 = subsequent part contour)

122 + angle

Angle setting < 30 for the Plasma Chamfering Unit


for the next part contour
> 30 = Point 4

Point 4
(76)

Select height control with sensor and lower the


sensor - only when the next contour is to be cut with
a chamfer.

Point 5
47

Height setting ON = light beam measurement


Height control with sensor = Point 4

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

43

Rules for Programming

End sequence
48

Height setting OFF

77

1. Select light beam measurement


2. Lift the sensor if HF 76 already applies

| 100 mm

Length = stand-off distance from sensor to jet,


plus safety margin

117

The Plasma Chamfering Unit maintains the direction


for the following contour element

54

Plasma cycle OFF

52

Tangential controller OFF

38

Cut joint OFF

122 + 0

Burner is set to 0

Program STOP

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

44

Rules for Programming

Variable Chamfering Angle


A variable chamfer - the angle changes continuously
between two defined points - can only be input for
sections.
122 start angle

Start angle of the chamfer

| (Start)
| (Section of the corner

According to which point the chamfer begins at

routine)
122 end angle + 1

End angle of the chamfer < 90

|
| Geometry

The geometry can be for one or more sections or

arcs

122

End of the chamfer


The chamfer varies from the point at which the end
angle (HF 122+ ... + 1) is determined, up to the point
at which the end of the chamfer is input (HF 122).
A corner which is to be cut with variable chamfers for
the previous and the following sections will be
handled as follows:

Point 1
48
77
|
Point 2
122

Change index: 0

End of the previous chamfer

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

45

Rules for Programming

Point 3
118
122 start angle

Start angle of the following chamfer < 30


> 30 = Point 4

Point 4
76
Point 5

(Height control with sensor = Point 4

47
Point 6
122 end angle + 1

End angle of the following chamfer.


The details relate to the previous illustration, see the
section Corner Routine.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

46

Rules for Programming

Variable Chamfer Angle Over


Multiple Sections (Over Curves)
or an Arc up to a Maximum of
90
If the chamfer is to vary over multiple sections
instead of just one there is no change with respect to
the chamfer angle definition as given in the section
Variable Chamfer Angles. It is only necessary to
ensure that HF 122 (end of the chamfer) is input at
the end of the section, after which the end of the
chamfer is to be reached.
The chamfer can be continuously varied during
cutting for an arc of up to a maximum of 90.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

47

Rules for Programming

List of Rules
In the case of a contour with a chamfer, the
larger contour is to be programmed.
The following details must or can be entered into
the program (details in brackets):
Angle

in 1/10

(Cutting speed)

in mm/min

Location of the cut joint


(Cut joint width)

in 1/10 mm

(Sheet thickness)

in 1/10 mm

All the details in brackets that are not


programmed must be entered in the
menu of the controller before cutting.

Warning:
Programmed values take priority.

The stand-off distance between the jet and the


sheet must be set at the machine, from which a
programmed cutting speed can be set
proportionally.
Take the values for vertical cuts as the values for
the cut joint (curve width), cutting speed and
stand-off distance between the jet and the sheet.
Technically related angles and deviations in size
can be equalised (see Section Organisation
Program for Plasma Chamfering Unit with NCE
520 NC Controller).

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

48

Rules for Programming

The sense of height control (HF 76) is used


when cutting a chamfer, and a light beam (HF 77)
is used for vertical cuts.
It is possible to punch holes diagonally (due to
the slag) or vertically. If you wish to punch holes
diagonally, the angle input (HF 122 .... ) must
be input before the beginning of the plasma cycle
and thus before HF 53, or otherwise afterwards.
Normally the cut joint (HF 29/30) is entered before
the first cut, i.e., before the initial chamfering. In
order to cut out an inner contour completely, it is,
however, meaningful to determine the cut joint
after the initial cutting.

