MPMVP Winmpm Manual v1.12

VERNON TOOL COMPANY
4 and 5-AXIS MICROPROCESSOR PIPE

MACHINE
INSTRUCTION MANUAL
WinMPM-VP WINDOWS
OPERATING SYSTEM
COPYRIGHT 2002-2010
REVISION 1.12 (WinMPM 7.xx)
MACHINE SERIAL NUMBER:
Table of Contents
INTRODUCTION........................................................................................................ 1
1.1 HISTORY.............................................................................................................. 1
1.2 SYSTEM CONCEPT ............................................................................................ 2
2 INSTALLATION AND SETUP.................................................................................. 5
2.1 INSTALLATION REQUIREMENTS .................................................................. 5
2.1.1 Foundation ...................................................................................................... 5
2.1.2 Location .......................................................................................................... 5
2.1.3 Environment.................................................................................................... 5
2.1.4 Electrical ......................................................................................................... 6
2.2 Assembly of the Vernon MPM machine: .......................................................... 6
2.2.1 Machine Shipment Arrival.............................................................................. 6
2.2.2 Open the Crates............................................................................................... 6
2.2.3 Installation of the Machine Bed...................................................................... 6
2.3 Installation of the conveyors.................................................................................. 9
2.4 Hydraulic System .................................................................................................. 9
2.5 Locate the Power Box.......................................................................................... 10
2.6 Install the new Operators Console. .................................................................... 10
2.7 Install the Y-axis carriage on the Y-axis track. ................................................... 10
3 GENERAL DESCRIPTION ...................................................................................... 12
3.1 MACHINE BED.................................................................................................. 12
3.2 MACHINE CONVEYOR ................................................................................... 12
3.3 TURNING ROLLERS ........................................................................................ 12
3.4 HYDRAULIC SYSTEM..................................................................................... 13
3.5 CONTOUR CARRIAGE .................................................................................... 13
3.5.1 Y-Axis........................................................................................................... 13
3.5.2 Vertical Carriage and Motor ......................................................................... 13
3.6 CONTROL (OPERATORS) CONSOLE........................................................... 14
3.6.1 Power pushbuttons ........................................................................................ 14
3.6.2 Control Panel ................................................................................................ 16
3.6.3 Positioning Controls...................................................................................... 18
3.6.4 Keyboard and Display................................................................................... 19
3.6.5 Power Box..................................................................................................... 21
3.6.6 Optional Straight Cut Off Carriage............................................................... 22
4 PROGRAMMING ..................................................................................................... 24
4.1 USE OF THE KEYBOARD................................................................................ 24
4.2 HELP (<F12>)..................................................................................................... 25
4.2.1 WinMPM Users Manual.......................................................................... 25
4.2.2 V-Assist (Vernon Electronic Assistance) ................................................ 25
4.2.3 Calculator...................................................................................................... 26
4.3 CUT PROGRAMMING (<F1>) ......................................................................... 27
4.3.1 Setting WinMPM Options ........................................................................ 28
4.3.2 Pipe Data (<F1>, <F1>)................................................................................ 30
i
4.3.3 Programming End 1 (<F1>, <F2>) ............................................................... 32

4.3.4 Programming End 2 (<F1>, <F4>) ............................................................... 38
4.3.6 Listing and Editing a Pipe Machine Program (.PMP) (<F1>, <F5>) .......... 39
4.3.7 Saving a Pipe Machine Program (.PMP) (<F1>, <F9>) ............................... 43
4.4 DATA OPTIONS ................................................................................................ 43
4.4.1 Types of Data................................................................................................ 43
4.5 Graphics (<F5>) .................................................................................................. 51
4.5.1 Rotate +15 <F1>........................................................................................ 53
4.5.2 Rotate 15 <F2>........................................................................................ 54
4.5.3 Roll <F3> .................................................................................................. 54
4.5.4 Return to Zero <F4>.................................................................................. 54
4.5.5 Full Screen <F5>....................................................................................... 54
4.5.6 Info ,F6>.................................................................................................... 54
4.5.7 Print Cut Sheet <F7>................................................................................. 54
5 CUTTING .................................................................................................................. 57
5.1 MAKING THE CUT ........................................................................................... 57
5.1.1 Position the pipe and torch............................................................................ 57
5.1.2 Press the "CYCLE START" pushbutton ...................................................... 57
5.1.3 Press the "CYCLE START" pushbutton again............................................. 57
5.2 CUTTING OPTIONS.......................................................................................... 58
5.2.1 SINGLE STEP. ............................................................................................. 58
5.2.2 RETRACE .................................................................................................... 59
5.2.3 DRY RUN..................................................................................................... 59
5.2.4 RETURN TO CUT START.......................................................................... 59
5.2.5 ABORT ......................................................................................................... 59
5.2.6 FEED HOLD ................................................................................................ 59
5.2.7 FEEDRATE SLIDER ................................................................................... 60
6 UTILITIES (<F6>)..................................................................................................... 61
6.1 PROGRAM OPTIONS (<F6>, <F1>) ................................................................ 61
6.1.1 Units .......................................................................................................... 61
6.1.2 Offset:........................................................................................................ 62
6.1.3 Hole Dihedral Limit .................................................................................. 62
6.1.4 Transition Cut Auto Select ........................................................................ 62
6.1.5 Auto Select Intersection Angle.................................................................. 62
6.1.6 Transition Start Angle ............................................................................... 62
6.1.7 Transition Zone: ........................................................................................ 63
6.1.8 Transition Backbevel................................................................................. 63
6.1.9 Transition Backbevel Angle...................................................................... 63
6.1.10
Rectangular Hole X Length ................................................................... 63
6.2 MACHINE OPTIONS (<F6>, <F2>) ................................................................. 64
6.2.1 Machine Options First Window................................................................. 64
6.2.2 Loading the Feedrate Table (<F6>, <F7>) ................................................... 68
6.2.3 Machine Options Second Window ............................................................ 68
6.3 Axis Scaling (<F6>, <F3>) .............................................................................. 70
6.4 Handwheel (<F6>, <F4>) ................................................................................ 71
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6.5
6.6
6.7
6.8
Home Offsets (<F6>, <F5>) ............................................................................ 71

Diameter Check (<F6>, <F6>) ........................................................................ 71
CAD Files (<F6>, <F7>) ................................................................................. 72
PASSWORDS (<F6>, <F8>) .......................................................................... 72
7
MAINTENANCE (<F7>) ........................................................................................ 73
7.1 Error Log (F7>, <F1>)..................................................................................... 74
7.2 I-VARIABLES (<F7>, <F3>) ............................................................................. 75
7.3 TERMINAL (<F7>,<F4>) .................................................................................. 75
7.4 UPGRADE (<F7>, <F6>) ................................................................................... 76
7.5 BACKUP (<F7>, <F7>)...................................................................................... 76
7.6 RESTORE (<F7>, <F8>) .................................................................................... 76
8 HOW THE MACHINE WORKS .............................................................................. 78
8.1 THE OPERATORS CONSOLE.......................................................................... 78
8.2 THE POWER BOX ............................................................................................. 78
8.2.1 The Computer ............................................................................................... 78
8.2.2 The I/O Controller......................................................................................... 78
8.2.3 The Motion Controller .................................................................................. 78
8.2.4 The Servo Drives .......................................................................................... 78
8.3 THE MACHINE BED......................................................................................... 78
9 PIPE MACHINE PROGRAM (.pmp) FILE FORMAT AND EXTERNAL
PROGRAMMING ............................................................................................................ 80
9.1 FORMATTING ................................................................................................... 81
9.2 SECTION DESCRIPTIONS ............................................................................... 81
9.2.1 [Program Options] ........................................................................................ 82
9.2.2 [Machine Options] ........................................................................................ 82
9.2.3 [Pipe Data] .................................................................................................... 82
9.2.4 [End1] ........................................................................................................... 82
9.2.5 [End2] ........................................................................................................... 82
9.2.6 [Mid Item1]................................................................................................... 83
9.3 Externally Created Pipe Machine Program (.pmp) ............................................. 83
9.3.1 Pipe Machine Programs (.pmp) Created by WinMPM Desktop Mode .... 83
9.3.2 Pipe Machine Programs (.pmp) Created by CAD or Other Third Party
Programs..................................................................................................................... 83
10
NC PROGRAMMING ........................................................................................... 86
10.1
FORMATTING................................................................................................ 86
10.1.1
Allowable Preparatory Functions (G Codes)............................................. 86
10.1.2
Allowable Miscellaneous Functions (M Codes). ...................................... 82
10.1.3
Axis and Feed Rate Functions. .................................................................. 84
10.1.4
Sequence Numbers and Comments. .......................................................... 84
10.1.5
Absolute Versus Relative Positioning. ...................................................... 84
11 MAINTENANCE AND REPAIR .......................................................................... 87
11.1
ELECTRICAL MAINTENANCE ................................................................... 87
11.2
USE OF AN EXTERNAL KEYBOARD AND MONITOR........................... 87
11.3
REPLACING PRINTED CIRCUIT BOARDS ............................................... 87
11.3.1
Servo Drive Printed Circuit Cards............................................................. 88
11.4
MECHANICAL MAINTENANCE................................................................. 88
12 TROUBLE SHOOTING GUIDE ........................................................................... 91
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12.1
PROBLEMS WITH THE MACHINE............................................................. 91
12.1.1
Machine will not start ................................................................................ 91
12.1.2
No Picture or Cursor on Screen................................................................. 91
12.1.3
Cannot Jog One Axis (X, Y, C, Z, OR A)................................................. 91
12.1.4
Unable To Move All Axes Using Either Jog or Offset ............................. 92
12.1.5
Axis Runs Continuously in One Direction. ............................................... 92
12.1.6
Unable to Raise or Lower Vertical Carriage. ............................................ 92
12.1.7
Sensors Do Not Work................................................................................ 93
12.1.8
All Conveyors Do Not Work..................................................................... 93
12.1.9
One Conveyor Does Not Work. ................................................................ 93
12.1.10 All Hydraulic Circuits Do Not Work. ....................................................... 93
12.1.11 One Hydraulic Circuit Does Not Work. .................................................... 94
12.2
Problems with Cut Quality............................................................................... 94
12.2.1
Depth of Cut (Heel to Toe) Measurement Is Incorrect.............................. 94
12.2.2
Distance Between Cuts Is Incorrect but Depth of Cut is Correct.............. 94
12.2.3
Bevel Angle Is Incorrect............................................................................ 94
13 MACHINE ADJUSTMENTS ................................................................................ 96
13.1
ALIGNMENT PROCEDURES ....................................................................... 96
13.1.1
Alignment of the Cutting Head ................................................................. 96
13.1.2
Torch Axis Offset ...................................................................................... 96
13.1.3
A-axis Center of Rotation (5 Axes Only).................................................. 96
13.1.4
Center of Rotation on Machine Centerline (5-Axes Only)........................ 96
13.1.5
Vertical Axis Alignment............................................................................ 97
13.1.6
Pivot point.................................................................................................. 97
13.1.7
Travel along centerline .............................................................................. 97
13.2
Calibration of Axis ........................................................................................... 97
13.2.1
Calibration of X-axis ................................................................................. 97
13.2.2
Calibration of Y-axis ................................................................................. 97
13.2.3
Calibration of C-axis ................................................................................. 98
13.2.4
Calibration of A-axis (5 Axes Only) ......................................................... 98
13.2.5
Calibration of Z-axis.................................................................................. 98
13.3
ADJUSTMENT OF PIVOT POINT. ............................................................... 98
13.4
SETTING OF KERF...................................................................................... 100
TRANSITION START ANGLE (Program Option): The transition start angle is the
dihedral angle of intersection between the two pipes where a transition cut will start
to transition from the inside diameter to the outside diameter. A typical value is 40
degrees...................................................................................................................... 106
TRANSITION ZONE (program Option): This parameter is for setting the transition
zone in a transition cut. It is the distance in dihedral degrees from where the
transition starts on the inside diameter to where it finishes on the outside diameter. A
typical value is 10 degrees. ...................................................................................... 106
Appendix A
Appendix B
Appendix C
Appendix D
Appendix E
Definitions
Error Codes
Pipe Machine Program (.PMP) Format
Graphical Representations of End Cuts and Midsection Cuts
Cut Vs Input Data Examples
iv
Appendix F WinMPM Directory and File Structure
INTRODUCTION
1.1
HISTORY
Vernon Tool Company has been manufacturing pipe-profiling machinery for over 50
years. Over the years, the product has been refined every few years, as new technology
becomes available. Even so, Vernon Tool Company's product line still contains the full
range of machinery from mechanical Pantograph profiling machines to optical tracers
to today's microprocessor controlled, multi-axis profiling machines.
All of the profiling machines so far produced have been built around a concept of
material flow. Each machine is designed to interface to a standard conveyor system that
eliminates the need for overhead cranes, forklifts, chucks, etc. A single operator can
easily perform all functions.
The first machines produced consisted of a single rotational drive that was linked,
through gears and levers, to the torch that then moved back and forth as the pipe rotated.
Over 500 of these machines were produced and most are still in operation throughout the
world. This machine, called a Pantograph, is still produced.
Over the years some design changes were made and various attachments were produced,
but the machine remained virtually the same until the optical tracer was introduced. This
attachment consists of a rotating drum mounted to the side of the machine that controls
two axis of motion. A profile drawing is attached to the drum and an optical scanning
head then follows the same contour that is on the drawing. Like the Pantograph, this
machine is still produced today.
After the optical tracer came computer numerical control, CNC. And with the CNC came
full profiling capability with continuously varying beveling and four full axis of motion
control. Programming was done off-line, brought to the shop and manually loaded. Also,
for the first time it was possible to create custom programs.
Finally, the technology became available to develop the microprocessor pipe machine.
This machine offers the best features of all of the machines we have produced to date. It
can be easily operated from the control console, programmed off-line or a combination of
the two. Standard cuts are easily and quickly retrieved and yet custom cuts, such as
crowns, can be created.
1.2
SYSTEM CONCEPT
Most microprocessor pipe machines consist of three parts - an entrance conveyor,

profiling machine, and discharge conveyor (See figure 1 at end of chapter). From the
main console, pipe is loaded from raw material storage racks onto the entrance conveyor
and transported onto the profiling machine. The pipe is profiled and then transported
onto the discharge conveyor where it is unloaded onto the finished material storage rack.
A single operator controls the entire process from a single console.
To accomplish the profiling process, the operator lowers the pipe to be cut onto a set of
turning rolls. He then inputs a description of the cut to be made, positions the torch and
commences the cut. During the cut, the operator has control over several options such as
dry run, feedrate control, etc.
Since all computations are made by the operating system of the Microprocessor Pipe
Machine (MPM), it is a simple task to link the machine to external devices. Off-line
programming can be performed by simply describing the cuts to be made or custom
programs can be created by listing the coordinates of each point on a cut. Options are
available for loading programs into the machine through hard wire, modem, floppy disk,
tape and even radio link. Vernon Tool Company has available a wide variety of
software programming aids as well as custom programming.
Note: This instruction book has been written to cover both the 4-axis (MPM4) and 5axis (MPM5) microprocessor pipe machines. When a certain subject matter, item or
machine component is only particular to the 4-axis (MPM4) or 5-axis (MPM5) it
will be so noted by "(4-axis (MPM4) only)" or "(5-axis (MPM5) only)".
Typical Vernon System
Diagram
Pipe storage racks (1) are located
on each side of entrance conveyor.
Selector gates (2) on entrance
conveyor are used to roll the pipe
from one rack to the other until the
piece is in position. A remnant
piece can be returned to the storage
rack by reversing the direction of
the entrance conveyor rollers and
raising the gates.
Pipe is hydraulically lowered onto
entrance conveyor rollers (3) which
can be power driven.
The lifter conveyor system (4)

moves the pipe into cutting position
on the Vernon Pipe Machine.
The desired cut is made by the
profiling assembly (5). The lifterconveyor is again raised to move
the finished piece onto the
discharge conveyor and to
reposition the pipe for the next cut.
Discharge conveyor (6) is
hydraulically tilted in either
direction to unload pipe onto
adjoining racks
Figure 1
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2.1
2.1.1
INSTALLATION AND SETUP

INSTALLATION REQUIREMENTS
Foundation
A good foundation is very important for the correct operation of the machine. A poor
foundation can decrease both the quality of the cuts and the life of the machine.
Foundation blueprints are furnished by Vernon Tool Company prior to shipment of the
machine.
The weight for the basic 20-foot machine section is relatively light compared to the
machine's load capacity. Thus, most of the floor loading will come from the pipe to be
cut. Approximate maximum pipe loads are as follows:
Model 0224
Model 0342
Model 0454
Model 1460
250 lbs. per foot to a maximum loading of 5,000 lbs.

These loads are for standard machines. Different maximums may have been designed for
your specific machine.
It is recommended that an H-beam or I-beam type foundation be used as shown on the
foundation blueprint. In addition to a good foundation, it will serve two purposes, - it
raises the control console to normal height and it makes a convenient path for cable runs.
2.1.2
Location
Again refer to the foundation print for your machine. There should be ample room
around the machine for personnel and equipment to be moved. When locating the
conveyors in relation to the machine, keep in mind that a short distance between the two
may be desirable to allow foot traffic to get through, but the distance may effect the
minimum length of pipe that can be carried from the conveyor to the machine.
Note that it will be necessary to run hydraulic and electrical lines between the machine
sections. This is best done to the side and along the floor or under the machine in a
trench.
Although the machine is rugged and may be placed outdoors, a roof should be placed
over it to keep it from direct exposure to rain, snow, etc.
2.1.3
Environment
As mentioned above, the machine and conveyors can be located indoors or out as long as
they are protected from direct exposure to weather. The power box, containing the
computer and other electrical equipment, should be placed in a clean environment. The
air supply should be clean with temperature and humidity controlled as follows:
5
Maximum Temperature
Minimum Temperature
Maximum Humidity
100 degrees (F)

40 degrees (F)
80 % Relative
If the power box is mounted in an enclosure, at least two inches clearance to the rear and
six inches on all other sides should be maintained.
2.1.4
Electrical
The amount of electrical power required to operate the machine varies with the type of
machine, options, etc. However, it should be as clean (free from electrical noise) as
possible and regulated to within plus or minus 10 percent of rated voltage. See the
foundation blueprint for location of the service connections and for details on power
requirements. Reference the AC wiring diagram for connection details.
2.2 Assembly of the Vernon MPM machine:

2.2.1
Machine Shipment Arrival.

a. When the machine equipment arrives move all the crates into an
environmentally safe location. The crates contain sensitive electronic
components and must be kept dry and clean.
2.2.2 Open the Crates.
a. Inspect for damage and report it to Vernon Tool immediately. Take
digital photographs of the damage and email the photos to Vernon.
b. Remove the instruction manual, drawing books, vendors information
book, and any software CDs and disks and place them in a safe place.
The information is usually located in the crate with the operator console.
The Vernon representative will need to access these documents.
c. Become thoroughly familiar with the various components by referencing
the drawings contained in the black drawing book that is supplied with the
machine. It is usually packaged with the operators console.
2.2.3 Installation of the Machine Bed.
a. Set the machine bed support beams in place and secure to the floor.
(Support beams supplied by customer.) Vernon Tool recommends the use
of beams to provide support and to facilitate leveling and alignment of the
profiling machine and the conveyors.
b. The machine bed should be set in place and assembled. The machine bed
and conveyors should be assembled according to the foundation drawing.
The drawing is in the black drawing book supplied with the machine.
c. Before placing the machine bed onto the support beams use the supplied
jacking nut and stud and attach the sub-plates to the machine bed base
plates. The jacking nut should be screwed half-way through the machine
bed base plate. The studs should be screwed flush with the bottom of the
sub-plate. Tighten the stud nut bring the sub-plate together with the
machine base plate. Refer to Figure 1 for reference. This will make it
easier to align the sub-plates to the base plates once the machine bed is on
the support beams.
d. Place the machine bed on the support beams. If you are using a sling, be
sure to loop it around the base of the machine. Do not lift it by the shafts
or lifter conveyor frame as damage will result. Use care when positioning
the lifting equipment as there are hydraulic and electrical lines located
6
under the machine.

e. Pipe Machines with more than 1 machine bed, follow the same procedure
and place all machine beds onto the support beams. Be sure to locate the
machine beds according to the dimensions on the foundation drawing.
Align the centers of the machine beds together using the center of the
main rotation shafts as a reference of measurement. This can be
performed with the transit level or a piece of string ran along the center of
the roller rotation shafts, pulled tight and terminated at each end of the
machine beds.
f. Using an optical transit, level the machine bed. Use the Main Rotation
Shafts as a reference of measurement. Do not use the rotation shaft
bearing blocks (pillow blocks). Start at 1 end of the machine bed and
check the dimension on the main rotation shafts at each of the machine
bed base plates on both sides of the machine. The machine should be
leveled to the highest dimension. Start at 1 end of the machine and adjust
each jacking nut individually. Loosen the stud and nut, adjust the jacking
nut to the desired height and lightly tighten the stud and nut. Next, adjust
the jacking nut on the opposite side of the machine bed until the desired
dimension is reached and lightly tighten the stud and nut bolt. Continue
adjusting each base plate down the machine bed until all of the jacking
nuts are set to the desired height and the main rotation shafts are parallel
and level to the same dimension. This adjustment process can be done
multiple times to accurately level the main rotation shafts of the machine
bed. The correct leveling of the machine is important to prevent the pipe
from creeping as it is rotated. A slight overall incline to the machine is
more tolerated than a twist of the frame.
Figure 1
g. If a single machine bed is being use go to Step 4, Installation of the
7
Conveyors. If more than 1 machine bed is being used continue to the

next step.
h. Check the alignment of the joining sections of the Y-carriage (Y-axis) rail.
Since the machine was completely aligned at the factory, only small
adjustments should be necessary.
Use the small length of rack included with the machine shipment
labeled Y-Axis Rack Alignment Tool. Invert the alignment tool,
place it up to the Y-axis rack and mesh the teeth of the racks together
as shown in Figure 2. The racks should mesh and fit tightly together.
If there is a gap between the joining racks move the machine beds
together to eliminate the gap. This will ensure a smooth and accurate
movement of the Y-axis carriage along the track. If the racks do not
align at the same height recheck the machine level and adjust if
necessary.
Alignment of the Y-axis tracks. The Y-axis tracks, top and bottom,
should meet smoothly together. Bring the machine beds together until
the tracks meet and there is no gap between them. The top track is the
most important. Misalignment of the top track will cause the vertical
carriage and profiler to jerk over this section.
If the rail does not align from side to side, use both the tension and
compression bolts to bring the sections into alignment. Do not use
excessive torque since this may force the entire machine out of
alignment.
Once the Y-carriage rails are in alignment, tighten the
tension/compression bolts in the plate linking the sections.
Figure 2
Figure 3
i. Insert the X-axis transfer shaft coupling in the gap between the two
machine beds as shown in Figure 3. Slide the collars over the joining
shafts evenly and tighten the collar onto both shafts. Ensure that the
coupling shaft has equal gaps inside the collars. The collars should slide
freely. If this is not the case, recheck that the machine level and alignment
is set properly.
j. Install and tack weld the Lifter Conveyor C-channel into the gap of the
machine bed lifter conveyor.
k. Do NOT make any permanent welds on the machine until after final
inspection by the Vernon representative.
2.3 Installation of the conveyors

a. Insure the conveyor shafts are at the same height as the machine bed
conveyor roller shafts when the lifter-conveyor assembly is in the full-up
position. The conveyor centerline must also be on the machine centerline
(pipe centerline). A string can be drawn along the machine centerline to
the centerline of the conveyor roller shafts for alignment. Reference the
foundation drawing that was went with the machine.
b. Run the conduit containing the conveyor DC motor armature leads to the
proposed location of the new power box.
NOTES:
Any welding points should be tack weld as it may be necessary to realign
the conveyors after the machine is operational. It is better to error in the low
side as it is always easier to shim up than cut something to lower it.
2.4 Hydraulic System

a. Set the hydraulic power unit in position. (Remote power units only)
Standard machine hydraulic pump units are located on the side of the
machine bed.
b. Run the hydraulic motor and solenoid valve cables to the proposed
location of the new power box.
9
c. Install the hydraulic lines and hoses to the appropriate locations. The
hydraulic pipes and hoses are labeled for proper assembly.
d. Check the fluid level of the hydraulic power unit and refill if necessary.
2.5 Locate the Power Box.

l. Place the power box in the new location according to the foundation
drawing.
m. Remove the main power fuses from the disconnect switch on the side of
the power box. Put these fuses inside the power box. Run the main power
lines from a customer supplied disconnect switch to the disconnect switch
on the side of the power box. DO NOT APPLY POWER TO THIS
CIRCUIT! The Vernon representative will oversee the power
application.
2.6 Install the new Operators Console.

a. Install the new operators console carriage on the track opposite of the
profile carriage that travels the length of the machine
b. Run the appropriate operators cables and cable carrier to the power box.
Do not connect the cables to the power box. The Vernon representative
will connect the cables.
c. Insure the operators console carriage runs smoothly the full length of the
track
2.7 Install the Y-axis carriage on the Y-axis track.

a. The new Y-carriage can be lifted with a shackle under the vertical carriage
motor cover at the top of the vertical mast. See Figure 4.
Figure 4
b. Carefully lift the Y-carriage and move it close to one end of the Y-axis
track. Guide the carriage onto the track. It may be necessary to adjust the
Y-axis motor pivot bolts to insure the pinion gear does not engage or hit
the rack. See Figure 5. With the carriage on the track roll out the cable
and hose carriers in the tray that runs along the track supports. Run the
appropriate cables to the power box location. Do not connect the cables
to the power box. The Vernon representative will connect the cables.
10
Figure 5
c. Assemble the 5-axes profiling assembly on the vertical carriage assembly
of the Y-carriage. Bolt the profiling head to the vertical carriage with the
supplied bolts. Refer to Figure 6.
Figure 6
d. With the Y-carriage and profiler fully assembled put the torch in the torch
holder.
e. DO NOT ADJUST the main rail. All adjustments have been made at the
Vernon Tool factory.
f. Final alignment adjustments will be made by the Vernon representative
when the machine is in operation.
g. Mount the sensor arms onto the vertical carriage with the supplied screws.
The sensors will be wired by the Vernon representative.
11
Installation, Testing, Commissioning, and Training Schedule:

Contact Vernon Tool Co. service department for scheduling.
Phone: (760) 433-5860
Fax: (760) 757-2233
service@vernontool.com
GENERAL DESCRIPTION
The cutting machine is made up of several functional components as described in the

following sections.
3.1
MACHINE BED
The machine bed is the base upon which all of the other components are mounted.
3.2
MACHINE CONVEYOR
The machine conveyor (sometimes called the lifter-conveyor) allows pipe to be

transported along the machine to position it for cutting or to discharge it after cutting. To
use it, the operator depresses the "MACHINE CONVEYOR UP" pushbutton on the
operators console. This pressurizes the hydraulic system and raises the conveyor to the
up position. In this position, the conveyor rollers are at the same height as the entrance
and discharge conveyors, which enables the pipe to roll directly onto the machine without
interfering with the turning rollers.
The conveyor is powered electrically by a motor control, DC motor and gearbox. A
chain drive is used to interconnect the rollers. From the control console, the operator can
move the pipe in either direction as well as control the conveying speed.
Once the pipe has been loaded onto the machine, the operator lowers the machine
conveyor so that the pipe comes to rest on the turning rollers.
WARNING: RAPID OR SUDDEN STARTING AND STOPPING OF THE
CONVEYOR WITH HEAVY PIPE LOADED MAY DAMAGE THE
CHAIN DRIVE SYSTEM.
3.3
TURNING ROLLERS
The turning rollers are the rollers that rotate the pipe as it is being cut. They may be
coated with a rubber compound or be made completely from metal. Larger machines
may have rubber-coated rollers to absorb shock and prevent slip when encountering
seams.
The spacing between rollers varies along the length of the machine. Closer roller spacing
is provided in areas that smaller lengths of pipe will be cut.
WARNING: NEVER GROUND THE PIPE THROUGH METAL TURNING
ROLLERS WHEN CUTTING WITH PLASMA.
12
3.4
HYDRAULIC SYSTEM
The hydraulic system is used to power the following standard and optional components:
1.
2.
3.
4.
5.
Machine conveyor lifter

Optional Pipe stop
Entrance conveyor gates
Discharge conveyor gates and tilt
Optional Loading and storage rack controls
The system is simple and reliable. Upon actuation, the hydraulic pump is started and the
appropriate hydraulic solenoid valve is opened. Pressure is then ported to the desired
actuator. When the device is fully actuated, pressure will increase until the pressure relief
valve causes the fluid to be bypassed back to the tank. System pressure is approximately
1000 - 1500 PSI depending on machine type and options.
3.5
CONTOUR CARRIAGE
The contour carriage is the mechanism that travels along the side of the machine on the
large machined track. It carries with it the following components:
3.5.1
Y-Axis
The Y-axis consists of a motor, encoder, tachometer, gearbox, and rack and pinion. The
Y-axis moves the vertical carriage along the pipe.
3.5.2
Vertical Carriage and Motor
The vertical carriage moves up and down the vertical mast that moves along the Y-axis.
A servomotor with a brake attached to a gearbox mounted on top of the mast drives a ball
screw. It provides the mounting and adjustment for the following components:
4.3.1.1
C-Axis
13
The C-axis consists of a gearmotor, encoder and tachometer that rotates the torch to
provide the bevel angle.
4.3.1.1
Z-Axis
The Z-axis, which is mounted to the C-axis, utilizes a gearmotor, encoder, tachometer
and linear gearbox (rack and pinion on the 5-axes) to move the torch up and down in a
direction perpendicular to the weld bevel angle. It functions as a torch standoff control to
provide torch to pipe clearance.
4.3.1.1
A-Axis (5-axes (MPM5) only)
The A-axis utilizes a motor, encoder and tachometer to rotate the assembly that holds the
C- and Z-axis. It maintains the bevel angle perpendicular to the direction of travel.
4.3.1.1
Contour Carriage Control Box
The contour carriage control box houses the sensor controls, igniter relay and contour
carriage terminal strip.
4.3.1.1
Sensor System
The sensor system consists of two sensors located on either side of the torch. The sensors
provide a signal that is proportional to their distance from the pipe. This signal feeds
back through the vertical carriage I/O controller to a servo amplifier, located in the power
box, and then to the vertical carriage motor. The result is that the carriage is adjusted up
and down to compensate for any out of round or bent pipe.
3.6
CONTROL (OPERATORS) CONSOLE
All of the controls required for the operation of the pipe machine are located on the
control console. The console may be moved along the side of the machine so as to
position it close to the work being performed. On the control console, pushbuttons and
controls are grouped according to the functions that they perform. (Some functions are
optional and are not included with all machines.) There are five main functional groups:
3.6.1
Power pushbuttons
Located in the upper right hand corner of the control console, the POWER ON and
EMERGENCY STOP pushbuttons
control the application of AC power
to the machine. Depressing the
Emergency Stop pushbutton will
cause all motion to stop. Any
program being executed will be
terminated and will have to be
reloaded and calculated. Note that
some items in the power box will
remain powered even after the EMERGENCY STOP pushbutton is depressed. To
14
completely remove power from the power box, use the disconnect switch.
15
3.6.2
Control Panel
The control panel is reached by pressing F9. Control Panel from the main screen. It is
a touch screen virtual panel that contains all of the pushbutton controls necessary to
control the machine. To return to the programming screens, press RETURN.
4.3.1.1
Conveyor pushbuttons.
The conveyor pushbuttons are located on a sub-panel at the bottom right of the control
panel. They control the motion of the pipe along the conveyor as well as
loading/unloading functions.
3.6.2..1
Left and Right pushbuttons
First the conveyor or conveyors to be moved

must be selected from the top row of buttons.
Then, pressing either the "CONVEYOR
LEFT"
or
"CONVEYOR
RIGHT"
pushbutton commences motion in that
direction (left and right are with respect to
the operator). The pushbuttons are
momentary and motion will continue as long as the pushbutton is held down. The
CONVEYOR SPEED slider controls the feedrate of the motion. Note that the machine
conveyor must be in the "UP" position in order to convey pipe onto that section.
WARNING: RAPID OR SUDDEN STARTING AND STOPPING OF THE CONVEYOR
WITH HEAVY PIPE LOADED MAY DAMAGE THE CHAIN DRIVE
SYSTEM. SLOW THE PIPE FIRST WITH THE SPEED CONTROL.
16
3.6.2..2
Conveyor Up/Down
The CONVEYOR UP and CONVEYOR DOWN pushbuttons raise and lower the
selected conveyor. When the machine conveyor is in the down position, the pipe rests on
the turning rollers so that it can be rotated for cutting and when it is up, the pipe rests on
the conveyor rollers so that it can be conveyed along the machine. On 4 and 5 axes
models of the pipe cutting machine the discharge conveyor can be selected so that it can
be raised and lowered approximately one inch. This allows the discharge conveyor to be
installed into the cutting area of the front of the machine and lowered one inch to provide
clearance between the rotated pipe and the discharge conveyor rollers.
3.6.2..3
Gates Up/Down
In the "up" position, steel "gates" on the selected conveyor are rotated up so that there is a
level surface across the top of the conveyor. This enables pipe to be rolled across the top
of the conveyor for nesting purposes. It is also used in conjunction with the "Tilt"
function to off-load pipe.
3.6.2..4
Tilt Right/Left
The entire discharge conveyor can be tilted for off-loading pipe onto storage racks. The
tilt is hydraulically operated.
3.6.2..5
Loading Rack Controls
Optional loading rack controls may be furnished which are used to control the operation
of pipe storage racks for loading, unloading and nesting pipe.
4.3.1.1
Torch Pushbuttons
The torch pushbuttons are located on a sub-panel at the bottom left of the control panel.
They control the operation of the gas or
plasma contour torch, the optional
cutoff torches and the optional marking
torch.
3.6.2..1
Contour Torch
The contour torch is the torch that

performs the profiling of the pipe.
When the CONTOUR TORCH
AUTO pushbutton is pressed, the light
in the pushbutton will blink and the
torch will be in the automatic mode. Then, if the three gas pushbuttons are on, the
computer will automatically control the operation of the gas torch. If the PLASMA
TORCH pushbutton is on, the computer will control the operation of the plasma torch.
To operate either torch manually, turn off the AUTO pushbutton and depress the gas or
plasma pushbuttons automatically.
17
3.6.2..2
Cutoff Torch (optional)
The cutoff torches are manual torches used with the optional straight cutoff carriage.
These torches are controlled by pressing each gas pushbutton and the igniter pushbutton
manually.
3.6.2..3
Marking Torch (optional)
The optional marking torch is controlled in the same manner as the contour torch.
3.6.3
Positioning Controls
The positioning controls are used to manually position the computer-controlled axis of
motion and the vertical carriage.
4.3.1.1
Jogging
To jog an axis, first select it by pushing one of the axis select buttons (X, Y, C, Z
and A). Then, pressing either the jog+ or jog- button causes the axis to move in
the appropriate direction.
The position will be
displayed on the screen in
the "Present Position"
area of the display as it
moves. The speed of
motion depends on the setting of the "Feedrate" slider. While running a program,
the jog pushbuttons will operate only when all axes have stopped. However, as
soon as the program is restarted, the axis will return to its previous position. If it is
desired to move an axis while the program is running, use the offset slider, described
below.
Note: If the machine is jogged off position while a program is running, an unacceptable
following error may result in program termination.
4.3.1.1
Using Offsets
To offset an axis, first select it by pushing one of the axis select buttons (X, Y, C, Z and
A). This will enable the offset slider to control the motion of that axis. In this mode the
position display is not updated so that the offsets may be used to alter the machine
position while it is running under computer control. The Z-axis offset is especially useful
for changing the torch tip-to-pipe clearance while a cut is in progress.
4.3.1.1
Homing
After selecting an axis (as above), depressing the home pushbutton will cause the axis to
start moving in a preprogrammed direction until it encounters a switch closure. The axis
must always travel in the same direction towards home. Pushing the home pushbutton
again or either jog pushbutton will stop the homing process.
18
4.3.1.1
Vertical Carriage Up/Down
These pushbuttons are used for adjusting the height of the cutting torch and sensors
manually while loading or unloading pipe.
4.3.1.1
Sensor Pushbuttons
The sensor pushbuttons are used to

enable height sensing during cutting. When the machine is not executing a program, the
sensors are disabled. This prevents the carriage from descending when there is no pipe
present.
3.6.4
Keyboard and Display
The keyboard and display are used for all communication with the computer. The
keyboard with Hula pointing device is a sealed membrane type to keep out dirt.
19
MAIN MENU DISPLAY

The display is a color, TFT LCD touchscreen monitor that displays VGA video. The data
on the display can be broken down into two areas: the Status area and the Programming
area.
Note: When cleaning the Touchscreen disconnect this equipment from any AC outlet
before cleaning. Any standard glass cleaner can be used to clean the touchscreen.
Always spray the glass cleaner on the cloth or towel and then clean the touchscreen.
Glass cleaner sprayed directly on the monitor could possibly leak inside a non-sealed unit
and cause damage. Do not use liquid or spray detergents for cleaning.
4.3.1.1
Status Area
The status area occupies the first four lines at the top of the screen. The line labeled
Present Pos gives the present position of each of the axis. The line below it labeled
Next Pos shows the calculated position towards which the axis is moving while it is
under computer control. It will be blank except when actually making a cut. Block
Feedrate % displays the percent of the maximum-programmed feedrate as varied by the
feedrate override potentiometer on the operators console. Block Feedrate displays the
actual feedrate in inches per minute or millimeters per minute, depending on selected
units of measure, over the surface of the pipe. Block Num is the program block
number that is currently being executed. X Degree displays distance around the pipe in
degrees. The units of measure (Inch/Metric) and cutting method (Oxy/Fuel or Plasma)
20
are display to the left of X Degree.

The fifth line on the display is called the status line. It will indicate the current status of
the machine; e.g. when a program is being entered, calculated, run, etc. The 4-axis
(MPM4) and 5-axis (MPM5) displays are exactly the same except the A-Axis
Present Position and Next Position are eliminated for the 4-axis (MPM4).
ERROR or WARNING will display any warning messages such as a limit switch trip
in the programming area.
Note: Displayed error messages will remain on the screen until specifically
acknowledged by the operator. This is done to ensure that they are not erased before
being observed by the operator.
4.3.1.1
Programming Area
Programming area includes the bottom window of the screen. The upper left corner of
the programming area displays the version number of WinMPM and in parenthesis is
the version number of calculations module for WinMPM. The lower right corner
displays the Vernon machine that WinMPM is set up for. The All menus including
programming, file loading, graphics display check, utilities, and maintenance screens are
in this window area. These functions will be discussed in detail in later chapters.
3.6.5
Power Box
The power box is located remote from the machine. It contains the computer, servo
drives, I/O controller and all of the various electronic devices necessary for machine
operation. All cables going to the machine and console originate at the power box.
21
3.6.6
Optional Straight Cut Off Carriage.
The optional straight cut off carriage (also called a "two torch" carriage) is mounted on
the operators side of the machine and is used to make end cuts. Through the use of the
two torches, simultaneous beveling of the leading and trailing edges of the pipe may be
accomplished. A "blow hole" eliminator gives a smooth finish all the way around the
pipe and stand off wheels allow for out of round pipe.
22
23
PROGRAMMING
This chapter is divided into three parts. The first deals with use of the keyboard and
entering data. The second deals with the basic steps used in programming a cut and the
third provides a description of other data operations associated with programming.
During the review of this chapter it may be helpful to refer to the appendix titled
"Definitions", in the back of this manual.
4.1
USE OF THE KEYBOARD
Throughout this chapter, the notation <command> refers to an actual keyboard entry to
be made at the control console keyboard. For instance <SPACE> <abcd> <enter>
indicates that the space bar on the keyboard should be hit followed by the letters a, b, c
and d followed by the enter (or return) key.
All menu selections are made with the function keys at the top of the keyboard. A
selection of <F10> or <ESC> will always take you back to the previous menu.
The special function keys F1 through F12 are used to select the function displayed at the
bottom of the screen. The cursor may be moved from input to input when entering data
by using the cursor ("arrow") keys, Tab key or Hula pointing device. Some models of the
Vernon machines have a touch screen, which allows moving the cursor by touching the
screen location desired. As it moves, the cursor will only stop at inputs that are required
for the cut being made. Also the window requiring input will remain with a white
background while the data not requiring input will have a gray background.
Note: When a program has already been entered and you wish to enter a new one, it is
only necessary to change the existing data. Do not cycle the power off and on in an
attempt to "clear" the machine.
24
4.2
HELP (<F12>)
The WinMPM software offers two sources of help, on screen access to the Instruction
Manual in Adobe .pdf file format and Vernon Tool Company online help known as
V-Assist. Both sources of help can be accessed through the Help on the Toolbar or
through the special function key <F12>.
4.2.1
WinMPM Users Manual
As mentioned, an Adobe .pdf file of the complete Instruction Manual can be brought up
on the screen at anytime by selecting Users Manual under the Help Toolbar or
selecting WinMPM Users Manual.
4.2.2
V-Assist (Vernon Electronic Assistance)
V-Assist (Vernon Electronic Assistance) sets up an interactive internet session

between your Vernon machine or desktop computer running WinMPM and a
Vernon service representative located at the factory. This unique service allows the
Vernon representative to actually view the customers machine or desktop display, take
control of the customers computer on approval, use a whiteboard tool to write on the
screen electronically, and transfer files.
Once V-Assist is selected a window will appear with guidelines for getting the most
out of the help session. To provide you with the best assistance possible it is necessary
to:
1. Have a clean, fast, high-bandwidth internet connection to the Vernon machine.
2. Schedule the V-Assist session with the Vernon Service Department via
Phone: (760)433-5860
25
Fax: (760)757-2233
Email: service@vernontool.com
3. Have a telephone or cell phone available during the session to receive the maximum
benefit from the assistance.
4.2.3
Calculator
Selecting Calculator will start the Windows accessory calculator. This help if one needs
to calculate piece of data to be input.
26
4.3
CUT PROGRAMMING (<F1>)
The programming window is selected from the main menu by pressing the <F1> key.
Programming the machine to make a cut is a relatively simple task. It is only a matter of
describing the geometry (or shape) of the cut you are going to make. To make this easier,
the programming is broken down into four parts: the data for the pipe being cut, data to
define the cut on end 1, data to define midsection cuts, and data to define the cut on end
2.
The input data is retained from the previous piece to facilitate editing or inputting the
data for a new piece. All previous data can be erased and the default data reset by
selecting <F6> New PMP.
Data may be entered using either inch or metric units. The selection is made by selecting
the units entry in the Program Options menu. When the metric system is used, data
must be entered in millimeter notation (1mm).
27
4.3.1
Setting WinMPM Options
WinMPM options are accessed through the Tools tool bar. Scroll down until
WinMPM Options is highlighted then hit <Enter>. The WinMPM Options
window shown below will appear.
Figure 1
4.3.1.1
Program mode:
The Production mode is a fully function operating system to run