The same applies if an outer contour or the start


do not have the same direction as the subsequent
contour.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

49

Rules for Programming

The angle is determined by HF 122 ... The


signed value determines the setting of the Plasma
Chamfering Unit. According to the position of the
cut joint (or the cutting direction), a positive angle
setting stands for a positive or negative chamfer
on the work piece.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

50

Rules for Programming

In the case of a variable chamfer, an end angle


must also be input and the end of the variable
angle must be indicated, as for example:

Only the so-called helping float functions may be


used between the end angle and the detail of the
end of the chamfer:
HF 47, 48, 76, 77.
Help functions 117 or 118 can or must be used at
all points at which there is a change of direction
which does not relate to the contour of the
work piece, in order to prevent the maximum
rotational capability of the Plasma Chamfering
Unit being exceeded ( 405, standard).
117 - The Plasma Chamfering Unit retains the
direction for the next contour element,
which will for example be used before an
exit.
118 - The Plasma Chamfering Unit turns about
the shortest path in the direction of the
contour element which will be the next but
one. The element that was input
immediately after the HF 118 does not
follow the tangential controller.
HF 118 is used if a contour is to be cut
which does not belong to the parts
contour, such as the start or a corner
routine.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

51

Rules for Programming

In the case of a corner routine, the use of HF


118 is unavoidable for cutting (if the tangential
controller - HF 51 - is switched on). Without HF
118, the Plasma Chamfering Unit would turn at
each corner of the contour by 135, in other words
by a total of 270, while it only turns in the
opposite direction by 90 when using HF 118.

118

135

90
135

Corner routines are required to preserve sharp


corners with acute angles and right angles. In the
case of obtuse angles this depends on the
desired quality.
In most cases 10 mm is enough for the size for
the corner routine. In any case, the corner
routine must not be smaller than the cut joint that
had been input, plus the automatic offset plus any
corrective values from the organisation program.
A larger corner routine may therefore be required
for thick sheet and large angles.
A guideline value for the stand-off distance
between the part and the plate edge or to the
next part can be taken by using double the
value of the corner routine. (Corner routine +
any stand-off distance of the cut joint + stand-off
distance for rotation of the Plasma Chamfering
Unit + safety margin for the path that will remain
stationary).

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

52

Rules for Programming

In the case of a chamfer, it is essential to switch


off the automatic height control in good time
before a corner, otherwise there is a danger that
the sensor could be located outside the plate or
above a neighbouring part (in the case of a feeler
foot sensor, no cut contour lines may be crossed).
The sensor is located approximately 60 mm
behind the jet. It is therefore adequate to switch
off the height setting 70 mm before the corner.
Refer to Corner Routine in this section
concerning the sequence and position of the help
functions for a corner routine. Please note the
following:
Height setting may only be switched off in the
case of a feeler foot if this has already definitely
crossed the contour line that has already been cut.
The height setting must likewise be switched
off earlier on the last contour of the cut section,
the guideline value is 100 mm before the
corner, if one considers the case that the first
contour must be cut with a positive chamfer and
the last one with a positive or negative chamfer.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

53

Rules for Programming

The stand-off distance must be even larger in the


case of thick sheet, large chamfering angles and
acute angles between the first and last contour.

In the case of a circle, you must not switch off


the height setting before the end of the contour
of the part if the sensor is located such that it runs
just inside the circle, in the case of an outside
contour, and just outside the circle in the case of
an inner contour.
If the side lengths for a part for which corner
routines must be cut are not greater than the
stand-off distance given above for switching off of
height setting, then height setting must not be
switched on. If the part is simply too small, only
switch on height setting briefly (at the start).

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

54

Help Functions
0

Program Stop

Machine will stop without loss of


information.

3
4
5

Ignore on
Ignore off
Rapid traverse on

Machine movement with


maximum cutting speed.

6
7

Rapid traverse off


Cutting cycle on

Starts the cutting cycle or a single


burner (middle burner in a three
burner set).

8
9
10
11

12

13

Cutting cycle off


Compressed air marking on
Compressed air marking off
Compressed air marking tool

The marking tool return the

offset on

position of the middle burner (or of

Compressed air marking tool

the single burner).