the Vernon MPM2, MPM4 or MPM5 pipe cutting machine.
The mode must always be Production when on the Vernon
machines.
The Desktop mode is for using WinMPM on a desktop computer
for generating Pipe Machine Programs (.PMP) offline. The PMP
programs generated offline may be downloaded onto the Vernon
through various methods; i.e. floppy disk, Local Area Network, etc.
The download programs can then be loaded into the machine by the <F2> Load PMP
function as described in section 4.3.1.1.1 above. When in the desktop mode
WinMPM will not attempt to communicate with motion control system of the Vernon
machine, therefore some functions will not be available.
28
The program mode can be toggled between Desktop and Production by highlighting
the Program mode box then using the arrow keys to toggle.
4.3.1.1
Remember window position between runs:
This function is only active in the Desktop mode. This box is either checked or
unchecked. When checked the pop-up windows will appear in the last location they were
moved to. When unchecked the pop-up windows will always appear in the center of the
screen.
The box may checked or unchecked by using the pointing device or <Tab> to
Remember window position between runs and hit the <Space> to toggle between
checked and unchecked.
4.3.1.1
Load last Pipe Machine Prog at startup:
This box is either checked or unchecked. When checked the last PMP program that was
in the machine at power shut down will be reloaded. When unchecked the machine will
load the default PMP program every time the machine is turned on.
The box may be checked or unchecked by using the pointing device or <Tab> to Load
last Pipe Machine prog at startup: and hit the <Space> to toggle between checked and
unchecked.
4.3.1.1
Print cut info with cut sheets
This box is either checked or unchecked. When checked, cut information such as weld
length, weld volume, and cut time for End 1, End 2 and Totals are printed on a separate
page of the cut sheet. If the box is unchecked the cut information will not be printed out
with the cut sheet. One may not need this information and therefore want to save paper.
4.3.1.1
Error alarm sound:
This box is either checked or unchecked. When checked an alarm sound will be emitted
whenever an error has occurred. When unchecked the alarm sound will be silenced.
The box may checked or unchecked by using the pointing device or <Tab> to Error
alarm sound and hit the <Space> to toggle between checked and unchecked.
4.3.1.1
Status font size (points):
This changes the font size of the status window lines message text.
The font size can be changed by pressing the <Tab> key until the box is highlighted then
enter the desired font size and press <Enter>.
29
4.3.1.1
Bold
This box is either checked or unchecked. When the box is checked the text in the status
window lines will be bold type. When unchecked the text will be standard type.
The box may checked or unchecked by using the pointing device or <Tab> to Bold and
hit the <Space> to toggle between checked and unchecked.
4.3.2
Pipe Data (<F1>, <F1>)
Selecting the <F1> key will move the cursor to the Pipe Data window. The Pipe
Data is the data pertaining to the pipe in the machine to be cut.
A brief description of the input data variables follows:
File Name The file name that the completed data input for the
cut programmed will be stored under. The part number may be up
to 32 alphanumeric characters long. The data format is explained
in section 4.3 below.
Pipe Diameter - The OUTSIDE diameter of the pipe being cut.
The Pipe Diameter is the actual pipe diameter, not the nominal
size: i.e. 6.625 must be entered for the diameter of 6 pipe. The
lower limit for pipe size is 1.0 and the upper limit is 999.9 in
English and 9999.9 in metric units. (Note that these limits may
not be the same as the physical capacity of your particular
machine).
Wall Thickness - This is the wall thickness of the pipe being cut.
The value must be entered as a decimal value. This can be any
value from 0.0 to 255.0.
Length - If both ends are cut, this will be the length input for the piece being cut. There
are two different methods of determining the length value. If the program option
Offset: is set to Baseline then length is from the shortest point on the first cut to the
shortest point on the second cut, measured along the inside of the pipe. If the first end is
not cut, the distance is from the point under the torch when the program was started to the
shortest point on the second cut.
If the program option Offset: is set to Workpoint then the length is the distance
between centerline of the member intersecting the first end and the centerline of the
member intersecting the second end. . If first end is not cut, the distance is from the point
under the torch when the program was started to the centerline of the member intersecting
the second end. Workpoint length is further discussed in Program Options section of
the manual and Appendix A-Definitions.
Cutting Method The programmer can select the cutting method, either Oxy/Fuel or
Plasma by highlighting the Cutting Method box and using the up and down arrows.
Part Number, Specification, Material, and Quantity This data is stored in the file
30
data for user reference only and does not have an affect on the programming of the cut.
This completes the data required for the branch pipe. The cursor will wrap around from
the last entry to the first entry if it is desired to edit or re-enter a value.
31
4.3.3
Programming End 1 (<F1>, <F2>)
Selecting the <F2> key will move the cursor to the F2 End 1 cut type selection window
for End 1. The arrow keys may be used to scroll through the various cut types that may
be cut. The pictorial representations of the various cuts are shown above on the pipe
graphics. Once the desired cut has been highlighted push the <Enter> key and data entry
window (or Edit) for the selected cut will appear.
32
4.3.1.1
Editing End 1 (<F1>, <F1>, <F1>)
The data required to make the cut is displayed in the upper left of the Edit window.
The graphical depiction to the right of the data input defines the various data inputs
required to make the cut. For all the different cut types, there is a corresponding
graphical depiction illustrating the required data.
Multiple intersection cuts, saddles, transitions, and miters, can be programmed by
inserting another main member anywhere in list by using either the <F3> Insert or <4>
Insert at End keys. Likewise any main be deleted by using the <F5> Delete key or
all of the main members can be deleted by using the <F6> Delete All key. The <F1>
Previous and <F2> Next keys are used for paging through the main member list to
select a members input data for editing.
Automatic error checking is done on the input data to ensure the data is correct and will
not cause an error during calculation of the cut path on the pipe. If an error does occur,
such as a main diameter smaller than the pipe diameter, an error message will be
displayed on the screen. Pressing the <F11> Acknowledge key eases the error message
and then the error can be corrected.
Weld Prep Angle - When a cut is made by the pipe machine, the bevel angle is varied
around the pipe to produce a constant weld preparation angle within physical limitations
33
of the machine. The default value is contained in the machine options as a parameter.
Although a permanent change can be made to the program options table, it is often
necessary to vary the weld prep angle for a particular cut or cuts. This is why the Weld
Prep Angle can be changed during the programming of a cut.
Outside Diameter - The outside diameter of the intersecting pipe is required for
intersections involving circular members (saddle and transition cut types). In all cases the
minimum diameter must be at least equal to the inside diameter of the pipe being cut
(Branch pipe).
Intersection Angle - This is the angle between the centerlines of the pipe being cut and
the pipe for which the intersection angle is being determined and it is measured in
degrees. Any angle, positive or negative may be entered but the following may produce
undesired results: negative angles will produce a mirror image cut and very small angles
can produce a cutback longer than the machine. For instance, an intersection angle of 1
degree on 18-inch pipe will produce a cutback of over 1000 inches. An angle of 0 degrees
will cause an error message. Angles of greater than 90 degrees may be used if desired,
however acute angles waste less pipe by allowing blow-through to occur in the waste
piece. They also promote simplicity and commonality.
For intersection angles from 0 to 90 degrees, the intersecting pipe will lean towards the
opposite end of the pipe.
Centerline Offset - If the centerlines of the Branch pipe and the Main pipe do not
intersect, there is a centerline offset. It is the distance between the two centerlines
measured perpendicular to each. If the centerline offset is greater than the radius of the
main pipe minus the inside radius of the Branch pipe, the cut cannot be made and an error
message will occur. A centerline offset that moves the main member towards the 90degree position on the pipe is positive.
Baseline Offset - Either Baseline offset or
Workpoint Offset calculations can be selected
in the Program Options window in the Utilities
Menu. A baseline offset occurs on multiple
intersections only and is skipped for single
intersection cuts. It is the difference between
the shortest points of the templates of the two
different intersecting pipes. Any point can be
chosen for reference and all main members can
have a baseline offset. However, usually the
first main member is chosen as zero and the
other main members are referenced to it. There
is more information on the Baseline Offset in Appendix A Definitions
To further illustrate, assume you wanted to make a two intersection cut by hand. One
way to do it would be to prepare a template for each intersection and locate them
separately on the pipe so that they overlap in such a way as to produce the final cut. The
baseline offset would be the distance between the shortest point on each template,
measured along the pipe. See figure to the right.
A positive offset indicates that the short point for that member has been moved towards
34
the end of the pipe being cut (i.e. its template has been moved towards the end of the
pipe).
Workpoint Offset - Either Baseline offset
or Workpoint Offset calculations can be
selected in the Program Options window in
the Utilities Menu. The work point offset is
measured along the centerline of the pipe
being cut. It is the distance between the
intersection of the centerlines of the main
member #1 (reference zero) and main #2 or
main #3. See figure to the right. There is
more information on the Workpoint Offset in
Appendix A Definitions.
Axial Angle - Also called the roll angle,
the axial angle is the location around the
pipe of the shortest point in the cut. It is also the point around the pipe at which the
intersection angle is measured. The reference point (zero degrees) on the branch
member is the point under the torch when the cutting sequence is begun.
For reference, the top of the pipe is zero degrees and the bottom is 180 degrees. The 90
and 270 degrees vary depending on the direction of pipe rotation for the particular
machine. When the machine is jogged 90 degrees in the positive X direction, the top of
the pipe will be at the 90 degree position. This is true for either end of the pipe.
Negative angles may be used: a -45 degree is equal to +315 degrees, a -225 degree is
equal to +135 degrees and so on.
When cutting commences, the pipe will rotate to the axial angle of the first main member
before piercing the pipe. Thus, it is always best to specify as the first main member the
one with the least amount of axial angle.
35
4.3.4
Programming Midsection (<F1>, <F3>)
Midsection cuts are the cuts made into the pipe between End 1 and End 2. These cuts can
be round holes for mating pipe intersections, both inner diameter and outer diameter,
square holes, i.e. access window, rectangular tube intersection, etc., and /or saw cuts
which are for size on size pipe intersection holes. Multiple midsection cuts can be
programmed. A very large number of midsection cuts could exceed the program buffer
memory. Each new midsection cut is assigned an item number, which is displayed in the
block next to the Inch/Metric block in the status window.
As in the end cuts there is a graphical depiction accompanied with the particular
midsection cut which fully describes the input data variables. All the special function
<Fxx> keys work as described in the End 1 section above.
Diameter - (This data is entered for circular holes only.) This is the actual diameter of
the desired hole measured on either the Inner Diameter (ID) or the Outer Diameter (OD)
as selected in the ID/OD description below.
X-Rotation - (This data is for both types of holes.) The X-angle is location of the center
of the hole around the pipe. Its definition is the same as axial angle.
Y-Distance -(This data is for both types of holes.) The Y-center is the location of the
center of the hole along the pipe. It is measured from the shortest point on the cut on end
36
1 or the initial position of the torch if end 1 is not cut. Distances measured towards the
second end of the pipe are negative.
Intersection Angle - (This data is entered for circular holes only.) It is the angle that is
made by an intersecting pipe that fit to the hole. An angle of 90 degrees will result in a
hole that will accept a pipe intersecting the Branch Member at a right angle.
Centerline Offset - (This data is also entered for circular holes only.) If the centerlines
of the Branch Member and the centerline of the hole do not intersect, there is a centerline
offset. A centerline offset that moves the hole towards the 90-degree side of the pipe is
positive.
Weld Prep (Weld Prep Angle) - (This data is entered for 5-axis circular holes only.)
When cutting holes on the 5-axis (MPM5), the edge may be beveled for welding. The
value specified will be added to the intersection angle to produce a constant bevel angle
around the hole. If the hole is beveled, the correct diameter will be on the surface
specified (ID or OD) with the bevel occurring towards the opposite surface. If the hole is
not beveled, both the inside and outside hole diameters will be the same.
When cutting holes on the 4-axis (MPM4) the input is labeled bevel angle and is the
angle the torch will be fixed at throughout the cut.
ID/OD When a hole is cut with a 4-axis (MPM4), it will have the correct diameter on
either the Inner Diameter (ID) or Outer Diameter (OD) of the pipe but not both.
Therefore, an ID hole is one which has the correct diameter on the ID of the pipe and is
beveled towards the outer diameter of the pipe. An OD hole has the correct diameter on
the outer diameter of the pipe and is beveled towards the inner diameter of the pipe.
(Note: These holes are sometimes refereed to as Saddle On or Saddle In.)
X-Length - (This data is entered for rectangular holes only.) The X-length is the length
of the sides of the square hole that are parallel to the X-axis. This length may be the
distance along a chord or arc, depending on the Rectangular Hole X Length setting in
Program Options. Chord length is measured in a straight line across the pipe and an arc
length is measured around the pipe.
Y-Length - (This data is entered for rectangular holes only.) The Y-length is the length
of the sides of the hole that are parallel to the centerline of the pipe.
Corner Radius - (This data is entered for rectangular holes only.) The Corner Radius
allows for inputting a radius in the corners of a rectangular hole to reduce or eliminate the
stresses of a sharp corner. The default is 0.0.
37
4.3.5
Programming End 2 (<F1>, <F4>)
To program the End 2 cut, the procedure described in <F2> End 1 above is repeated. The
same options are available. Note that it is not necessary to cut the first end of the pipe in
order to cut the second end.
4.3.1.1
Calculating a Pipe Machine Program (.PMP) (<F1>, <F7>)
The last step required before making a cut is to perform the calculations. Enter a <F7>
and the calculation sequence will begin. A message in the status line will appear to show
the progression. If there was an error during data entry that prevents completion of the
calculations, the sequence will stop and an error message will appear. Review the pipe
data and main menus and make the necessary corrections.
Once the calculations are complete the screen will automatically go the graphics screen
(reference section 4.5 Graphics (<5>). This screen will give a graphical representation of
finished piece of pipe. It is an excellent method of checking the inputs.
38
4.3.6
Listing and Editing a Pipe Machine Program (.PMP) (<F1>, <F5>)
After a Pipe Machine Program (.pmp) is programmed it may be listed and/or edited by
entering <F5> from the Program menu. A .pmp program that has been generated by
another offline computer may also be listed and/or edited by this method. The List/Edit
screen is shown below.
39
This will open the listing window, which shows input data in the .pmp file. Reference
Section 9 of this manual for a full explanation of the .pmp file format. The background
on list window is shaded to signify that the edit function is not enabled. The cursor keys
may be used to scroll through the listing. <F1> Start of File will move the cursor to the
beginning of the file. <F2> End of File will move the cursor to the end of the file.
To edit a .pmp file the editing function must be enabled which is password protected.
From the listing screen select <F8> Enable Edit and the following window will be
displayed.
40
Once the Level 2 password has been entered and the <Enter> key pressed the background
screen will turn white signifying .pmp editing has been enabled. The screen below
depicts an enabled .pmp editing screen.
41
The .pmp editing function is a very simple text editor with many of the same features as
Notepad. To close the listing window, hit <F10> or <Esc>. Once the editing window
has been closed it will be necessary to re-enter the Level 2 password to again enable .pmp
editing.
If the .pmp has been calculated the NC (Reference Section 10 NC Programming) will be
generated and can also be listed and edited by selecting <F6> List/Edit NC.
To close the listing window, hit <F10> or <Esc>.
42
4.3.7
Saving a Pipe Machine Program (.PMP) (<F1>, <F9>)
Before or after calculating, the .pmp program may be saved. Simply hit <F9> and the
program will be saved in the default directory under the File Name entered in the <F1>
Pipe Data.
After the calculation sequence is completed, select <F10> or <Esc> to return to the main
menu. The status "Ready" will be displayed on the status line at the top of the screen and
cutting may begin.
4.4
DATA OPTIONS
The previous section dealt with the basics of programming of a cut. There are several
options to this process which allow programs to be saved and retrieved from various
sources.
This section will deal with these options from the operators point of view, i.e. how to use
these functions. How they are implemented is discussed in the Section 9 Pipe Machine
Program (.pmp) File Format and External Programming and Section 10 NC
Programming.
4.4.1
Types of Data
The machine can use two forms of data: Pipe Machine Program Data, which has a file
extension of .PMP and NC Data, which has a file extension of .NC.
4.3.1.1
Pipe Machine Program Data (.PMP)
The Pipe Machine Data (.PMP) is the type of data generated from the programming of a
cut as described in the preceding section. This data defines the cut in terms of pipe sizes,
angles, etc. When the data entry is complete, the machine calculates the cut path that the
machine must follow.
The Pipe Machine Program (.PMP) data is saved when the <F9> Save PMP key was
hit in the programming window. It was stored in the directory specified in the Machine
Options window under the Utilities window. Reference Section 6 Utilities for further
explanation of setting the default directory. The PMP file is a simple text file with the
variables clearly defined. A typical example of a Pipe Machine Program (.PMP) file
format is in Appendix C.
43
4.4.1..1
Loading a Pipe Machine Program (.PMP) (<F2>)
Selecting <F2> Load PMP from the main menu (shown above) will display the open
file window (shown below) for the .PMP directory specified in the Machine Options.
44
Once the Open window, which lists all the stored programs, is displayed, hit <Tab> until
the first program is outlined. Now use the up/down arrow keys to highlight the desired
program and hit the <Enter> key. The program can also be loaded by typing the
program name in the File Name box and hitting <Enter>. The Pipe Machine Programs
(.PMP) stored in other directories or locations and be accessed by selecting the directory
in the Look In: box. For example, to load a file from the floppy disk (the A: drive), hit
the <Tab> key until the Look in: box is highlighted then use the up/down arrow keys to
highlight 3 Floppy (A: ) drive and hit <Enter>. A quick method of selecting a drive is
to type the first character of the drives name then hit the <Enter> key, i.e. 3 for 3
Floppy (A: )
45
4.4.1..2
Deleting a Pipe Machine Program (.PMP) (<F2>)
The preferred method of deleting programs is to delete a program from the Open
window above. As above, hit <Tab> until the first program is outlined. Now use the
up/down arrow keys to highlight the program to be deleted and press the <Delete> key.
The Confirm File Delete window will be displayed. Just hit the <Enter> key to delete
the selected file or use the < > key to highlight the No button and hit the <Enter> key
to cancel the delete function.
46
4.4.1..3
Batch Processing of Pipe Machine Programs (PMP ) (<F8>)
A batch of Pipe Machine Programs may be processed at one time by selecting <F8>
Batch on the Top Menu. If the Machine Option Create NC Files has been checked
(reference Section 6.2.1.6) the batch processing will create the NC files for all the
selected files. The cut sheet may also be printed for the processed files if desired.
Once Batch has been select the Open Window appears. This is the same Open Window
as the Load Program as described in 4.4.1.1.3 above and shown above. Use the Windows
standard key sequences of multiple files; 1) select a file then hold the <Shift> down and
select another file, the files between the two selected files are now select or 2) hold the
<Ctrl> key down and select the desired files randomly.
Once the selected files are highlighted, hit the "Open"
button. The screen shown to the right appears. Selecting
Yes will allow for both the NC files generated and the
Cut Sheets to be printed for all the selected files.
4.3.1.1
NC Data
NC data is data that is already calculated to produce the cut path. It consists of one line
of data for each move the machine must make. This type of data is either produced as
result of calculating the cut path from the Pipe Machine Program (.PMP) input variables
47
above or a NC program that was generated offline on another offline computer or a CAD
system output and brought to the Vernon machine for execution. Section 10 of this
manual is dedicated to NC programming and contains full explanation of NC format and
commands.
4.4.1..1
Loading an NC Program (.NC) (<F3>)
Selecting <F3> Load NC from the main menu (shown above) will display the open file
window for the .NC directory specified in the Program Options.
Once the Open window, which lists all the stored programs, is displayed, hit <Tab> until
the first program is outlined. Now use the up/down arrow keys to highlight the desired
program and hit the <Enter> key. The program can also be loaded by typing the
program name in the File Name box and hitting <Enter>. The NC Programs (.NC)
stored in other directories or locations and be accessed by selecting the directory in the
Look In: box. For example, to load a file from the floppy disk (the A: drive), hit the
<Tab> key until the Look in: box is highlighted then use the up/down arrow keys to
highlight 3 Floppy (A: ) drive and hit <Enter>. A quick method of selecting a drive is
to type the first character of the drives name then hit the <Enter> key, i.e. 3 for 3
Floppy (A: )
Once an NC file has been loaded the screen will automatically change to the List/Edit
screen shown in section 4.3.1.2.2 below.
48
4.3.1.2.2.
Listing and Editing an NC File (.NC)
The resultant NC file from programming and calculating a .pmp file may also be listed
and edited by selecting <F5> List/Edit on the program menu and then select <F6>
List/Edit NC on the edit/list menu.
The steps used to list and edit of a NC program are exactly the same as the listing and
editing a .pmp file. The listing window shows each step in the program in NC format,
shown below. Reference Section 10 of this manual for a full explanation of the NC
format and commands. While the program is running, the line numbers, prefixed with
N and followed by a 5 digit number, at the left correspond to the block number
displayed in the status area in the Block Num block. The background on list window is
shaded to signify that the edit function is not enabled. The cursor keys may be used to
scroll through the listing. <F1> Start of File will move the cursor to the beginning of
the NC file. <F2> End of File will move the cursor to the end of the NC file. To close
the listing window, hit <F10> or <Esc>.
49
4.3.1.2.3
Deleting an NC Program (.NC) (<F3>)
The preferred method of deleting programs is to delete a program from the Open
window above. As above, hit <Tab> until the first program is outlined. Now use the
up/down arrow keys to highlight the program to be deleted and press the <Delete> key.
The Confirm File Delete window will be displayed. Just hit the <Enter> key to delete
the selected file or use the < > key to highlight the No button and hit the <Enter> key
to cancel the delete function.
50
4.5
Graphics (<F5>)
Once a Pipe Machine Program (.PMP) has been generated and calculated the screen will
automatically switch to the graphics screen, shown below. The graphics screen may be
entered at any time by selecting <F5> from the Top Level Menu as long as the program
has been calculated.
51
The graphics screen is a true graphical representation of the finished piece from the
program inputs. The top third of the screen represents a 3 dimensional (3D) view of the
finished piece from the machine operators prespective. The 3D view can be rotated as
described below. The bottom two thirds of the screen is a 2 dimensional (2D) view,
which represents the pipe as if it had been split longitudinally and laid flat. Users of the
machine that have dealt with the old wrap around template method of cutting contours
will be familiar with this view. Thus the graphics display provides an excellent means for
checking the Pipe Machine Program (.PMP) data input.
The screen above represents a piece of 18 OD pipe with End 1 intersecting an 18 pipe
at 90 degrees, 2 round holes, 1 square hole with corner radii, and End 2 intersecting an
18 pipe at 45 degrees. The inputs for this screen can be verified by the Cut Sheet
described below. As mentioned the data used to create the graphics is exactly the same
as the data used to create the pipe machine cut path. There may be some distortion of the
graphics as it is extremely difficult to provide a readable graphical representation of a
finished piece of pipe when the range of diameters can be from 2 to 60 and the lengths
vary from inches to over 40 feet.
Several items have been added to the graphic screen to better identify features of the 2D
and 3D representations.
The 3D view has degree readings on both left and right side of the view. The degree
readings corrspond to the degrees around the pipe as the pipe is being cut with reference
to the operators view and position display on the operators console. In the view above,
the 0 degree or initial position at programming is at Top Dead Center (TDC), 270
52
degrees around the cut is facing the operator and 180 degrees at Bottom Dead Center
(BDC). If the pipe is rotated as described below, the degree readings will change
according to degrees of cut path at Top Dead Center, operators view, and Bottom Dead
Center.
Note: The 3D view degree readings and direction of rotation will change whether the XAxis Reversed box in the Machine Options is checked or not. This view represents
the view of the operator and position display on the operators console.
The 3D view includes end cut contour cutback dimensions and the overall finished
lengths based on shortest to shortest points and longest to longest point. The length
dimensions can be physically measured by the operator to provide verification and
quality control.
In the 3D view the contour lines of cuts that are on the side of the pipe facing the operator
have a red outline and the contour lines on the back side of the pipe from the operator
have a black outline. As the view is rotated the contour lines will change color
depending on which side of the pipe they are rotating to, red for operators side and black
for the back side of the pipe.
Both the 3D and 2D views have blue dots to present the cut start point for each contour
cut. The midsection cuts on the 3D view do not have a blue dot designating the cut start
point.
The 2D view also has degree readings on both left and right side of the view. These
readings represent the degrees around the pipe as the cuts progress and the location of the
midsection cuts as they were programed. To observe a simple clarification of this
feature, first program a midsection cut with X-Rotation of 90 degrees and view the
graphics. Then re-program the same cut with X-Rotation of 270 degrees and view the
graphics. The same clarification can be made for End cuts by programming an axial
angle of 90 degrees and then re-programming the same cut with an axial angle of 270
degrees.
In the 2D view there is a measurement which is the length between the End 1 cut and the
End 2 cut at Top Dead Center(TDC). In other words, this is the length of the finished cut
at X-axis equals 0 degrees at the beginning or end of the program.
Note: The 2D view will not change whether the X-Axis Reversed box in the Machine
Options is checked or not. This view is based on the programmers inputs while
creating the .PMP program.
In the 2D view the midsection cuts are numbered in the order that they were programmed
in generating the .pmp program.
The brief discussion of the special function <F> keys follows.
4.5.1
Rotate +15 <F1>

This key allows 15 degree rotation of the 3D view in the plus direction. The plus
direction is determined by whether or not the X-axis Reversed option is
checked under the Machine Options window.
53
4.5.2
Rotate 15 <F2>
This key allows 15 degree rotation of the 3D view in the minus direction. The
minus direction is determined by whether or not the X-axis Reversed option is
checked under the Machine Options window.
4.5.3
Roll <F3>
This key continually rotates the 3D view in the plus direction. The plus direction
is determined by whether or not the X-axis Reversed option is checked under
the Machine Options window. When this key is selected a second time the
rotation will stop.
4.5.4
Return to Zero <F4>

This key returns the 3D view program start (0 degrees) to Top Dead Center after
the view has been rotated off of Top Dead Center either by the rotate keys or roll
key. If the 3D view is in the roll mode and the Return to Zero is selected the veiw
will return to program start but then continue to roll in the plus direction.
Selecting the Roll function a second time will stop the roll.
4.5.5
Full Screen <F5>

This key switches the graphics view to full screen. Selecting this key a second
time returns the screen to the normal view.
4.5.6
Info ,F6>
This key displays a dialog box that will list various information about the
calculated pipe machine program. Currently the information includes the weld
length, weld volume for each end and the total for the piece and the total time to
cut the pipe. The weld length is the sum of the blocks of the contour of each end
cut. The weld volume is sum of the intergral area formed by the dihedral angle
and weld prep bevel at block . The total weld length and volume is the sum of
both end cuts. The cut time is based on the length of the linear length of the
contour cuts and the part program calculated feedrate. The feedrate is based on
the feedrate table and effective wall thickness. The time is based on a 100%
feedrate setting on the feedrate override potentiometer on the operators console.
Note: The lengths, volumes and times are based on the theoretically ideal
conditions and can vary dramaticall depending on operator, torch type, torch
settings, and machine settings. This information is for reference only.
This is information will also be printed on the Cut Sheet described below.
4.5.7
Print Cut Sheet <F7>

This key prints a Vernon Tool WinMPM Cut Sheet to the default printer. The
default printer is the printer that has been set as the default printer under the
Windows operation system. The cut sheet contains all the inputs used to generate
the pipe machine program (.pmp) and includes the graphics view. The cut sheet is
an extremely helpful tool for the operator to review the inputs and finished piece
prior to cutting the piece. Some Vernon customers use the cut sheet for quality
control (QC) verification for their clients. The cut sheet can also be used for
verifing the dimensions for the finished piece.
54
The cut sheet can be customized to suit the customers specific requirements or
desires.
4.3.1.1
Customizing Title Banner on Page 1

There is an area at the top of page 1for a customized banner that can include a
company logo, pictures, text, etc. What ever can be produced and saved as a
CutSheet Banner.gif or Cutsheet Banner.wmf file format can be display in the
banner area. The Cutsheet Banner file must reside in the Help subdirectory
under the WinMPM directory. In the cutsheet example below the Vernon logo,
address, Inspected by:, Date:, and Status: were created and stored in the
Cutsheet Banner.gif file.
4.3.1.1
Customizing Data Blocks
There are four data blocks which can be customized for data that
they customer wants to print out on the cutsheet. This data will
appear on the Pipe Data Input screen when programming a cut and
will appear in the .pmp program file. The four data blocks are the
four that appear under the Cutting Method: input block in the F1
Pipe Data. In the example to the right the four data blocks are
Part Number:, Specification:, Material:, and Quantity.
The labels for these four data block can be changed to suit the
customers needs but are limited to 15 characters. The label names
reside in the file Labels.txt found in the Help subdirectory under
the WinMPM directory. The Labels.txt is a text file and can be
edited with a simple text editor program. Below is a listing of the
Label.txt file.
; IMPORTANT: This file MUST be located in
WinMPM's "Help" subdirectory.
; Default labels are "Part Number",
"Specification", "Material", and
"Quantity".
; Label names must be unique and lengths
must not exceed fifteen characters.
[Last Four Pipe Data Labels]
Part Number
Specification
Material
Quantity
55
56
CUTTING
The first part of this chapter will deal with the steps in making a cut. The second part
deals with options that are available to the operator to make the cutting job easier.
5.1
MAKING THE CUT
Prior to making the cut, the program must be entered and calculated. Once this is done,
you are ready to begin the cutting by performing the following steps and Ready will be
displayed in the Status block of the display screen.
5.1.1
Position the pipe and torch
The pipe should be positioned on the machine taking into account the location of the cuts
to be made. Usually, the first end to be cut is positioned over an area where the waste
piece can freely drop and be disposed of. There is less control over the second end since
it is located relative to the first end. The torch should be placed over the longest point on
the cut on the first end. This ensures that there is enough pipe positioned in front of the
torch to make the cut. If there will not be a cut on the first end of the pipe, then position
the torch to the longest point on the second end. (Note: if a "Distance between Cuts" has
been entered, then the torch will move this distance before starting to cut the second end).
Be sure that the sensors have been selected and the contour torch has been set to the
"AUTO" position.
Home the C-, Z- and A-Axis. (A-axis is on 5-axis MPM only)
5.1.2
Press the "CYCLE START" pushbutton
This will cause the following things to happen:

1.
The Status Line on the display will change to "Program Running".
2.
The position registers will preset to their starting values.
3.
The sensors will come on and the vertical carriage will lower the torch to
the proper cutting height.
4.
If the first cut being made is on the second end of the pipe, the torch will
travel to the longest point of that cut.
Note: At this time the torch will be located over the longest point in the cut. By making
note of these positions, the operator has a convenient check on the length of the cut.
At this time, it is a good idea to adjust the height of the torch above the pipe using the Z
OFFSET button and handwheel.
5.1.3
Press the "CYCLE START" pushbutton again
The torch will move to its blow through position, lay over to the initial pierce angle
(usually 30 degrees) and stop. If required by the cut, the pipe will also rotate and/or the
torch will move to an offset position. If oxy/fuel cutting is being used, the pre-heat
oxygen, fuel and spark will come on, igniting the gas (the spark will shut off after
57
approximately 1 second). If plasma cutting is being used, the plasma gas will start and
the pilot arc will spark.
5.1.4
When the pipe is sufficiently pre-heated (or, in the case of plasma, the main arc has
started and pierced the wall), press the "CYCLE START" pushbutton again and the cut
will start.
While the cut is progressing, the status line will indicate "Program Running" and the
progress of the cut may be monitored at the top of the screen. The "Present Pos:" line on
the screen shows the present position and the "Next Pos" line shows the calculated
position at the start of the next calculated block. The feedrate may be adjusted to achieve
the best-cut quality.
It is not necessary to monitor the machine and it may be run "Hands Off" once the
feedrate has been set.
4.3.1.1
Automatic Torch Shut off
When the cut is completed, the cutting torch will shut off and the machine will stop to let
the operator get the waste piece out of the way.
5.1.5
The next operation depends on the program. If the other end or any holes remain to be
cut, the torch will move to the next cut and steps 5.1.3 through 5.1.4 above would be
repeated.
If all of the cuts have been finished, the machine will return to the start of the cut
program. Another piece of pipe can be loaded and the above procedure repeated to make
another cut.
5.2
CUTTING OPTIONS
The operator has many options available to

him while he is cutting. These options are
discussed below.
5.2.1
SINGLE STEP.
Pressing the "SINGLE STEP" pushbutton

puts the pipe machine into the single step
mode. Pressing the "CYCLE START" pushbutton while in this mode causes the machine
to execute only one block of data and then stop. If the machine is operating, pressing the
"SINGLE STEP" pushbutton causes the machine to finish executing the current block
and then stop. This function may be used to slowly step the machine through a cut so
that the position of the torch can be monitored to check a cut
The "SINGLE STEP" pushbutton is modal; pressing it a second time will extinguish the
lamp and, when the "CYCLE START" pushbutton is activated, motion will begin and
58
continue from the next block in sequence as in normal operation.

5.2.2
RETRACE
To enter this mode, first push the RETRACE pushbutton and wait for the machine
motion to stop. Then, push the CYCLE START pushbutton and the machine motion
will run backwards. (Note: Do not use the RETRACE function to move through the
start sequence or into the previous cut. Use the RETRUN TO ZERO function for
stepping back to start of previous cuts.) To retrace the program a single step at a time,
press SINGLE STEP pushbutton then CYCLE START PUSHBUTTON to execute a
block at a time. The RETRACE function is very useful for retracing the program when
the cut has been lost due to too high of a feedrate for the cutting process.
To exit the RETRACE function, press the RETRACE pushbutton again.
5.2.3
DRY RUN
The Dry Run mode may be entered any time by depressing the "DRY RUN" pushbutton.
This causes all moves to be executed at approximately twice the programmed feedrate.
Turning the pushbutton off returns the feedrate to the programmed feedrate. This is
useful for testing programs that have a very low-programmed feedrate.
5.2.4
RETURN TO CUT START
When the RETURN TO ZERO pushbutton is activated, the machine returns to the start
of current cut. If it is already at the start of the current cut, it moves to the start of the
previous cut if there is one. The path followed during the return will be the shortest
direct path, not the calculated path. Further activation of this pushbutton after the
machine is at program start position will be disregarded and will result in no motion.
5.2.5
ABORT
The abort pushbutton causes the current program to be aborted and re-loaded from the
beginning. It can be activated at any time. Activating this pushbutton also causes the
Present Position display to reset to all zeros. Once the pushbutton has been activated, the
cut must be setup and started from the beginning. It is not necessary to re-enter the data
or recalculate. If there was no program entered, its only effect will be to zero the position
displays.
5.2.6
FEED HOLD
This pushbutton, when pressed once, will light and immediately cause all axes motion to
come to a stop at whatever position they are in. This will not necessarily be at the end of
a block. Depressing "FEED HOLD" a second time causes motion to resume as
programmed and the lamp to extinguish.
On the 5 axes machines (MPM5) there is a collision switch mounted on the Z axis
assembly. When the 5 axes head brought down and the torch makes contact with the
pipe, the torch is pushed out of the torch holder and the collision switch is opened. The
signal back to the I/O controller is lost and all axes including the vertical carriage are
stopped, the FEED HOLD actuated and the FEED HOLD light will be lit. To correct
this situation the vertical carriage must be raised, the torch re-seated in the torch holder,
59
and the FEED HOLD pushed to deactivate the feed hold condition.
5.2.7
FEEDRATE SLIDER
The feedrate slider, which acts as a potentiometer, allows the operator to

override the programmed feedrate from 0% to 100% of its programmed
value. (The feedrate may be turned to 0 to temporarily halt motion while
cutting, if desired). Although the computer calculates the optimum
feedrate for each block of the cut, it cannot take into account the actual
condition of the pipe being cut, such as rusty or clean surface, cold soaked
or hot, etc. Cuts usually can be made at the same setting, once it is
initially set.
60
6 UTILITIES (<F6>)
When <F6> is pressed from the main menu screen the screen above appears. From this
screen several option tables can be accessed. Since changing the various parameters in
the tables can have drastic consequences on the program and machine functions several
of the tables are password protected. There are different levels of password protection of
the different option tables depending on that option tables affect on the machine
function.
6.1 PROGRAM OPTIONS (<F6>, <F1>)

Program options are settings that affect how the WinMPM
program operates. They are accessed by a Level 1 password.
The following options may be set from this screen. After
changing any of the options click on OK and the changes are
now permanent and saved as the default values.
6.1.1
Units
The data that is entered into the machine can be entered in

English (inch) or metric (mm) units. Note that if this option is
set for one type of unit in the machine but the offline computer
61
used to generate the Pipe Machine Program (.PMP) was set in the other type of unit, a
warning will be displayed that units are not equal. The option must be changed before
the .pmp can be read in and calculated.
The units can be changed by pressing the <Tab> key until the box is highlighted then use
the arrow keys to select either English (inch) or Metric (mm).
6.1.2
Offset:
There are two methods of defining the intersection point of a multiple intersection end
cut. One is through the use of baseline offset and the other is workpoint offset. One
method or the other has to be select so the programmer/operator knows which data
variable to enter. Also, the operating system, WinMPM, needs to know which variable
is used so the calculations are performed correctly. The definitions and descriptions for
baseline offset and workpoint offset can be found in section 4.2.2.1 above.
The offset method of calculation can be changed by pressing the <Tab> key until the box
is highlighted then use the arrow keys to select either Baseline or Workpoint.
6.1.3
Hole Dihedral Limit
In some cases, especially size-on-size holes and top flush offset holes, the torch will
attempt to cut tangent to the inside wall of the pipe. Although this is the mathematically
correct profile, it sometimes produces a poor quality cut. Many fabricators would rather
have a small amount of bevel in this area. By setting the Hole Dihedral Limit, the
dihedral angle will be prevented from reaching 180 degrees and a small amount of bevel
will remain. A value of 10 to 15 degrees is usually sufficient.
6.1.4
Transition Cut Auto Select
When this option is checked it allows for the automatic selection of a transition cut type
when the intersection angle of the intersecting main member is equal to or less than the
angle set in Auto Select Intersection Angle option. See 6.1.5 below.
If this option is un-checked then the transition cut type must be manually selected cut
type list for each end.
Note: A warning box will appear during calculations when a saddle is automatically
changed to a transition type cut a warning box will appear on the screen. Once Ok is
clicked the box disappears and calculations continue. Also the note Program Options
setting for Auto-transition has changed a saddle cut to a transition cut. appears in the
upper right section of the printed cut sheet.
6.1.5
Auto Select Intersection Angle
If the Transition Cut Auto Select check box is check (see 6.1.4 above) and the
intersection angle between the pipe and the main is equal to or less than the angle entered
in this option then a saddle cut type will be automatically calculated as an AWS ID/OD
transition cut type and the PMP file changed appropriately.
6.1.6
Transition Start Angle

62
The transition start angle is the dihedral angle of intersection between the two pipes
where a transition cut will start to transition from the inside diameter to the outside
diameter. A typical value is 40 degrees.
6.1.7 Transition Zone:
This parameter is for setting the transition zone in a transition cut. It is the distance in
dihedral degrees from where the transition starts on the inside diameter to where it
finishes on the outside diameter. A typical value is 10 degrees.
Note: If programming transition cuts and change the Start Transition or Transition Zone,
one MUST select <F6> New PMP when programming the cut. Other than manually
editing the .PMP file, this is the only way the change will take effect. If loading a PMP,
the transition values for that PMP will be used for all cuts until one selects <F6> New
PMP. This is because the transition variables are Program Options that take priority.
6.1.8
Transition Backbevel
Transition back bevel is only used on Transition cuts. When a transition cut is made, the
area in the throat makes contact with the Main Member at the OD of the Branch instead
of the ID as in a normal cut. This leaves a weld prep angle on the INSIDE of the pipe
and in some cases it is desirable to vary it. If No is selected, the torch will remain
vertical while the transition area is cut and the bevel will be fixed. In most cases this is
used. If a particular weld prep is desired on the inside of the pipe (for instance to put a
backup weld on the inside), Yes may be selected.
Note: The setting in this Program Option is the used as the default setting for doing
batch calculations.
6.1.9
Transition Backbevel Angle
If Yes is selected for the Transition Back Bevel entry above, this specifies the weld
prep angle on the inside of the pipe.
Note: The setting in this Program Option is the used as the default setting for the
Backbevel Angle when doing for batch calculations.
6.1.10 Rectangular Hole X Length
There are two methods of defining the X-axis length of a
rectangular hole.
First is the Chord length which is actual width of the
rectangular hole opening in the pipe. In other words if one
wanted to pass a piece of bar stock or plate through the hole
the chord length should be use. The maximum valve for the
chord length is less than the inner diameter of the pipe being
cut. If the chord length is greater than the ID an error will be
generated and displayed.
The second method of specifying the X-axis length is by Arc length. The arc length is the
X-axis length along the circumference of the pipe. . The arc length has no maximum.
63
6.2 MACHINE OPTIONS (<F6>, <F2>)

Machine options affect how the machine operates. Some can affect accuracy or the final
contour of the cut. Machine options are machine particular and will override any
machine options contained in .pmp program file. A Level 1 password is required to
access the Machine Options windows. Some machine options require a password higher
than Level 1 to change. The dimensional values in the machine options are in the units,
either English (inch) or Metric (mm), of measure selected in the Program Options
window under Units:. There are two windows that will appear under the Machine
Options menu.
6.2.1
4.3.1.1
Machine Options First Window