Cancels help functions 11 and

offset off

114.

Left burner on

Starts the cutting cycle with the


left burner.

14
15

Left burner off


Right burner on

Starts the cutting cycle with the


right burner.

16
19
19
19+

Right burner off


Cross drive Y2 on
Y2 congruent/laterally reversed
Y2 congruent/laterally reversed

Cross-drive Y1 off.

+ stand-off distance
20

Cross drive Y1 on

Change index: 0

Cross-drive Y2 off.

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

55

Help Functions

21-28

Rotate 90 and reverse laterally

29

Cut joint compensation on, left

Compensation for the cut joint


through offsetting of the burner to
the left in the direction of travel.

29+nnn Cut joint offset on, left

As for help function 29 - plus input


of the cut joint width (= cutting
beam thickness) in 1/10 mm.

30

Cut joint offset on, right

Compensation for the cut joint by


offsetting the burner to the right in
the direction of travel.

30+nnn Cut joint offset on, right

As for help function 30 + input of


the cut joint width (= cutting beam
thickness) in 1/10 mm.

31+135

Burner carriage 1, 3, 5

31+...+. Type of carriage clamp

+ 0 = free
+ 1 = fixed to the bracket
+ 2 = congruent to the motor
carriage
+ 3 = laterally reversed to the
motor carriage

32

Burner carriage selection off

All burner carriages off.

32+35

Burner carriages 3 and 5 off.

37+n+xxxx Burner carriage positioning

Burner carriage in programmed


stand-off distance from the motor
carriage on the congruent side of
the steel band.

38

Cut joint compensation off

Deletes HF 29 + 30 and the burner


travels along the programmed
track.

39+.

Programmed cutting speed

Change index: 0

+ value in mm/min

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

56

Help Functions

41+..

Hold time

Time input in 1/10 second.

42

Burner bridge on

After a section, start of the contour.

42+

Automatic burner bridge on

The machine executes the


programmed path (start).

43

Cutting oxygen off

HF 7, 13 or 15 start the first section


cycle again.

45

Automatic height setting on

To lower the burner slide after a


waiting time, e.g., for marking.

46

Automatic height setting off

Automation off and raise burner


slide.

47

Height setting automation on

48

Height setting automation off

Automation on without waiting time.


The height at that moment will be
retained.
Switch on the automation again
with HF 47 or 45 (without a waiting
time).

51

Tangential controller on

In the case of rotation units for


bevelling.

52

Tangential controller off

The plasma-chamfering-unit turns


into the 0 position (starting point).

53

Cutting cycle plasma burner on

54

Cutting cycle plasma burner off

55

Select second pre-heating time

The time is given in the menu.

56

Edge start off

Start - select selection edge start


off = hole-punching cycle on.

57

Edge start on

Start - select edge start


on = hole-punching cycle off.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

57

Help Functions

61

Machine zero point

The machine travels in a direct


path and in rapid traverse to the
machine zero point.

61+n

Working range zero point

To reach multiple working range


zero points which are at fixed
distances from the machine zero
point and are indicated numerically.

62

Program zero point

The machine travels in a direct


path and in rapid traverse to the
machine zero point.

63

Program end

All stored help functions are


deleted.

76

Burner height control via a

Cancels help function 77.

sensor foot
77

Burner height control via a light

Selection for the feeler system, to

beam

lift the sensor at the


plasma-chamfering-unit, cancels
HF 76.

81
82

Absolute dimension

Incremental programming is

programming on

standard.

Absolute dimension

Cancels absolute dimension

programming off

programming, returns to
incremental programming.

86++

Zero point off

Only in connection with HF 81


absolute dimension programming.

87

2nd absolute zero point

Dimension of 2nd absolute zero


point.

88

1st absolute zero point

Dimension of 1st absolute zero


point in connection with zero point
offset.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

58

Help Functions

100

Extract optional set on

Extract the following information


into the program.