Machine Type:
The Machine Type option takes a Level 3 password to

change. The machine type should always be set to
MPM Microprocessor Pipe Machine.
4.3.1.1
Number of axis:
This is set to the number of axis on the machine. This parameter is set at the factory and
should not be changed. There may be very special circumstances when a customer may
want to run a 5-axis machine as a 4 axis. It is impossible to run a 4-axis machine as a 5axis machine. The number of axes for a machine can be found on the machines
name/data plate, MPM5 = 5 axes, MPM4 = 4 axes, MPM2 = 2 axes.
4.3.1.1
Plasma Type
The plasma type is set according to the plasma manufacturer to start and stop the torch
correctly. H = Hypertherm, T = Thermodynamics, L = Esab.
4.3.1.1
X-axis Reversed
This parameter is to set the direction of rotation of the pipe in all data input modes and
graphic displays to correspond to the pipe direction of rotation on the Vernon pipe
machine. The X-axis Reversed box is either checked or unchecked. This parameter is
set at the factory and normally should not be changed. However, during the installation
of the machine the customer may want to reverse the rotation of machine. The changing
of the rotation of the machine should only be done by the on-site Vernon installation
engineer. The best method to change the WinMPM program pipe rotation to
correspond to the machine rotation is to manually jog the machine in the plus direction
and note the direction from the operators perspective. Now generate a pipe machine
program (.pmp) and calculate the program. When the graphics view automatically
appears, select Roll <F3> and note the direction of rotation. Both the machine rotation
from the operators perspective and the graphics view rotation should be the same. If the
rotations are not the same then either check or uncheck the box by using the pointing
device or <Tab> to X-axis Reversed and hit the <Space> to toggle between checked
and unchecked.
64
4.3.1.1
Curve smoothing:
In some instance of very acute intersection angles on saddles, the change in the angle of
bevel (C-axis movement) can be very abrupt. Although calculations and torch movement
are correct, the appearance of the cut is not what is desired. The curve smoothing option
reduces the weld prep angle at the maximum dihedral angle. The reduction is an arbitrary
amount and is useful on some cuts on heavy walled pipe. When the Curve smoothing:
box is checked the curve smoothing will take place.
The box may checked or unchecked by using the pointing device or <Tab> to Curve
smoothing and hit the <Space> to toggle
4.3.1.1
Create NC files:
This box is for use in the Desktop mode only. When checked the NC data files will be
created and placed in the NC directory. Under normal operation this will be unchecked
so that the NC files are not created, thus saving disk space by not creating and saving
large unused files. It may be useful to generate NC files so they can may be easily edited
to create a special motion program.
The box may checked or unchecked by using the pointing device or <Tab> to Create NC
files: and hit the <Space> to toggle between checked and unchecked.
4.3.1.1
First cut left:
This setting is used to make the graphics display conform to the actual layout of the
machine. If, when cutting both ends of the pipe, the End 1 that is cut is to the operators
left, check the box. If not, the box should be left blank. In most cases this will be
correctly set at the factory and does not need to be changed.
The box may checked or unchecked by using the pointing device or <Tab> to First cut
left and hit the <Space> to toggle between checked and unchecked.
between checked and unchecked.
4.3.1.1
Auto Run
If the Auto Run option is checked it will allow an entire pipe machine program (.pmp)
to be run with Cycle Start switch only being pushed one time at the beginning of the
program. The machine will cut End1, any Mid section cuts, and End2 then stop. This
feature is only operational in the plasma cutting mode and requires special electronics to
be installed in the machine to accept the Machine Motion command from the plasma
unit. Consult the factory before ever turning on this option for the first time.
4.3.1.1
Return to Zero
With this block checked the pipe will return to the zero degree line (top-dead-center) after
cutting each Midsection cut. This is useful if it is extremely critical to have all
midsection cuts be positions in degrees around the pipe base off the top-dead center
from where the program is started. If this block is un-checked the machine will travel to
the next midsection cut without stopping on top-dead-center.
65
4.3.1.1
NC directory:
The NC directory is the default setting for the path and location of the NC storage in the
computer. It may be changed to point to another location such as the floppy disk or a
network drive. In general this option should never be changed from the factory setting.
The data directory can be changed by pressing <Tab> key until the box is highlighted
then enter the desired path and location.
4.3.1.1
PMP directory:
The PMP directory is the default setting for the path and location of the Pipe Machine
Program (.pmp) storage in the computer. It may be changed to point to another location
such as the floppy disk or a network drive. In general this option should never be
changed from the factory setting.
The data directory can be changed by pressing <Tab> key until the box is highlighted
then enter the desired path and location.
4.3.1.1
Feedrate Table:
The feedrate block displays the feedrate table being used in the calculation of the cut. It
is possible to create different feedrate tables to use on the machine. The default feedrate
table shipped with the machine was based on both the torch suppliers recommendation
and Vernon Tool Companys practical experience. Another feedrate table may be
desirable when a different cutting medium is used or different pipe material is being cut.
To change feedrate tables or create new ones, see New Feedrate Table, below.
6.2.1..1
New Feedrate Table
When a program is calculated, a table is used to determine

how fast the cutting torch should travel for the thickness of
pipe it is penetrating (which changes with the C-axis). Two
feedrate tables, INCHFEED and MMFEED for inch and
metric units respectively, are furnished with the machine. The
table used is entered into the Program Options as described
above.
Note that the feedrate table is only used for programs
calculated at the machine. For NC files that are downloaded
to the machine, the feedrate table in the original application is
the one that determines the feedrate.
0.00
0.12
0.25
0.37
0.50
0.75
1.00
1.50
2.00
2.50
3.00
4.00
5.00
6.00
8.00
10.0
12.0
99.9
99.9
45.0
42.7
39.0
33.0
28.5
25.5
22.5
20.7
17.2
15.7
9.90
8.00
7.00
5.50
4.50
4.00
3.00
99.9
99.9
99.9
99.9
80.0
70.0
60.0
50.0
40.0
30.0
20.0
10.0
1.00
1.00
1.00
1.00
1.00
1.00
Default Feedrate Table
To add a new feedrate table, first you need to create it and then you need to load it.
6.2.1..2
Creating a Feedrate Table
The feedrate table is created using a text editor such as Windows Notepad. Do not use a
word processor, as this will insert formatting characters in addition to the characters you
type.
66
The table is made up of three columns of 18 rows. Each column must be separated by at
least one space. The first column is the thickness for that entry. The next column is the
corresponding feedrate for a gas torch and the last column is the corresponding feedrate
for a plasma torch. The table must have exactly 18 entries.
When saving the table, give it a name of 32 characters or less with a suffix of .TBL.
For instance, the default feedrate table is: FEEDRATE.TBL.
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6.2.2
Loading the Feedrate Table (<F6>, <F7>)
To load the table you have created in the

step above, put it on a floppy disk and
insert the disk into the drive. Open the
Utilities menu by pressing the <F6> key
and select <F7>. Use the <Tab> key until
the first file is outlined then use the arrow
keys to highlight the desired feedrate table.
To select this new table for use, open
Program Options, (F6, F1), and enter the
name of the table.
To select another feedrate table press the
<Tab> key until the small box next to feedrate block is highlighted then press <Enter>
and an open window will appear for selecting the feedrate table.
6.2.3
Machine Options Second Window
These options specifically relate to the gas and plasma

torches physical characteristics and limitations on
functions of the machine.
4.3.1.1
Gas Torch and Plasma Torch

Groupings
The parameters under the Gas Torch (Oxy/fuel torch)

and Plasma Torch are used in the calculation of cut
path. Which set of parameters is used in the calculation
is determined by the cutting method selected in the
Cutting Method: block in the F1 Pipe Data in the programming window (<F1>).
The values in these groupings can be changed by pressing <Tab> key until the box is
highlighted then enter the desired value in the proper units.
6.2.3..1
Height:
The torch height is the clearance between the torch tip and the pipe at the beginning of
the cut when the C-axis angle is 0 degrees. It is used by the Z-axis to determine torch
standoff distance. There are separate values for gas and plasma torches. A typical value
is 0.25 inch (6mm).
6.2.3..2
Width:
The width of the bottom of the torch tip. It is used by the Z-axis to determine torch
standoff distance. There are separate values for gas and plasma torches.
6.2.3..3
Kerf:
The kerf is the amount of material that is cut away by the torch. If a straight line is cut
68
with a torch, the width of that line is the kerf. This loss of material is significant and
must be accounted for by the computer in its calculations. The width of the kerf will vary
depending on the type of cutting gas, type of torch, pressures, speeds, material, etc. To
determine the kerf, see the section on setting the kerf. There are separate settings for
plasma and gas torches. Typical values are 0.1 inch (2.5mm).
6.2.3..4
Max Angle:
The torch angle constantly changes in order to maintain a constant weld prep angle.
However, if the torch angle increases past a certain point, the torch will hit the pipe. This
angle will vary with the type of torch, so there are separate settings for a gas torch and
plasma torch. Typical values are 68 degrees for gas torches and 55 degrees for plasma
torches.
4.3.1.1
Torch Clearance:
The torch clearance is the minimum distance that is allowed between the torch and the
pipe at any C-axis angle. It is used by the Z-axis to determine torch standoff distance. A
typical value is 0.1 inch (2.5mm).
4.3.1.1
Min Torch Angle:
The minimum torch angle is the amount that the C-axis can rotate in the negative
direction. It is usually limited by the cut quality that is achieved when cutting back into
the work piece. A typical value is 15 degrees.
4.3.1.1
Weld Prep Angle:
The weld prep (preparation) angle is the angle between the two pieces of pipe produced
by the torch bevel angle (C-axis). The value that is set here is the default (usual) value
that is used. The weld prep angle may be changed on individual cuts by changing the
Weld Prep Angle values in the various data input screens. Typical values are 37.5
degrees and 30 degrees.
4.3.1.1
Torch Leadin:
Usually it is not desirable to pierce the pipe on the cut line because it produces a flaw on
the surface of the cut. Instead, the torch pierces the pipe a short distance into the waste
piece and moves onto the cut path at cutting speed. The distance may be set to zero to
reduce waste on end cuts. A typical value is 0.5 inch (12mm).
4.3.1.1
Torch Leadout:
Sometimes when plasma cutting pipe with a large wall, a dimple will occur at the cut
start/stop point. This is due to plasma cutting stopping exactly at the start point therefore
there may not be any metal directly under the torch to conduct the current. The plasma
arc will pass to the nearest metal, which is the previous cut surface. The leadout
parameter is amount of displacement, in units selected, off of the start/stop point into the
waste. This parameter can be varied to eliminate the dimple and it is even possible to
create a bump at the cut start/stop point.
69
4.3.1.1
Blow Thru Angle:
When the torch pierces the pipe, it is usually desired to have it leaning over at an angle to
the pipe so that slag does not blow up onto the tip. Typical values are 15 or 30 degrees.
4.3.1.1
VC Up Time Limit
This option sets the time limit, in seconds, that the Vertical Carriage will travel up at the
end of any cut including End 1, any Mid section cuts, and End 2. Increasing the time
limit will increase the clearance distance between the torch tip and pipe at the end of the
cut when the sensors are disabled by the program.
6.3 Axis Scaling (<F6>, <F3>)

Axis scaling parameters affect the scaling of various axes.
Axis scaling is a procedure to set the number of encoder
counts to a desired distance moved by the selected axis. The
correct scale factors were set up at the factory prior to
shipment of the equipment. Any change will affect the
accuracy of the cutting process and are protected by a level 2
password. The changes are permanent. Then to perform this
procedure, just follow the prompts on the screen. Further
explanation follows:
1. Enter the letter of the axis or use the arrow keys to select axis to be scaled.
2. Press the abort key so that the axis position reads 0.00.
3. Jog the axis for a known distance and enter that distance into the Actual
distance: block. The distance must be entered in the units selected in the
Units: block under Program Options, either English (inch) or Metric (mm).
4. Press <Enter> or <Tab> to the Calculate box and press <Enter>. If the
procedure is to be aborted press the <Esc> key.
5. The screen will then display the current scale factor for
that axis and a suggested scale factor to make that axis
scale correctly.
6. The suggested scale factor will appear in the New scale
factor: block. A scale factor other than the suggested can
be entered.
7. To accept the value and save it, hit <Enter>. To leave the
process without making a change, hit <Esc>.
70
6.4 Handwheel (<F6>, <F4>)

The handwheel scale factor determines how the
handwheel reacts when it is rotated. When this function
is selected, the current handwheel scale factors for each
axis are displayed. To change a factor, press <Tab>
until the desired axis is highlighted then enter the new
value and press <Enter>. The new factor is active and
may be checked while the Handwheel Scale Factors
window is still displayed.
6.5 Home Offsets (<F6>, <F5>)

The Home Offset screen is used to enter the distance and
direction that the axis moves after it encounters the home
pushbutton. Only the Y-, C-, Z- and A-axis have home
pushbuttons. To make a change, just enter the new
value. As soon as the new value is entered, it is active
and may be checked by pushing the appropriate home
pushbutton.
6.6 Diameter Check (<F6>, <F6>)

Diameter checking is used to temporarily adjust the X-axis
scale factor for variations in the nominal diameter of the pipe.
The change in the scale factor is made so that the pipe rotates
360 degrees with no over- or under-travel. This feature is
normally only used when very large fabricated pipe is being
cut. In these case it will compensate for out of tolerance pipe
and greatly increase the accuracy of the cut.
To use diameter checking, follow the prompts on the screen. Further description of the
process is as follows:
1. Press the abort key so that axis position reads 0.00.
2. Enter the pipe diameter that was used in the Pipe Data
of the program.
3. Rotate the pipe one complete revolution.
4. When the above steps are complete, press <Enter>.
5. The screen will then display the current X-axis scale
factor and suggest the correct scale factor for the current
piece of pipe.
6. The suggested scale factor will appear in the New scale
71
factor: block. A scale factor other than the suggested can be entered.
7. To accept the value and save it, hit <Enter>. To leave the process without making
a change, hit <Esc>.
Note that the changes made by diameter checking are held as long as power is applied
and will be reset to the default value the next time power is cycled.
6.7 CAD Files (<F6>, <F7>)

This option can load certain output files from third party modeling or CAD programs and
convert them to WinMPM .pmp files that can then be loaded and calculated by
WinMPM. Consult the factory concerning this option as new conversion programs are
being developed and instructions are particular to the modeling or CAD programs being
used.
6.8 PASSWORDS (<F6>, <F8>)

This option is used to change the change the passwords in
level 1 through 3. Passwords are not case sensitive. To use
this option, the Level 3 password must be entered when
prompted. Next the window to the right is displayed. The
passwords shown in the window to the right are the default
passwords as shipped from the factory. Use the <Tab> key
to highlight box next to the level to be changed. Enter the
new password and press the <Enter> key.
If you press <ENTER> on an empty field or close the window without entering a
password in each field, then the passwords for the empty fields will revert back to their
original password.
72
MAINTENANCE (<F7>)
Enter the Maintenance window by press the <F7> key from the main menu. Maintenance
functions are used to test, determine status and make adjustments to the machine. Some
of these functions are quite detailed and are only used by factory service personnel or
under their supervision.
73
7.1 Error Log (F7>, <F1>)

A log is kept of all the errors that have occurred and can be viewed by selecting <F1>
while in the maintenance window. The error log resides in the WinMPM directory and
the file is named ErrorLog.txt. It is a text file.
The log lists the date and time the error occurred, type of error, error code number and
description of the error. A complete listing of error code numbers can be found in
Appendix B.
74
7.2 I-VARIABLES (<F7>, <F3>)

I-variables are settings that control how the motion control system behaves. They may be
viewed at any time, but they should only be changed under the supervision of factory
personnel.
WARNING: MAKING ARBITRARY CHANGES TO THESE VARIABLES
COULD RENDER THE MACHINE UNUSABLE, CAUSE PHYSICAL DAMAGE
TO IT OR POSSIBLY CAUSE BODILY INJURY.
When selected, the parameters are listed on the screen with a brief definition. You may
scroll through the file using the mouse or keyboard keys. The <F1> and <F2> keys may
be used to jump to the start or end of the file.
To edit the file, please contact the factory for assistance.
7.3 TERMINAL (<F7>,<F4>)
The terminal is used for direct communications with the motion control system. It can be
used to monitor certain system variables or to issue direct commands. It is intended for
use by factory personnel only; if it is necessary to use it in the field, the factory should be
contacted for guidance.
75
7.4 UPGRADE (<F7>, <F6>)

From time to time, Vernon Tool may furnish upgrades to the software that operates the
machine. The upgrade feature allows easy installation of the new software and also
allows re-installation of an older, archived version if desired. This feature is password
Level 3 protected.
If installing a new version, put it on a floppy disk and
insert it into the drive before selecting the upgrade
feature. Then, after selecting the feature, a window
will appear showing the versions of each of the
software types that are installed on the machine. If
upgrading, the new version will appear already
selected; if not, select the version that you wish to
install and then select Change Version to continue.
A green banner will appear, instructing you to close
down the program to complete the installation (it will
not be necessary to restart the machine). Close the
program by selecting File, Exit. Then, when the
program closes, wait at least 15 seconds and then
restart it. Check the version listed on the main screen
to confirm that the new version has been installed.
7.5 BACKUP (<F7>, <F7>)

There are two files on every machine that are unique to that machine; they contain the
personality of the machine. These files should be backed up to a floppy disk any time
there is a change to any of the items listed under the Utility Menu (<F6>), including:
I parameters
Program Options
Machine Options
Axis scaling
Handwheel scaling
Home Offsets
Passwords
To perform the backup, you will need to insert a blank diskette into the disk drive (the
program will prompt you to do this) and then hit the OK button to continue. A red
highlighted message will appear on the screen: copying files to diskette please wait,
followed by a green highlighted message: Backup complete. Remove the diskette and
store it in a safe place away from the machine (magnetic fields in the machine could erase
it).
7.6 RESTORE (<F7>, <F8>)

If it should be necessary to restore any of the items listed above, just insert the backup
diskette into the drive and select F8. Restore. The files will then be copied into the
machine.
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77
8 HOW THE MACHINE WORKS

The intent of this section is to provide a simple explanation of how the machine works to
help the operators and maintenance personnel get the most out of the machine.
8.1 THE OPERATORS CONSOLE

From the operators point of view, the console consists of three things: the display, the
keyboard and the controls. The display and keyboard are basically the same as on any
computer except that a special driver is used because of the cable length.
All of the operator controls are handled by a touchscreen interface on the display. It is
linked to the computer in the power box via the extender/sharer module and cable.
8.2 THE POWER BOX

8.2.1
The Computer
The computer handles all of the program information to and from the console. It
performs calculations on the data and then sends cutting path information to the motion
controller.
8.2.2
The I/O Controller
The I/O controller in the power box receives information from the operators console
about which controls the operator is using and sends that information to either the motion
controller or computer. It also receives information from another I/O Controller located
on the Y-axis carriage out on the machine bed that controls cutting and pipe handling.
8.2.3
The Motion Controller
The motion controller is the heart of the system. It takes the cutting path information
from the computer and generates a voltage that tells the servo drives how to move the
axis motors. It also receives information from the I/O controller about the status of the
machine and sends instructions to the machine to handle parts of the cutting process.
8.2.4
The Servo Drives
The servo drives are like the engine in a car. They receive the low voltage instructions
from the motion controller and convert it into current to drive the motors. They are also
connected to the I/O controller to control the limits and inhibits.
8.3 THE MACHINE BED

The machine bed does all of the cutting and movement of the pipe. Most of this is
handled by an I/O controller located in the Y-axis carriage. This I/O controller is
connected to the power box I/O controller through Ethernet cable.
78
79
9 PIPE MACHINE PROGRAM (.pmp) FILE FORMAT AND

EXTERNAL PROGRAMMING
When ever a program is generated in the WinMPM operating system and the program
saved, it generates a Pipe Machine Program file that ends with the extension .pmp. This
file is normally saved in the PMP subdirectory under the WinMPM directory. The
.pmp file is saved with the name the operator entered under the File Name: block of the
F1. Pipe Data window (reference Section 4.2.1).
A sample Pipe Machine Program is listed below:
; "PMPEXAMPLE.pmp" Pipe Machine Program file
[Program Options]
Units=INCH
Offset=Baseline
HoleDihedralLimit=10.000
TransitionStartAngle=40.000
TransitionZone=10.000
[Machine Options]
MachineType=MPM
NumberOfAxes=5
CuttingMethod=Oxy/fuel
PlasmaType=H
XAxisReversed=N
FirstCutLeft=Y
CurveSmoothing=N
AutoRun=N
CreateNcFiles=N
NCDirectory=C:\WinMPM\NC
PmpDirectory=C:\WinMPM\PMP\040302-Programming Questions
FeedrateTable=C:\WinMPM\TBL\Feedrate.TBL
GasTorchHeight=0.250
GasTorchWidth=0.375
GasTorchKerf=0.063
GasTorchMaxAngle=68.000
PlasmaTorchHeight=0.750
PlasmaTorchWidth=0.750
PlasmaTorchKerf=0.125
PlasmaTorchMaxAngle=55.000
TorchClearance=0.100
MinTorchAngle=-5.000
WeldPrepAngle=37.500
TorchLeadin=0.250
TorchLeadout=0.000
BlowThruAngle=30.000
VCUpTimeLimit=3.8
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[Pipe Data]
FileName=PMPEXAMPLE.pmp
PipeDiameter=12.75
WallThickness=.5
Length=120
PartNumber=1234567890ABC
Specification=A36
Material=STEEL
Quantity=1
[End1]
Type=Saddle
[End1 Main1]
Diameter=18.000
IntersectionAngle=90.000
CenterlineOffset=0.000
BaselineOffset=0.000
AxialAngle=0.000
Through=Y
[End2]
Type=Saddle
[End2 Main1]
Diameter=18.000
BaselineOffset=0.000
AxialAngle=180.000
Through=Y
[Mid Item1]
Type=Round
Diameter=6.625
XRotation=0.000
YDistance=-60.000
IdOd=ID
9.1 FORMATTING
The .pmp file is a simple text file and can be viewed by any text editor program. The file
contains both the variables necessary to calculate the cut path and several of the options
settings. To better understand the .pmp format and meaning, program example cuts with
either the production or desktop version of WinMPM and then view the created file
with a text editor such as Note Pad.
9.2 SECTION DESCRIPTIONS

The file is very straight forward and begins with the file name, i.e. ;
PMPEXAMPLE.pmp Pipe Machine Program File as shown above. The ; in front of
the file name designates that the following is a comment and not read during the
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calculations of the cut. The body of the file follows with each section having a heading
in brackets ([ ]). Each of the sections will be discussed below.
9.2.1
[Program Options]
These are the program options settings that were set in the program that created the .pmp
file. For a full discussion of each variable reference Section 6.1 of the instruction
manual.
9.2.2
[Machine Options]
These are the machine options settings that were set in the program that created the .pmp
file. For a full discussion of each variable reference Section 6.2 of the instruction
manual.
9.2.3
[Pipe Data]
These are the pipe (the pipe in the machine to be cut) data variables that were entered
when the cut program was created and saved in .pmp file. For a full discussion of each
variable reference Section 4.2.1 Pipe Data of the instruction manual.
9.2.4
[End1]
These are the variables that describe the type of cut that will be performed on the first end
of the pipe (the pipe in the machine to be cut). These are the data variables that were
entered when the cut program was created and saved in .pmp file. For a full discussion of
each variable reference Section 4.2.2 Programming End 1 of the instruction manual.
4.3.1.1
[End1 Main1]
Depending on the cut type selected in 1.2.5 [End1] it may be necessary to describe the cut
in more detail. The variables that are under this heading are discussed in Section 4.2.2.1
Editing End 1. If the cut is a multiple intersection then there will be a heading for each
main member fully describing the intersection of the pipe with that main member. The
headings will run consecutively such as [End1 Main1], [End1 Main2], [End1 Main3], etc.
9.2.5
[End2]
These are the variables that describe the type of cut to that will be performed on the
second end (end 2) of the pipe (the pipe in the machine to be cut). These are the data
variables that were entered when the cut program was created and save in the .pmp file.
For a full discussion of each variable reference Section 4.2.4 Programming End 2 of the
instruction manual.
4.3.1.1
[End2 Main1]
As with 1.2.5.1 End1 above, depending on the cut type selected in 1.2.6 [End2] it may be
necessary to describe the cut in more detail. The variables that are under this heading are
discussed in Section 4.2.2.1 Editing End 1. If the cut is a multiple intersection then there
will be a heading for each main member fully describing the intersection of the pipe with
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that main member. The headings will run consecutively such as [End2 Main1], [End2
Main2], [End2 Main3], etc.
9.2.6
[Mid Item1]
There will be a heading for every midsection cut put into the pipe. The variables under
this heading fully describe the type of midsection cut to be made. For a full discussion of
each variable reference Section 4.2.3 Programming Midsection of the instruction manual.
When multiple midsection cuts are programmed each midsection cut will have its own
heading and the will be numbered consecutively in the order that the cuts were
programmed such as [Mid Item1], [Mid Item2], [Mid Item3], etc.
9.3 Externally Created Pipe Machine Program (.pmp)

As long as the Pipe Machine Program (.pmp) file format is maintained, the .pmp file
may be generated from an external program such as the desktop version of the
WinMPM CAD system or other third party programs. There are considerations when
loading externally created Pipe Machine Programs (.pmp).
9.3.1
Pipe Machine Programs (.pmp) Created by WinMPM Desktop Mode
Pipe Machine Programs (,pmp) may be created at a remote site by the optional
WinMPM-Desktop software. These programs may be loaded into the Vernon
equipment via floppy disk or local area network.
It is important to note that Program Options in the .pmp file take precedence over the
Program Options in the Vernon equipment when the .pmp file is calculated. Of equal
importance is that the Machine Options in the Vernon equipment take precedence of any
Machine Options that may be contain in the .pmp file. These priorities were set to insure
the .pmp program is exactly what the programmer intended. The Machine Options are
particular to the machine and cutting method.
9.3.2
Pipe Machine Programs (.pmp) Created by CAD or Other Third Party

Programs
When a Pipe Machine Program (.pmp) is created by a CAD system or third party
program it is important that the file have the extension .pmp. Otherwise it will not be
read by the WinMPM operating system.
The variable names and format must be exactly same as described above.
It is also recommended that Pipe Machine Program only contain [Pipe Data], [End1],
[End2], and [Mid Items] information which define the required geometry to make the cut.
When the [Program Options] and [Machine Options] sections are missing in the Pipe
Machine Program (.pmp) the WinMPM operating system will default to those within
the operating system. The [Program Options] and [Machine Options] are particular to the
cutting process and best left to operator or production management.
Vernon has been the leader in providing direct links between third party 3D modeling and
CAD software to and their pipe cutting equipment. The conversion of CAD output files
to Vernon .pmp input files is done through WinMPM Desktop. The optional modules
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for converting the various third party 3D modeling and CAD files to .pmp is sold
separately as an optional add-on to WinMPM. An instruction manual specific to third
party modeling or CAD conversion to Vernon .pmp input file is provided separate from
this manual.
Note: There are several Modeling and CAD programs, such as ProSteel, Telkas
Structures, and Alias IOSGEN that now interface with Vernons WinMPM program.
Consult with the factory if your Modeling or CAD software is not mentioned as new
interfaces may have been created since this printing.
84
85
10 NC PROGRAMMING
NC (Numerical Control) programming provides the user with the capability of creating
custom cuts. Using a slightly modified version of standard NC programming language
(G-code), all of the axes and functions of the machine may be controlled as desired.
Programming is done off line to produce a text file. This file may then be loaded into the
machine using either a floppy disk or other transfer method. The operator then makes the
cut from the control console exactly like any other cut.
10.1 FORMATTING
A line of NC code is comprised of a sequence number, NC block and any optional
comments. The sequence number is mandatory but does not have to be in any special
order. The NC block contains machine function commands for interpretation into action
by the machine. All characters except comments must be in upper case. Spaces may be
used as desired for clarity and will be ignored by the compiler. All of the following are
acceptable NC lines.
N1234X2.34Y3.25C23.2Z1.00F100
X2.34 Y3.76 F97.5 *This is a comment
N100 C23.45 X32.32 Y117.2 F101 ;This is also a comment
The text file itself can be edited with any word processor or text editor. However, if a
word processor is used, the document should be prepared in the non-document (text)
mode so there are no extra formatting characters. The last line in the file must contain the
M code "M30".
10.1.1 Allowable Preparatory Functions (G Codes).
The following G codes are valid any others will be ignored. Only one G code may be
used per block. An M code and G code must not appear in the same block.
G00 Rapid Traverse.
All subsequent moves will be made at 100% feed

rate until a G01 is encountered. At that time, the
feed rate will revert to the last F value received,
even if it was received while G00 was in effect.
G01 Linear Interpolation.
All moves are made using linear interpolation;

circular interpolation is not allowed.
G04PX.XXX Time Delay.
Sets a time delay in seconds. For instance, G04

P1.5 would be a 1.5 second time delay.
G90 Absolute Positioning.
Any position values that occur after a G90 appears

will be referenced to the position of absolute zero.
Absolute zero is the position of the machine when it
was turned on. It may be modified by a G92.
86
G91 Relative Positioning.
Any position values that occur after G91 appears

will be taken as moves relative to the last position
of that axis.
G92 Preset Registers.
This command is followed by a value for one or

more of the axis. These values become the current
position of the axis.
10.1.2 Allowable Miscellaneous Functions (M Codes).

The following M codes may be used to control operation of various switches and relays.
Multiple M codes may be included on the same lines they will be executed in order. M
codes must be the only function in a block, i.e. they must be on a line by themselves.
M00 Program Stop.
Machine operation stops after a block containing an

M00 is executed. The program is continued by
depressing the Cycle Start pushbutton.
M04 Fuel On.
This function turns on the cutting fuel solenoid

valve.
M05 Fuel Off.
This function turns off the cutting fuel solenoid

valve.
M07 Preheat Oxygen on.
This function turns on the preheat oxygen solenoid

valve.
M08 preheat Oxygen Off.
This function turns off the preheat oxygen solenoid

valve.
M09 Cut Oxygen On.
This function turns on the cut oxygen solenoid

valve.
M10 Cut Oxygen Off.
This function turns off the cut oxygen solenoid

valve.
M12 Sensors On.
This function turns on the sensors.
M13 Sensors Off.
This function turns off the sensors.
M15 Plasma On.
This function turns on the plasma relay located in

the power box. This relay can be used to activate an
external plasma source.
M16 Plasma Off.
This function turns off the plasma relay.
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M20 Spark On.
This function turns on the spark for cutting gas

ignition.
M21 Spark Off.
This function turns off the igniter spark.
M22 Cycle Start Light On.
This function turns on the light in the cycle start

pushbutton.
M23 Cycle Start Light Off.
This function turns off the cycle start light.
M30 End of Program.
This function signals the last line of the program. It

must be present.
M33 Carriage Up On.
This function turns on the carriage up relay causing

the vertical carriage to raise.
M34 Carriage Up Off.
This function turns off the carriage up relay.
M90 Marking Oxygen On.
This function turns on the marking oxygen solenoid

valve for the marking torch option.
M91 Marking Oxygen Off.
This function turns off the marking oxygen solenoid

M92 Preheat Oxygen On.
This function turns on the preheat oxygen solenoid

M93 Preheat Oxygen Off.
This function turns off the preheat oxygen solenoid

M94 Preheat Fuel On.
This function turns on the preheat fuel solenoid

M95 Preheat Fuel Off.
This function turns off the preheat fuel solenoid

M96 Igniter On.
This function turns on the igniter for the marking

torch option.
M97 Igniter Off.
This function turns off the igniter valve for the

marking torch option.
M98 Swirl Oxygen On.
This function turns on the swirl oxygen solenoid

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M99 Swirl Oxygen Off.
This function turns off the swirl oxygen solenoid

10.1.3 Axis and Feed Rate Functions.

These functions are used to assign movements and feed rates to individual axis.
4.3.1.1
X,Y,C,Z,A Axis Command.
All axes movement must be preceded by an axis command (the A would not be
programmed for a 4-axis (MPM4)). This assigns a move to a particular axis. Multiple
axes commands may appear in the same block, but only one assignment per axis may be
made. Example: X123.45Y23.45C56.788.
4.3.1.1
F Feed Rate Command.
A letter F must precede the assignment of a feed rate. The assignment remains in affect
for all subsequent moves until it is changed by another feed rate assignment. A feed rate
assignment may appear in a block by itself or as part of an axis command.
10.1.4 Sequence Numbers and Comments.
Although not required, blocks may contain both sequence numbers and comments.
4.3.1.1
Sequence Numbers.
Sequence numbers (sometimes called N numbers) may be used by the programmer to

keep track of program blocks. They are optional and need not be included in each block.
Also, since the numbers themselves are ignored, numbering sequences may be repeated
in the program.
4.3.1.1
Comments.
Comments can either be displayed on the screen or contained within the program as an
aid to the programmer. A semicolon (;) denotes a comment within the program and all
following characters in that line will be ignored.
10.1.5 Absolute Versus Relative Positioning.
4.3.1.1
Absolute Positioning.
When using absolute positioning, all measurements are made from a single "zero" point
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on the pipe. The "zero" point is wherever the torch happens to be when the Cycle Start
pushbutton is pressed for the first time. Consider the following program:
N1010 X10
N1000 G90
N1015 M00
N1020 X20
N1025 M00
N1030 X30
N1035 M30
The "G90" in the first line sets absolute positioning. When the Cycle start pushbutton is
pressed the first time, the machine will rotate the pipe 10 inches to X = 10 inches. The
second time the pipe will rotate another 10 inches to X = 20 inches, and the third time the
pipe will rotate another 10 inches to X = 30 inches.
The position of the "zero" point may be modified by the use of the Preset Registers
function code (G92). If a line were inserted into the above program so that it now reads:
N1000 G90
N1005 G92X25
N1010 X10
N1015 M00
N1020 X20
N1025 M00
N1030 X30
N1035 M30
This time, when the "Cycle Start" pushbutton is pressed, the machine will assume that it
is located at a starting position of X = 25 inches. The pipe will then move -15 inches to X
= 10 inches. All of the rest of the moves will be the same as above.
Relative Positioning.
When using relative positioning, the "zero" point becomes the present position of the
torch. Each move is then made relative to this position. Consider the original program
above.
N1000 G91
N1010 X10
N1015 M00
N1020 X20
N1025 M00
N1030 X30
85
N1035 M30
This time, a "G91" in the first time sets relative positioning. When the Cycle Start
pushbutton is pressed the first time, the machine will rotate 10 inches to X = 10 inches,
just as before. However, the second time the Cycle Start pushbutton is pressed, the pipe
will rotate 20 inches from its present position to an absolute position of X = 30 inches (10
+ 20). The third time, the pipe will rotate 30 inches to a new absolute position of X = 60
inches (10 + 20 + 30).
Although the initial position could be modified by the use of G92, there would be no
point in it since the motion of the machine would remain the same.
Use of both relative and absolute positioning in a program can greatly simplify certain
cuts. For instance, if identical cuts are to be repeated at various positions on the pipe,
program the cut using relative positioning. Then use absolute positioning to locate the
cut and relative positioning to make the cut. In this way, the same data for the cut can be
used over again for each cut reducing programming time and complexity. See the
programming examples in the appendix.
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11 MAINTENANCE AND REPAIR

The Microprocessor Pipe Machine has been designed for a rugged environment and to
require a minimum of scheduled maintenance. Of primary concern to maintenance
personnel should be general cleanliness of the machine. In the environment in which
most pipe machines are used, both electrical and mechanical systems are exposed to high
levels of airborne contaminants. Daily attention to general cleanliness of the machine
will go a long way towards a long, trouble free machine life.
11.1 ELECTRICAL MAINTENANCE

The following items should be performed periodically as indicated:
Daily
Clean (dust) operators console.
Weekly
Check all cables for burns and wear. If inner wire has not been damaged,
wrap outer jacket in damaged area with abrasion resistant tape.
Monthly
Open power box and inspect components for evidence of excessive heat or
arcing.
Inspect power box for cleanliness. If required, remove accumulated dust and dirt with
small portable vacuum. Do not use vacuum on circuit cards. If circuit boards need
cleaning, be sure to use static free methods. Consult factory before attempting to wash
circuit boards.
Annually
Check grounding connections. Good grounding is essential. Grounding

rods may corrode due to electrolytic action; if this is the case, they should
be replaced.
WARNING: BE SURE TO TURN OFF THE POWER BEFORE INSTALLING

OR REMOVING COMPUTER CARDS OR CONNECTING EXTERNAL
DEVICES.
11.2 USE OF AN EXTERNAL KEYBOARD AND MONITOR

For maintenance purposes, a standard keyboard and monitor (CRT) may be plugged
directly into the computer. Standard receptacles may be found on the computer chassis.
Also, a keyboard and monitor can be plugged into the Keyboard and Monitor port of
the KVM extender/sharer remote module located in the operators console.
11.3 REPLACING PRINTED CIRCUIT BOARDS

In general, replacing one of the printed circuit boards (PCB) involves simply removal of
87
the old one and installation of the new one. Be sure to take precautions to prevent static
discharge while handling them.
Before installing a new circuit board, it is good practice to compare the new PCB with
the old one. Many boards contain jumpers and small switches that are used to tailor the
board to a specific application. Be sure that the jumper and switch settings on the new
PCB match the old one.
11.3.1 Servo Drive Printed Circuit Cards.

The installation of a new servo drive PCB is straight forward (refer to the axis drawing
for jumper settings). If the board has a personality module, be sure to unplug if from the
old board and use it on the new one. Refer to the servo drive manual for more
information.
11.4 MECHANICAL MAINTENANCE

In general, all mating surfaces where motion occurs should be kept well lubricated. Use
good general-purpose oil. Lightweight spray-on oils should be avoided, as they tend to
wash away existing lubricants and evaporate quickly.
The following items should be performed periodically as indicated:
Daily
1.
2.
3.
4.
The operator should check and adjust pivot point.

Clean and wipe down Y-axis track.
Remove accumulated slag from pipe and conveyor rollers.
Using compressed air, blow off dust and dirt from all machine surfaces.
Weekly
1. Check hydraulic fluid level in tank. Fill as necessary.
2. Cycle all hydraulic functions at least once.
3. Check the gear rack that runs along the Y-axis rail for wear and foreign
matter.
Monthly
1. Check conveyor chain drives for proper tension and tighten as necessary.
2. Check all hydraulic fittings for leaks.
3. Lubricate pipe roller bearings at each pillow block. Be sure to inject enough
grease to force out the dirty grease.
88
Annually
1. Lubricate conveyor chain drive sprockets, chain and shaft bearings.
2. Check proper adjustment of bearings that ride on horizontal (Y-axis) track.
Adjust as necessary.
3. Check proper adjustment of bearings that ride on vertical carriage track.
Adjust as necessary.
4. Check the Y-axis pinion gear for wear. Replace if necessary.
89
90
12 TROUBLE SHOOTING GUIDE

When trouble shooting a problem, always check the obvious first. Be sure that proper
operating voltages are present; check fuses and switches; and make sure the problem was
not caused by incorrect input of data. When checking what appears to be an electrical
problem, do not overlook the possibility that there is a mechanical fault. Many an hour
has been wasted tracing an encoder circuit only to find that a mechanical coupling had
broken on the encoder shaft.
WARNING: BE SURE TO REMOVE POWER FROM THE MACHINE WHEN
REMOVING OR DISCONNECTING ANY CABLE OR PCB
(PRINTED CIRCUIT BOARD).
12.1 PROBLEMS WITH THE MACHINE

12.1.1 Machine will not start
1.
2.
3.
4.
5.
6.
7.
8.
Refer to the AC Wiring Diagram.

Check fuses in the main disconnect switch box.
Check for power at input to contactor in power box.
Check fuses 4 and 5 for 480vac (208vac or 240vac if machine supply is non
standard).
Check fuse 6.
Check power cable J1 from the Power box to the Operators Console.
Check wiring in control console to POWER ON and EMERGENCY STOP
pushbuttons.
Consult factory for further troubleshooting.
12.1.2 No Picture or Cursor on Screen.

1. Make sure there is power to the machine. See above.
2. Check all connections to host and remote extender/sharer modules.
3. Check that the green LEDs on the front of the display is on. If not on, display is
either faulty or not receiving power.
4. Plug a standard video monitor into the KVM remote extender.
5. Consult factory for further troubleshooting or replacement.
12.1.3 Cannot Jog One Axis (X, Y, C, Z, OR A)
1. Check the diagnostics menu on the Virtual Control Panel for the limit switch status
at the Power Box and at the Machine.
2. Check appropriate motor for short, open or mechanical binding.
3. Check the diagnostic LEDs on the servo drive. The green LED should be
91
illuminated to show the drive is not uninhibited and operational. If any of the red
LEDs are illuminated then the drive is not operational. Refer to the LED status in
the Glentek Instruction Manual.
4. Check cable or cables to motor.
5. Consult factory for further troubleshooting.
12.1.4 Unable To Move All Axes Using Either Jog or Offset
1. Check to make sure that the servo drive is not inhibited. The X, Y, C, Z, and A axes
are not inhibited when the green LED is lit.
2. Check that the green connector to the servo drive is tightly plugged in.
3. Check that the sensor arms are down and safety switches are actuated and that the
crash switch (MPM5 only) is closed and the Feed hold light is not lit.
4. Check to see if cooling fans on the servo drives are turning. If not, trace AC wiring.
5. Check for the presence of all power supply voltages.
6. Check fuses.
12.1.5 Axis Runs Continuously in One Direction.
1. Check display and observe if the present position of the axis motor is changing as the
motor is running.
2. Check the motor cable for damage and loose connection.
3. Check the Encoder terminal plug connection at the UMAC controller. Check for
good wire connections.
4. Shut the machine down and contact the factory.
12.1.6 Unable to Raise or Lower Vertical Carriage.
1. Refer to the Wiring Diagram, Vertical Carriage Motor
2. Make sure the brake on the servomotor is releasing when axis is activated. Fuse F27
is used inline with the brake.
3. Check that the servo drive is not inhibited, by pressing the up or down button then the
green LED on the servo should light.
4. When the Carriage up or down switch is pushed, check for a signal at the Aux input
to the servo drive. If the input signal is present, check for output voltage to Vertical
Carriage motor. If there is no output, replace the servo drive. If output voltage is
present, check wiring to the vertical carriage motor.
5. Check for mechanical binding of vertical carriage. Vertical Carriage motor may be
removed and shaft turned manually.
6. Contact the factory.
WARNING: IF THE VERTICAL CARRIAGE GEARBOX IS DISCONNECTED,THE
SHAFT WILL ROTATE DUE TO THE WEIGHT OF THE CARRIAGE.
THE CARRIAGE WILL DESCEND AND POSSIBLY CAUSE DAMAGE.
WHEN REMOVING THE MOTOR OR GEARBOX, SUPPORT THE
VERTICAL CARRIAGE TO PREVENT DAMAGE.
92
12.1.7
Sensors Do Not Work.
Note: THE SENSORS WILL NOT FUNCTION UNTIL A CUT HAS BEEN
PROGRAMMED AND STARTED.
1. Refer to the Wiring Diagram, Y Carriage Ethernet I/O.
2. Check to make sure that Vertical Carriage up/down pushbuttons work. If not, refer to
above.
3. Check that appropriate sensor arm has been lowered.
4. Check that appropriate sensor switch has been actuated.
5. Check sensor arm switch wiring.
6. Check for changing signal output from the sensor while bringing metal close to
appropriate sensor coil. If signal does not vary, try the other sensor. If signal is
obtained check/replace sensor coil.
12.1.8
All Conveyors Do Not Work.
Consult the AC Wiring Diagram and the Wiring Diagram, Power Box Ethernet I/O.
1. Check appropriate fuse(s).
2. Check fuse for 24VDC power.
3. Check all common wiring.
12.1.9
One Conveyor Does Not Work.
Refer to the trouble shooting section of the motor controller manual.
1. Check fuse on appropriate controller.
2. While operating the controller, check for the presence of the forward, stop and
reverse signals. If not present, check I/O controller.
3. Check for armature voltage at controller.
a. If armature voltage is present, check at motor. If still present, check/replace
motor.
b. If armature voltage is not present, controller may be defective.
12.1.10 All Hydraulic Circuits Do Not Work.
Consult the AC Wiring Diagram and the Wiring Diagram, Power Box Ehternet I/O.
1. If the hydraulic pump is not operating, check to see if the hydraulic motor starter
inside the power box is activating. If not, check the following:
a. Fuse in hydraulic motor starter circuit.
b. Coil in hydraulic motor starter.
93
c. Cable and connections between the power box I/O controller and the motor
starter.
2. If the hydraulic pump motor is operating, check the following:
a. Check that hydraulic fluid reservoir is full.
b. Check the 24VDC power supply.
c. Check at the hydraulic solenoid for indication that it is operating.
d. Check the common connection for the solenoid valves.
e. Check for an obstruction in the hydraulic lines
12.1.11 One Hydraulic Circuit Does Not Work.
1. Operate pushbutton on the operators control console and check for presence of a 24
VDC signal at appropriate hydraulic solenoid.
a. If signal is present, check/replace hydraulic solenoid.
b. If signal is not present, trace wiring back to the power box I/O controller.
12.2 Problems with Cut Quality.