101

Extract optional set off

102

Optional program stop

110

Powder marking on

111

Powder marking off

114

Powder marking tool offset on

Cancels HF 100.

The marking tool returns the


position of the middle burner
(or of the single burner).

117

Last position of tangential

Only takes effect for one half

controller is retained

information program block.


Must be repeated.

118

Tangential controller rotates

The geometry set following

around the shortest path in the

immediately will thus not be taken

direction of the next but one

into consideration.

contour
122

Angle input for the plasma

+ for angle type of HF 29

burner in steps of 1/10


- for angle type and HF 29
122...+1 Variable chamfering angle end

Until the next HF 122 or 122.

angle
122

End of the variable angle

Only in conjunction with


HF 122 ... + 1.

129+

Material thickness

Input in 1/10 mm

161+

Current strength = amperes

If the plasma cutting unit is


equipped for this.

163+

Jet stand-off distance control =

If the plasma cutting unit is

volts

equipped for this.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

59

Organisation Program
for Plasma Chamfering
Unit with NCE 520 NC
Controller
An organisation program is used to compensate for
non-linearities during chamfer cutting.

Layout of an organisation
program
An organisation program is an ASCII File with the
filename extension .ORG. Only capital letters,
numbers, minus signs, spaces and slashes may be
used in producing this file. Individual input values
must be separated from each other by at least one
space. A slash is used at the beginning to indicate a
comment line. All characters after the slash will be
ignored.
Organisation programs can either be produced on a
PC with an ASCII editor (such as EDIT.COM ), or
with the ANC editor. The ANC must be switched into
service mode for this purpose.
A distinction must be made between upper and
lower programming in the organisation program.
The relevant program time is determined by the
combination of the cut joint, side and the direction of
the bevel.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

60

Organisation Program for Plasma Chamfering Unit with NCE 520 NC Controller

Upper programming:

Kerf right (HF 30) and negative bevel or


kerf left (HF 29) and positive bevel

Lower programming:

Kerf right (HF 30) and positive bevel or


kerf left (HF29) and negative bevel
A series of values for cut joint correction and
correction of the bevel can be input for each sheet
strength. A series of values must be available for
both upper and lower programming to provide cut
joint and bevel correction. The cut joint correction
values are input in 1/10 mm and the bevel
correction values in 1/10 . These characteristic
lines are described by four starting points (angles).
A characteristic line is interpolated in a linear fashion
between the individual starting points.

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

61

Organisation Program for Plasma Chamfering Unit with NCE 520 NC Controller

Basic layout of an organisation


program with sample values

Materialthickness
[1/10 mm]

1st angle

2nd angle

3rd angle

4th angle

[1/10]

[1/10]

[1/10]

[1/10]

Angle starting point for cut


joint correction [1/10]

100

100

220

350

Upper programming [1/10]

100

100

175

200

225

Lower programming [1/10]

100

-120

-130

-130

-150

Angle starting point for cut


joint correction [1/10]

100

100

220

350

Upper programming
[1/10 mm]

100

-80

85

95

100

Lower programming
[1/10 mm]

100

-80

-60

-50

-30

Example of an organisation program: /sheet thickness 100 [1/10 mm]


100

000

100

200

300

/ANGLE [1/10]

100

100

175

200

225

/CUT JOINT CORRECTION FOR UPPER PROGRAMMING: [1/10 mm]

100

100

100

100

100

/CUT JOINT CORRECTION FOR LOWER PROGRAMMING: [1/10 mm]

100

000

100

200

300

/ANGLE [1/10]

100

-080 +85

+95

+99

/BEVEL CORRECTION FOR UPPER PROGRAMMING: [1/10]

100

-080 -060 -050 -040 /BEVEL CORRECTION FOR LOWER PROGRAMMING: [1/10]

Example of an organisation program: /sheet thickness 200 [1/10 mm]


200

000

100

200

300

/ANGLE [1/10]

200

100

100

100

100

/CUT JOINT CORRECTION FOR UPPER PROGRAMMING: [1/10 mm]

200

100

100

100

100

/CUT JOINT CORRECTION FOR LOWER PROGRAMMING: [1/10 mm]

200

000

100

200

300

/ANGLE [1/10]

200

-037 000

000

000

/BEVEL CORRECTION FOR UPPER PROGRAMMING: [1/10]

200

-037 000

000

000

/BEVEL CORRECTION FOR LOWER PROGRAMMING: [1/10]

Change index: 0

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

62

Organisation Program for Plasma Chamfering Unit with NCE 520 NC Controller

The NCE is able to run multiple organisation


programs. The software options available determine
which of the organisation programs is to be used.
The name of the organisation program to be loaded
can be input in the cutting package. If only one
organisation program is to be used, it is enough to
make the corresponding entry in the basic cutting
package (PARAM.CUT). If more than one
organisation program is to be used it is necessary to
use additional programmable cutting data. The
corresponding file names can be entered in the SDP
files.
The filename extension for organisation programs is
.ORG. The filename of the organisation program to
be loaded is input in the first cutting set description
line of the plasma process (N1) without the filename
extension. The syntax for this M = FILENAME. In
this example of an SDP file, the name of the
organisation program is N2FER_A.

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Programming of the Plasma Chamfering Unit


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63

Organisation Program for Plasma Chamfering Unit with NCE 520 NC Controller

03
SP_START
N1
(ST37, F3500, K4.7, M=N2FER_A S=8.0)
(CUTTING GAS, OXYGEN, JETS: 0,187)
M0000000000000000
P105

W140

U65

Q260

;U-ARC

T10

W0.2

U0.2

Q10.0

;PLASMA DELAY

T11

W0.1

U0.1

Q0.4

;RAMP SIGNAL EXTENSION

T2

W2.0

U0.1

Q10.0

;BURNER ON

P102

W1.7

U0.0

Q4.8

;INJECTION WATER

P115

W1.8

U0.0

Q4.8

;PILOT GAS

P126

W3.5

U0.0

Q4.8

;PILOT GAS TOGETHER WITH CUTTING GAS

P116

W0.0

U0.0

Q0.0

;PREFLOW CUTTING GAS

P117

W0.0

U0.0

Q0.0

;CUTTING GAS

T52

W0.5

U0.1

Q1.0

;CURRENT RISING RAMP

P152

W250

U150

Q400

;CURRENT RAMP STARTING VALUE

P153

W540

U150

Q600

;CURRENT RAMP END VALUE

T13

W10

U0.1

Q99

;TEST OPERATION

T22

W3.0

U2.0

Q10.0

;PREFLOW TIME

P106

W0

U0

Q99

;IHS

P156

W10.0

U0

Q10.0

;EQUALISE POTENTIOMETER FOR PROPORTIONAL VALVES

K4.7
F3500
SP_END
4

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Programming of the Plasma Chamfering Unit


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64

Organisation Program for Plasma Chamfering Unit with NCE 520 NC Controller

Production of an organisation program for cut joint


and angle compensation in a plasma cutting unit:
1.

Set all compensation values in the organisation


program to 0.

2.

Determine the cut joint for light beam control


(vertical).

3.

Produce a test program for 4 test pieces with


angles 0, +10, +30, +45, and cut.

4.

Evaluate the angles and dimensions, and enter


them into the organisation program.

5.

Repeat the cutting with compensation values


entered into the program and correct as
necessary.

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65

Annex Z: List of valid


pages
This instruction manual contains 66 pages.

Date of issue of the basic edition and


of changes:
Edition
Basic edition

Version number

Date of issue

List of pages
Amended pages of this instruction manual are
identified by following symbols:
Asterisk, bar or pointing hand.
The asterisk () identifies pages that have been
affected by the last change.

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Page

Change index

1 to 65

Z-1

Programming of the Plasma Chamfering Unit


for NC Controller NCE 520 (GB)

Z-1