12.2.1 Depth of Cut (Heel to Toe) Measurement Is Incorrect.
1. Check that torch angle is set to zero before starting cut.
2. This problem is usually due to incorrect setting of pivot point. Since the torch is
usually vertical at the long point, if the pivot point is at fault then the long point will
be correct and the short point will be incorrectly located. Check the pivot point.
3. Check the value for kerf. See Chapter 11.
4. Check scale factor. This is rarely the cause since it would take a very large error in
the scale factor to cause a significant error in the relatively short distance of the depth
of a cut.
12.2.2 Distance Between Cuts Is Incorrect but Depth of Cut is Correct.
1. Check the value for the kerf.
2. Check Y-axis scale factor.
12.2.3 Bevel Angle Is Incorrect.

1. Check that the C-axis was homed before starting cut.
2. Check that weld prep angle was entered correctly.
3. Home the C-axis. Press the abort key to set the Present Position to zero. Jog the Caxis and compare the present position with the actual position on the scale. If there is
a large error, adjust the C-axis scale factor.
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95
13 MACHINE ADJUSTMENTS
13.1 ALIGNMENT PROCEDURES
13.1.1 Alignment of the Cutting Head
The following adjustments should be made in the order in which they are presented.
13.1.2 Torch Axis Offset
This adjustment places the centerline of the torch radially in line with the C-axis ring
guide. Start with the torch vertical. Home the C-axis, Hit Abort so that the C-axis
present position reads zero. Then lean the torch to one side to approximately 50 degrees
(be careful not to hit the pipe with the torch). Note the clearance between the pipe and
the closest point on the torch. Then lean the torch to the same number of degrees on the
other side of vertical and again note the clearance. If it is not the same on both sides, lean
the torch to the side with the greatest clearance to the pipe at the same angle. Adjust the
torch (not the C-axis) by moving it half the clearance distance to the pipe. Repeat until
the clearance is the same on both sides.
13.1.3 A-axis Center of Rotation (5 Axes Only)
Again, start with the torch vertical. Put a pointer on the end of the torch. Mark the pipe
on the centerline and position the pointer above the mark. Slowly rotate the A-axis
through 360 degrees. If the A-axis is aligned, it will have rotated about a single point. If
it is not aligned, the marks will form a circle. Loosen the adjustment bolts and move the
entire cutting head to the center of the circle.
CAUTION: RETURN THE CUTTING HEAD TO ITS ORIGINAL POSITION
BY ROTATING THE AXIS BACK IN THE OPPOSITE DIRECTION AFTER
EACH TEST. FAILURE TO DO SO WILL RESULT IN THE A-AXIS CABLES
BECOMING TWISTED AND POSSIBLY DAMAGED.
13.1.4 Center of Rotation on Machine Centerline (5-Axes Only)
At this point the A-axis is rotating about a point. However, this point may not be exactly
over the centerline of the machine. Using the slotted bolt holes provided, move the
ENTIRE torch assembly so that the torch is over the centerline of the machine. The
machine centerline is defined as the midpoint between the main shafts or between the
pipe rollers. Do NOT use the center of the pillow block that houses the shaft bearings as
these may not be symmetrical. Do not use the centerline of a piece of pipe as it may be
egg-shaped or bent and not straight.
96
13.1.5 Vertical Axis Alignment

The above procedures have aligned the head correctly at a single height on the vertical
carriage. However, if the vertical carriage is not exactly vertical, the torch will move
away from the centerline as the height is changed.
Attach a plumb bob or weighted string to the tip of the torch so that it points to the
centerline of the machine. Raise the torch to its maximum height and check that the torch
is still over the centerline. Repeat at minimum height. If the torch moves off of
centerline, the most likely cause is that the machine is not level. Check the level of the
machine and check again. If the level of the machine is not at fault, then Y-axis rail is
out of adjustment vertically and must be adjusted using the set screws at each mounting
location. Since this is a tedious adjustment that is usually correctly made at the factory,
make absolutely sure that machine leveling is not the problem. Contact the factory for
further information regarding adjustment procedure.
13.1.6 Pivot point
Adjust the pivot point in accordance with chapter 13, section 13.3 of the instruction
manual.
13.1.7 Travel along centerline
It is important that the Y-axis and the machine centerline be parallel. For best results use
the turning roll main shafts as a reference for the longitudinal machine centerline. An
alternative is to use a straight and round of pipe, mark a centerline from end to end.
Remember this using pipe as a reference the alignment may only be as good as the piece
pipe. If pipe is used place the torch over it at one end of the pipe and move the Y-axis
along the pipe to the other end. The torch should track down the line. If not, the
centerline of either the machine or the Y-axis carriage must be shifted to bring it in line.
13.2 Calibration of Axis

13.2.1 Calibration of X-axis
Because the X-axis has diameter checking for use with the roller encoder and a spider
encoder for absolute rotational measurement, it is not necessary to set the X-axis scale
factor to a close tolerance. The use of these features allows accurate measurement of
rotation without having to repeatedly use the monitor to change the scale factor for
different pipes.
13.2.2 Calibration of Y-axis
Along a length of pipe, measure two points at a reasonable distance from one another
say 20 feet or 8 meters. Align the torch with the first mark and press Abort to zero the
axis at this position. Then jog (do not use the offset) to the second position.
97
Note the present position on the screen. If it is not the same as the actual measurement,
refer to Section 6.3 for setting the Y-axis scale factor.
13.2.3 Calibration of C-axis
First home the axis so that the torch is vertical (this should be checked as it is possible
that the home switch is out of adjustment.) Then move the torch to some angle greater
that 45 degrees and check it against a standard (protractor, triangle, etc.). Then repeat in
the negative direction. If the angles are not correct, move the axis to a known angle and
adjust the scale factor until the position reading is correct. This is the same procedure as
used for the Y-axis.
13.2.4 Calibration of A-axis (5 Axes Only)
From a known position, rotate the A-axis until it returns to the same position. Then
check the display to see that it moved 360 degrees. If not, adjust the scale factor using
the procedure described for the Y-axis.
13.2.5 Calibration of Z-axis
The calibration of the Z-axis does not affect the cut quality so it is not necessary to
calibrate it.
13.3 ADJUSTMENT OF PIVOT POINT.

This is undoubtedly the most important adjustment to be
made to the machine. It should be checked by the
operator daily or any time the torch arm or sensors have
been disturbed. The intent of the pivot point adjustment
is to ensure that when the torch is rotated with the
sensors active, the C axis rotates about a point on the
PIPE SURFACE
surface of the pipe. See figure 11-1. If the pivot point is
CORRECT PIVOT POINT SETTING
not located on the surface of the pipe, the following
Figure 11.1
errors will occur:
1. The distance between cuts will be incorrect.
2. The "heel" to "toe" distance on any contour cut will be incorrect.
The above errors will increase with an increase in weld prep angle.
The steps to adjust the torch axis offset are as
follows:
1. Make sure there is a piece of straight pipe in the
Machine and that it falls underneath the torch and
PIPE SURFACE
PIVOT POINT TO TORCH'S LEFT
(MOVE TORCH LEFT)
98
both sensors.
2. Raise the Z-axis until it is just below its UP
limit.
3. Turn on the LEFT sensor.
4. Enter a program, calculate and press the CYCLE
START button one time. This will activate the
sensors and the vertical carriage will descend until
it comes within range of the pipe.
5. Rotate the torch about 45-55 degrees to one side,
being careful not to contact the pipe with the torch
tip. If necessary, use the Z-offset and raise the
torch tip.
Figure 11.2
PIPE SURFACE
PIVOT POINT TO TORCH'S RIGHT
(MOVE TORCH RIGHT)
The steps to set the pivot point are as follows:

6. Rotate the torch to the other side and note
whether it is closer or further away than it was on
the first side. See figures 11-2 and 11-3.
a. If there was no difference, proceed to step 7.
b. Rotate the torch straight up and down. Move
the torch holder right or left so that the torch
moves away from the closest side.
c. Repeat steps 5 and 6 until there is no difference
on either side. The torch rotation should be
gradually increased until it is 55 to 65 degrees.
Figure 11.3
PIPE SURFACE
PIVOT POINT TOO LOW
(ADJUST SENSOR DOWN)
Figure 11.4
PIPE SURFACE
7. Now place a pointer on the torch tip, rotate the

torch from side to side and observe the position of
the pointer.
a.
If the pointer can be placed so that it is
almost touching the pipe and it remains
pointing at a single spot on the pipe (see figure
11-1), the adjustment is correct and you are
done.
b.
If the torch tip follows a line that moves
from the left to the right as the torch is rotated
from the left to the right, then the pivot point is
too low. (See figure 11-4). Adjust the sensor
down slightly (which will raise the torch
slightly it may be brought back down to the
pipe with the Z offset). Start over again with
step 5.
c.
If the torch tip follows a line that moves
from the right to the left as the torch is rotated
from the left to the right, then the pivot point is
PIVOT POINT TOO HIGH

(ADJUST SENSOR UP)
99
too high. (See figure 11-5). Before adjusting

the sensor, raise the torch slightly using the Z
offset. Then adjust the sensor up slightly
which will bring the torch back down to the
pipe.
d.
Repeat step 7 until the torch remains
pointed at a single point on the pipe as it is
rotated back and forth.
Figure 11.5
6. After performing step 7 a few times it may be necessary to repeat steps 5 and 6 to get
closer adjustment.
7. When the adjustment is complete you will have adjusted the main sensor. Raise the
Z-axis so the torch is away from the pipe and turn on the RIGHT Sensor. If the
vertical carriage moved, the Aux sensor needs to be adjusted. Simply adjust it until
there is no movement when switching back and forth between the main sensor and the
Aux sensor.
8. Turn the sensors off and press the ABORT key to exit the program.
13.4 SETTING OF KERF.

Kerf is amount of material that is cut away by the torch. If a straight line is cut with a
torch, the width of that line is the kerf. This loss of material is significant and must be
accounted for by the computer in its calculations. Therefore, the proper determination of
kerf is important for obtaining correct fit ups. It is recommended that the operator use the
following procedure to determine the actual kerf rather that using a value published by a
torch manufacturer.
1.
2.
3.
4.
5.
Go to Machine Options (F6,F2) and change the setting of the kerf to 0. Be

sure to set the correct kerf parameter for the type of cutting torch being
used.
Load a piece of pipe and make a straight cut on both ends by setting the
weld prep angle to 0. This will keep the torch vertical and eliminate any
error caused by the incorrect setting of the pivot point. Make the piece at
least 6 inches or 15 centimeters long.
Measure the length of the piece along the inside of the pipe. It will be
short since the kerf value was set to zero in the first step.
Subtract the actual length from the programmed length. This value is the
kerf.
Again go to Machine Options (<F6>,<F2>) and enter the correct kerf
value.
The above method will be adequate in most cases. However, in some instances the kerf
may actually be slightly greater in an area of high bevel angle. In this case, repeat the
above procedure with a bevel angle of 45 degrees (which will also give a torch angle of
100
45 degrees). After subtracting the actual length from the programmed length in step 4,
multiply the resulting value by 0.707. This will be the correct value for the kerf.
TO UTILIZE THIS METHOD, IT IS IMPERATIVE THAT THE PIVOT POINT BE
CORRECTLY SET. ANY ERROR IN THE PIVOT POINT WILL CAUSE AN ERROR
IN THE AMOUNT OF KERF DETERMINED.
101
APPENDICES
102
103
APPENDIX A - DEFINITIONS
A-AXIS (5-axis (MPM5) only): The A-axis is the axis that maintains the bevel angle
perpendicular to the direction of travel (or contour path). Angles are measured plus and
minus from 0 degrees, which is when the C-Axis horseshoe track is parallel to the pipe's
longitudinal centerline and facing the operator. The travel limits are +/- 450 degrees and
set by software.
ARC LENGTH: The length of a curved section between two points on a
circle.
AXIAL ANGLE: The axial angle is the angle measured around the
branch member. It is referenced to zero degrees which is the point
under the torch when the "CYCLE START" button is pushed. It is used to measure the
angle at which the main members intersect with the branch member. As the X-axis is
jogged in a plus direction, the point under the torch increases from zero degrees.
BASE LINE OFFSET: In a multiple intersection cut, each intersecting member would
produce its own profile or template. The shortest point on the template for each
individual member is the baseline for that template. Thus, the offsets of those baselines
are baseline offsets. Another way of putting it is that the baseline offset is the distance
along the pipe that the various individual pipe templates would have to be moved to
produce the final multiple intersection template. A positive base line offset moves the
template towards the end of the pipe.
BRANCH MEMBER: The branch member is the pipe being cut.
C- AXIS: The C-axis is the axis of rotation of the torch with respect to the pipe being
cut. It is the axis that produces the bevel, or weld groove angle. Angles are measured
plus and minus from 0 degrees, which is when the torch is perpendicular to the pipe being
cut.
CENTERLINE OFFSET FOR PIPES: The centerline offset for pipes is the distance
between the centerline of the branch member and the main member and is measured
along a line perpendicular to both. The centerline offset is positive if it moves the main
member towards the 90-degree position of the pipe.
CHORD LENGTH: The length of a straight line joining any two points
on an arc.
CENTERLINE OFFSET FOR HOLES: The centerline offset for holes
is the distance between the centerline of the branch member and the centerline of the hole
and is measured along a line perpendicular to both. It is positive if it moves the hole
towards the 90-degree position of the pipe.
104
DISTANCE BETWEEN CUTS: The distance, measured along the inside of the pipe,
from the shortest point on the first cut to the shortest point on the second cut. If there is
no first cut, the distance is measured from the position of the torch when the "CYCLE
START" button is pushed. The distance measured includes the bevel. Thus, the distance
is easily checked by simply using a tape measure along the inside of the pipe.
INTERSECTION ANGLE: The intersection angle is the angle between a main member
and the branch member. It is measured in degrees.
KERF: The amount of material removed by the width of the flame or plasma arc.
LIFTER-CONVEYOR: See Machine Conveyor.
MAIN MEMBER: The main member is a pipe that intersects with the branch member.
Up to three main members may be defined for each cut.
MACHINE CONVEYOR: The part of the conveyor system that is attached to the section
of the machine that rotates the pipe for cutting. It is hydraulically operated. When down,
the pipe rests in the turning rollers and when raised, the pipe rests on the conveyor rollers.
Sometimes called "Lifter-Conveyor".
MITER CUT: A miter cut is the intersection of the branch member with a flat surface at
any intersection angle, i.e. it is a pipe to plate intersection. On the pipe machine, a miter
cut at 90 degrees is easier defined by using the "straight cut" option.
OUTER DIAMETER: The diameter of the pipe measured to the outside.
SADDLE CUT: A saddle cut is the intersection of the branch member with one or more
main members, i.e. a "pipe on pipe" intersection.
STRAIGHT CUT: A straight cut is the intersection of the branch member with a flat
surface at an intersection angle of 90 degrees, i.e. a "pipe to plate" intersection at 90
degrees.
THROUGH/NOT THROUGH MEMBER: Normally when plotting pipe intersections it
is assumed that any pipe which intersects with the branch member passes completely
through it. However, there are instances where a second or third main member may not
pass completely through an intersection. In this case, that main member is considered a
"not thru" member.
TRANSITION CUT: A transition cut is a saddle cut which transitions from an inside
diameter fit-up to an outside diameter fit-up in the "heel area" of the cut. It is used for
small intersection angles. Both the start and stop points of the transition zone are
dependent on the local dihedral angle and may be specified by the user.
105
TRANSITION START ANGLE (Program Option): The transition start angle is the
dihedral angle of intersection between the two pipes where a transition cut will start to
transition from the inside diameter to the outside diameter. A typical value is 40 degrees.
TRANSITION ZONE (program Option): This parameter is for setting the transition zone
in a transition cut. It is the distance in dihedral degrees from where the transition starts
on the inside diameter to where it finishes on the outside diameter. A typical value is 10
degrees.
TRANSITION CUT BACKBEVEL(Program Option): Back bevel is only used on
Transition cuts. When a transition cut is made, the area in the throat makes contact with
the Main Member at the OD of the Branch instead of the ID as in a normal cut. This
leaves a weld prep angle on the INSIDE of the pipe and in some cases it is desirable to
vary it. In the data screen for a transition cut if No is selected, the torch will remain
vertical while the transition area is cut and the bevel will be fixed. In most cases this is
used. If a particular weld prep is desired on the inside of the pipe (for instance to put a
backup weld on the inside), Yes may be selected.
TRANSITION CUT BACKBEVEL ANGLE (Program Option): Backbevel Angle
specifies the weld prep angle on the inside of the pipe in the throat area of a transition
cut. See Transition Cut Backbevel above.
VERTICAL CARRIAGE: The tower-like carriage that moves longitudinally up and
down the machine. It includes the Y, C and Z axis, out-of-round sensing, torches and gas
solenoids.
WALL THICKNESS: The thickness of the wall of the pipe. It is not necessary to know
the wall thickness of the main members - only the branch member.
WASTE PIECE: Any piece of pipe that is cut off of the Branch Member or any scrap
pipe left over after cutting.
106
WORKPOINT OFFSET: The work point offset is measured along the centerline of the
pipe being cut. It is the distance between the intersection of the centerlines of main
member #1 or any subsequent main members.
107
X - AXIS: The X-axis is the axis of rotation of the pipe. Motion can be measure both in
degrees and inches/centimeters. Since the direction of rotation varies from machine to
machine, the positive direction of rotation is defined as the direction the pipe moves
when the X+ jog button is pushed.
Y - AXIS: Y-axis motion is measured along the centerline of the pipe being cut. Motion
is measured in inches/centimeters. Positive travel is always towards the discharge end of
the machine and negative towards the entrance end.
Z - AXIS: The Z-axis controls the distance from the pipe to the torch tip. Its motion is
always in the plane of the bevel and thus does not effect the precision of the cut. Positive
motion is upwards, away from the pipe.
108
109
APPENDIX B ERROR CODES
0 No error
1 Error reading Units from Options.ini
2 Unable to open Feedrate Table
3 Bad data in feedrate table
4 Cannot create primary NC file
5 Cannot open ODdata file
6 Pipe Data Error: Branch Diameter is 0
7 Main Data Error: C'line Offset > Main Diam/2 - (Branch Diameter)/2
8 Main Data Error: Main Diameter < Branch inside diameter
9 Main Data Error: Intersection angle is 0
10 Hole Data Error: Hole Diameter bigger than ID of pipe
11 Hole Data Error: Centerline Offset > (Pipe ID)/2-(Hole Diam)/2
12 Hole Data Error: Intersection angle = 0.00
13 Pipe wall thickness > Radius of pipe
14 Cannot find CutData.INI file
15 Cannot find Options.INI file
16 Elbow Data Error: C'line Offset > Main Diam/2 - (Branch Diameter)/2
17 Elbow Data Error: Centerline offset < Bend Radius
18 Elbow Data Error: ID of Elbow support > Diameter of Elbow
19 Can not find WinMPM.ini file
20 Hole Data Error: Hole Diameter is 0
21 Main Data Error: Main Diameter is 0
22 Cannot create secondary NC file
23 Cannot open primary NC file to create secondary
24 File NCcut not found
25 Cannot create Rev file
26 Cannot find pierce delay table, delay set to 0
27 Crown Data Error: Points overlap. Check radius.
28 Crown Data Error: Must have at least 2 points
29 I/O error in Holes
30 General error in Holes
31 Math error in Holes
32 I/O error in Bumpers
33 Math error in Bumpers
34 General error in Bumpers
35 Bumper data error: MainDiam = 0;
36 Bumper data error: Centerline offset too large
37 Bumper data error: Intersection angle = 0
902 Cone math error: Pipe does not fully intersect cone
903 Non-math error in basic Cone calcs
904 Cone math error: Dihedral Angle
905 Offset error in Cones
110
906 I/O error in Cones

907 General error in Cones
1001 Math error in GetData
1002 IO error in GetData
1003 General error in GetData
1004 Math error in Repad calcs
1005 IO error in Repad calcs
1006 General error in RePad Calcs
111
APPENDIX C Pipe Machine Program (.PMP) FILE FORMAT

; "EXAMPLE.pmp" Pipe Machine Program file
[Program Options]
Units=INCH
Offset=Workpoint
HoleDihedralLimit=10.000
TransitionStartAngle=40.000
TransitionZone=10.000
[Machine Options]
MachineType=MPM
NumberOfAxes=5
PlasmaType=H
XAxisReversed=N
FirstCutLeft=Y
CurveSmoothing=N
AutoRun=N
CreateNcFiles=N
NCDirectory=C:\WinMPM\NC
PmpDirectory=C:\WinMPM\PMP
FeedrateTable=C:\WinMPM\TBL\Feedrate.TBL
GasTorchHeight=0.250
GasTorchWidth=0.375
GasTorchKerf=0.063
GasTorchMaxAngle=68.000
PlasmaTorchHeight=0.750
PlasmaTorchWidth=0.750
PlasmaTorchKerf=0.125
PlasmaTorchMaxAngle=55.000
TorchClearance=0.100
MinTorchAngle=-5.000
TorchLeadin=0.250
TorchLeadout=0.000
BlowThruAngle=30.000
VCUpTimeLimit=3.8
[Pipe Data]
FileName=EXAMPLE.pmp
PipeDiameter=6.625
WallThickness=.28
Length=140.5
112
PartNumber=1234567890ABC
Specification=A36
Material=STEEL
Quantity=1
[End1]
Type=Saddle
[End1 Main1]
Diameter=12.750
WorkpointOffset=0.000
AxialAngle=0.000
Through=Y
[End2]
Type=Miter
[End2 Main1]
WorkpointOffset=0.000
AxialAngle=0.000
[Mid Item1]
Type=Round
Diameter=3.500
XRotation=90.000
YDistance=-10.000
IdOd=ID
[Mid Item2]
Type=Square
XRotation=0.000
YDistance=-30.000
IdOd=ID
XLength=2.000
YLength=3.000
CornerRadius=0.250
[Mid Item3]
113
Type=SawCut
Diameter=4.500
XRotation=0.000
YDistance=-60.000
IdOd=ID
114
115
APPENDIX D GRAPHICAL REPRESENTATIONS OF END CUTS

AND MIDSECTIN CUTS
END CUTS
BRANCH
PIPE
DIAMETER
BRANCH
WALL
THICKNESS
INTERSECTION
ANGLE
PIPE
MAIN MEMBER
CENTERLINE
OFFSET
SADDLE - SINGLE INTERSECTION
116
MAIN
OUTSIDE
DIAMETER
AXIAL
ANGLE
MAIN #2
PIPE
OUTSIDE
DIAMETER
INTERSECTION
ANGLE
MAIN #2
PIPE
WALL
THICKNESS
PIP
INTERSECTION
ANGLE
MAIN #1
MAIN #1
AI
N
#2
BASELINE
OFFSET
OUTSIDE
DIAMETER
MAIN #2
WORKPOINT
OFFSET
OUTSIDE DIAMETER
MAIN #1
SADDLE - MULTIPLE INTERSECTION
AXIAL
ANGLE
PIPE
DIAMETER
BRANCH
WALL
THICKNESS
INTERSECTION
ANGLE
MITER - SINGLE INTERSECTION

117
WELD PREP
ANGLE
MAIN #2
AXIAL
ANGLE
MAIN #2
INTERSECTION
ANGLE
MAIN #1
INTERSECTION
ANGLE
WELD
PREP
ANGLE
PIPE
DIAMETER
WALL
THICKNESS
MITER - MULTIPLE INTERSECTION

WELD PREP ANGLE
STRAIGHT CUT
118
WELD PREP ANGLE

FIXED TORCH ANGLE
(4 & 5 AXES)
NUMBER
OF POINTS
POINT
HEIGHT
POINT
RADIUS
CROWN
WELD PREP ANGLE
FIXED TORCH ANGLE
(4 & 5 AXES)
SLOT HEIGHT
SLOT
WIDTH
END SLOTS
119
NUMBER
OF SLOTS
ELBOW
RADIUS
OFFSET
ELBOW
BEND
RADUIS
ELBOW
ELBOW
RADIUS
PIPE
LENGTH
OF
SUPPORT
PIPE
WALL
THICKNESS
PIPE
DIAMETER
ELBOW SUPPORTS
120
ELBOW
CENTERLINE
OFFSET
MIDSECTION CUTS
OUTSIDE
DIAMETER
WELD PREP
(4-AXIS ONLY)
WALL
THICKNESS
INTERSECTION
ANGLE
WELD PREP
(5-AXIS ONLY)
X
ROTATION
Y-DISTANCE (CENTER)
HOLES - ROUND
WELD PREP
(4 & 5-AXES)
X-LENGTH
X-ROTATION
Y-LENGTH
CORNER
RADIUS
Y-DISTANCE
HOLES - RECTANGULAR
121
CENTERLINE
OFFSET
DIAMETER
(ID TYPE ONLY)
INTERSECTION
ANGLE
WELD PREP ANGLE

(FIXED TORCH ANGLE
4-AXES ONLY)
WELD PREP ANGLE

(5 AXES ONLY)
Y-CENTER DISTANCE
HOLES - SAW CUT
INTERSECTION
ANGLE
CENTERLINE
OFFSET
Y-DISTANCE
(CENTER)
DIAMETER
HOLES - BUMPER
122
X
ROTATION
DIAMETER
WELD PREP
(5-AXIS ONLY)
WELD PREP
(4-AXIS ONLY)
INTERSECTION
ANGLE
X
ROTATION
CENTERLINE
OFFSET
WALL
DIAMETER
Y-DISTANCE (CENTER)
RE-INFORCING PADS
123
WIDTH
APPENDIX E CUT VS INPUT DATA EXAMPLES
CONVENTIONS USED IN EXAMPLES
In the following examples, the BRANCH member is shown as pictured below, as viewed by the
operator with the pipe in the horizontal position on the pipe machine, ready to cut. END 1 of the
pipe is at the operator's left and END 2 of the pipe is at the operator's right. On standard pipe
machines, END 1 of the pipe will be toward the machine discharge end and END 2 will be toward
the machine entrance end. Where applicable, additional views will be presented.
On machines that discharge to the operator's right, the data input will be the same, except that
the distances along the pipe will be measured from right to left instead of left to right.
+ CENTERLINE
OFFSET
0
TORCH X-AXIS LOCATION AT CYCLE START
DETERMINES THE 0 RADIAL FOR AXIAL ANGLE
MEASUREMENT.
- CENTERLINE
OFFSET
0
45
AXIAL ANGLES
END 1
90
315
MACHINE DISCHARGE
END 2
BRANCH MEMBER
135
270
180
OPERATOR
225
- CENTERLINE
OFFSET
MACHINE ENTRANCE
+ CENTERLINE
OFFSET
0
TORCH
45
315
+X
270
90
225
135
180
VIEW A
124
ROTATING THE PIPE IN THE

+ X DIRECTION INCREASES
THE AXIAL ANGLE
VIEW A
125
EXAMPLE 1
EXAMPLE ONE - INTERSECTION ANGLE = 90
This cut is also known as a Tee intersection. The BRANCH member and the MAIN member
intersect at 90 degrees. There is no axial angle or centerline offset.
90
INTERSECTION ANGLE
MAIN 1
BRANCH
END 1
END 2
OPERATOR
TEE (90 ) INTERSECTION CUT
90
INTERSECTION ANGLE
END 1
END 2
BRANCH
OPERATOR
BRANCH
MAIN 1
MAIN 1
OPERATOR
126
Input Data:
127
Graphics:
128
129
EXAMPLE 2
130
Input Data:
131
Graphics:
132
133
EXAMPLE 3
EXAMPLE THREE - AXIAL ANGLE = 30
This example shows a MAIN member intersecting END 1 of the BRANCH member at an
AXIAL ANGLE of 30 degrees. The AXIAL ANGLE is measured from the 0 position and is
always measured away from the operator around the axis of the Branch member, regardless
of the end of the pipe being cut. The 0 degree position on the BRANCH member will be the
torch position, or the top of the BRANCH member, when the operator presses the cycle
start button.
The INTERSECTION ANGLE for this example is 90 degrees. Note that this example is
identical to example one except for the inclusion of an AXIAL ANGLE.
0
30 AXIAL
ANGLE
90
INTERSECTION
ANGLE
BRANCH
MAIN 1
END 1
AXIAL ANGLE
MEASURED FROM 0
POSITION, AWAY
FROM OPERATOR
END 2
CUT WITH AXIAL ANGLE
0
OPERATOR
30
TORCH POSITION
AT CYCLE START
90
INTERSECTION
ANGLE
MAIN 1
MAIN 1
END 1
BRANCH
END 2
OPERATOR
134
OPERATOR
BRANCH
Input Data:
135
Graphics:
136
137
EXAMPLE 4
EXAMPLE FOUR - COMBINATION OF INTERSECTION AND AXIAL ANGLES
In this example, the MAIN member has both a 45 intersection angle and a 30 axial angle.
This example is a combination of examples one and two.
0
30 AXIAL
ANGLE
45 INTERSECTION
ANGLE
MAIN 1
BRANCH
END 1
END 2
AXIAL ANGLE
MEASURED FROM 0
POSITION, AWAY
FROM OPERATOR
OPERATOR
0
30
TORCH POSITION
AT CYCLE START
MAIN 1
MAIN 1
END 1
END 2
BRANCH
OPERATOR
138
OPERATOR
BRANCH
Input Data:
139
Graphics:
140
141
EXAMPLE 5
EXAMPLE FIVE - CENTERLINE OFFSET
The CENTERLINE OFFSET is the distance between the centerlines of the BRANCH member
and the MAIN member and is measured along a line that is perpendicular to both. The
CENTERLINE OFFSET is positive if it moves the MAIN member towards the 90 position of
the BRANCH member.
In this example, MAIN 1 has a positive CENTERLINE OFFSET. The INTERSECTION ANGLE
is 90 and the AXIAL ANGLE is 0 . Note that the positive CENTERLINE OFFSET moves the
centerline of MAIN 1 towards the operator.
0
90
INTERSECTION
ANGLE
MAIN 1
BRANCH
CENTERLINE
OFFSET
END 1
END 2
OPERATOR
- CENTERLINE
OFFSET
MOVES MAIN MEMBER
AWAY FROM OPERATOR
+ CENTERLINE
OFFSET
MOVES MAIN MEMBER
TOWARDS OPERATOR
TORCH POSITION
AT CYCLE START
MAIN 1
CENTERLINE OFFSET
END 1
END 2
OPERATOR
BRANCH
BRANCH
MAIN 1
OPERATOR
142
Input Data:
143
Graphics:
144
145
EXAMPLE 6
EXAMPLE SIX - MULTIPLE INTERSECTION
This example contains two MAIN members. Deciding which is MAIN 1 and whcih is MAIN 2 is
arbitrary, although the more nealy vertical member is usually chosen as MAIN 1. In this example
MAIN 1 has an INTERSECTION ANGLE of 90 and MAIN 2 has an INTERSECTION ANGLE of 30 .
Both MAIN 1 and MAIN 2 have an AXIAL ANGLE of 0 and all centerlines intersect at one point.
The most important point of this example is the determination of BASELINE OFFSET. Since the
baseline of MAIN 2 is further away from END 1 of the BRANCH member than the baseline of
END 2, the BASELINE OFFSET is negative. The BASELINE OFFSET is measured from the
shortest point on the cut for MAIN 1 to the shortest point on the cut for MAIN 2.
MAIN 1
INTERSECTION
ANGLE = 90
MAIN 1
MAIN 2
MAIN 2
INTERSECTION
ANGLE = 30
END 1
BRANCH
END 2
OPERATOR
MAIN 2
MAIN 2
MAIN 1
END 1
END 2
OPERATOR
BRANCH
BRANCH
MAIN 1
OPERATOR
146
Input Data:
147
Graphics:
148
149
EXAMPLE 7
EXAMPLE SEVEN - MULTIPLE INTERSECTION
This is an example of a three intersection cut. It is similar to the previous example, except a
third MAIN member, MAIN 3, has been added. MAIN 3 intersects the BRANCH member at
an AXIAL ANGLE of 180 .
MAIN 1
INTERSECTION
ANGLE = 90
MAIN 2
MAIN 1
MAIN 2
INTERSECTION
ANGLE = 30
BRANCH
END 1
END 2
MAIN 3
MAIN 3
INTERSECTION
ANGLE = 30
OPERATOR
0 AXIAL ANGLE
MAIN 2
MAIN 2
MAIN 1
BRANCH
END 1
END 2
OPERATOR
BRANCH
MAIN 3
MAIN 1
MAIN 3
OPERATOR
180 AXIAL ANGLE
150
Input Data:
151
Graphics:
152
153
EXAMPLE 8
EXAMPLE EIGHT - MULTIPLE INTERSECTION
This is another example of a two intersection cut, but with one major difference; one of the
MAIN members, MAIN 2, does not continue through the other side of the BRANCH member.
MAIN 1 is the same as in the previous example, with an INTERSECTION ANGLE of 90 and
an AXIAL ANGLE of 0 . MAIN 2 also has an INTERSECTION ANGLE of 90 , but has an
AXIAL ANGLE of 270 . The MAIN 2 AXIAL ANGLE could also be entered as -90 .
Notice that MAIN 1 results in the BRANCH member being cut away at both the 0 and at the
180 axial angle positions, while MAIN 2 results in the BRANCH member being cut away at
the 270 axial angle position only - there is no cut away on the opposite side (90 axial angle
position). Thus, the second member is said to be not thru. On the screen input, MAIN 2 "THROUGH"
value is set to NO.
MAIN 1
INTERSECTION
ANGLE = 90
MAIN 1
THRU
MAIN 2
NOT THRU
BRANCH
END 1
END 2
MAIN 2
INTERSECTION
ANGLE = 90
OPERATOR
MAIN 1
MAIN 2
NOT THRU
END 1
MAIN 2
END 2
OPERATOR
BRANCH
BRANCH
MAIN 1
THRU
MAIN 2 AXIAL
ANGLE = 270
(OR -90 )
OPERATOR
154
Input Data:
155
Graphics:
156
157
EXAMPLE 9
EXAMPLE NINE - BOTH ENDS CUT
Both ends of the BRANCH member are cut in this example. Boths ends of the BRANCH member
have an INTERSECTION ANGLE of 45 and an AXIAL ANGLE of 0 . The DISTANCE BETWEEN
CUTS (DS BTW CUT on the console screen) is measured from the shortest point on END 1 to
the shortest point on END 2. In this example, the measurement would be along the top of the I.D.
of the BRANCH member because both MAIN 1 and MAIN 2 have an AXIAL ANGLE of 0 .
As a reminder, the DISTANCE BETWEEN CUTS is measured on the BRANCH I.D., as indicated
below:
TORCH POSITION @ CYCLE START
DS BTW CUT
DS BTW CUT
END 2
END 1
DS BTW CUT
END 2
END 1
END 1
END 2
EXAMPLES OF DISTANCE BETWEEN CUTS ON THE BRANCH MEMBER
MAIN 1
MAIN 2
END 1
BRANCH
END 2
OPERATOR
0 AXIAL ANGLE
45 MAIN 1
INTERSECTION
ANGLE
45 MAIN 2
INTERSECTION
ANGLE
MAIN 1
BRANCH
END1
BRANCH
END 2
OPERATOR
MAIN 1
MAIN 2
MAIN 2
180 AXIAL ANGLE
OPERATOR
158
Input Data:
159
Graphics:
160
161
EXAMPLE 10
EXAMPLE TEN - BOTH ENDS CUT
As in example 9, both END 1 and END 2 of the BRANCH member are cut. The END 1 cut is the
same as example 9, with an INTERSECTION ANGLE of 45 and an AXIAL ANGLE of 0 . END 2,
however, has an INTERSECTION ANGLE of 60 and an AXIAL ANGLE of 180 . Although the
END 2 INTERSECTION ANGLE could be entered as 120 with a corresponding AXIAL ANGLE
of 0 , entering the acute angle is generally preferred.
MAIN 1
INTERSECTION
ANGLE = 45
0 AXIAL ANGLE
MAIN 2 - ALTERNATE INPUT

INTERSECTION ANGLE = 120
AXIAL ANGLE = 0
MAIN 1
0 AXIAL ANGLE
MAIN 2
END 1
BRANCH
END 2
OPERATOR
180 AXIAL ANGLE
MAIN 2 - PREFERRED INPUT
INTERSECTION ANGLE = 60
AXIAL ANGLE = 180
0 AXIAL ANGLE
45 MAIN 1
INTERSECTION
ANGLE
MAIN 1
BRANCH
END1
BRANCH
END 2
OPERATOR
MAIN 1
MAIN 2
OPERATOR
MAIN 2
180 AXIAL ANGLE
60 MAIN 2
INTERSECTION
ANGLE
162
Input Data:
163
Graphics:
164
165
EXAMPLE 11
EXAMPLE 11 - BOTH ENDS CUT
In this example, END 1 of the BRANCH member is the same as the previous two examples. END 2
has a cut with an INTERSECTION ANGLE of 90 and an AXIAL ANGLE of 90 .
MAIN 1
INTERSECTION
ANGLE = 45
0 AXIAL ANGLE
MAIN 2
INTERSECION
ANGLE = 90
MAIN 1
0 AXIAL ANGLE
90 AXIAL ANGLE
END 1
BRANCH
MAIN 2
END 2
OPERATOR
0 AXIAL ANGLE
45 MAIN 1
INTERSECTION
ANGLE
MAIN 1
90 MAIN 2
INTERSECTION
ANGLE
BRANCH
END1
BRANCH
90
AXIAL
ANGLE
END 2
OPERATOR
MAIN 2
MAIN 1
OPERATOR
166
MAIN 2
Input Data:
167
Graphics:
168
169
EXAMPLE 12
EXAMPLE 12 - COMPLEX INTERSECTION
This example is of a complex intersection. It is typical of a cut that might be required for an
offshore oil well structure. MAIN 1 would be one of the platform legs and has a double batter.
MAIN 2 and the BRANCH member are in the horizontal plane.
0 AXIAL ANGLE
MAIN 1
MAIN 1 INTERSECTION
ANGLE = 87.417
END 1
BRANCH
END 2
MAIN 2
MAIN 2 INTERSECTION
ANGLE = 41.336
OPERATOR
MAIN 2 AXIAL
ANGLE = -82.417
0 AXIAL ANGLE
MAIN 2
END 2
OPERATOR
BRANCH
MAIN 1
MAIN 2
MAIN 1
OPERATOR
170
BRANCH
Input Data:
171
Graphics:
172
173
EXAMPLE 13
EXAMPLE 13 - HOLES
In this example, the BRANCH member has two circular holes, HOLE 1 and HOLE 2, and
straight cuts at END 1 and END 2. Both HOLE 1 and HOLE 2 have an INTERSECTION ANGLE
of 90 . The locations of the holes along the Y-axis of the BRANCH member (Y-CNTR on the
input screen) are each measured from the short point of the first cut (END 1). Note that the
Y-CNTR values are negative, being measured from END 1 to END 2. The AXIAL ANGLE
(X-ANGL on the input screen) of HOLE 1 is 0 and the AXIAL ANGLE of HOLE 2 is 270 . Note
that the values for wall thickness (W THCK on the input screen) is 0.000, which will result in
the hole diameters being the same size as the specified outer diameter (0 DIAM).
HOLE 1 Type is specified as "OD=1", which will result in a HOLE 1 diameter equal to the
specified outer diameter (O DIAM) of the intersecting pipe. HOLE 2 Type is specified as "ID=2",
which will result in a HOLE 2 diameter equal to the specified outer diameter minus the wall
thickness (W THCK). Since the wall thickness is 0.000 for HOLE 2, the hole diameter will be
equal to the outer diameter, even though it is specified as an inside diameter.
0 AXIAL ANGLE
HOLE 1
INTERSECTION
ANGLE = 90
END 1
HOLE 1
BRANCH
HOLE 2
INTERSECTION
ANGLE = 90
END 2
Y-AXIS
270 AXIAL ANGLE
HOLE 2
0 AXIAL ANGLE
OPERATOR
HOLE 1
HOLE 2
HOLE 1
Y-AXIS
END1
270
AXIAL
ANGLE
END 2
OPERATOR
BRANCH
BRANCH
HOLE 2
-20.000
-50.000
OPERATOR
174
Input Data:
175
Graphics:
176
177
EXAMPLE 14
EXAMPLE 14 - HOLES
In this example, the BRANCH member has a circular hole, HOLE 1, and a square hole, HOLE 2.
END 1 and END 2 are straight cuts. HOLE 1 has an outer diameter of 8.000 and a wall thickness
of 0.500, which results in a hole diameter of 7.000 (8.000 - 2 x 0.500 = 7.000). Note also that the
TORCH ANGLE (Weld Prep Angle on the input screen) will be 45 . Generally, the angle of the torch
will be the same as the angle of intersection, in order to cut the hole wall parallel to the intersecting
member for proper fit. Remember, however, that the TORCH ANGLE is measured from the
perpendicular to the BRANCH Y-axis while the INTERSECTION ANGLE is measured from the
BRANCH Y-axis itself. Thus, the TORCH ANGLE will usually be entered as the compliment of
the INTERSECTION ANGLE.
HOLE 1
TORCH
ANGLE = 45
0 AXIAL ANGLE
HOLE 1
INTERSECTION
ANGLE = 45
TORCH
ANGLE
MEASUREMENT
HOLE 1
BRANCH
TORCH
END 1
INTERSECTION
ANGLE
MEASUREMENT
END 2
HOLE 1
Y-AXIS
270 AXIAL ANGLE
Y-AXIS
HOLE 2
OPERATOR
BRANCH
A
VIEW A-A
0 AXIAL ANGLE
HOLE 1
HOLE 2
HOLE 1
Y-AXIS
END1
270
AXIAL
ANGLE
END 2
OPERATOR
BRANCH
BRANCH
HOLE 2
-20.000
-50.000
OPERATOR
178
Input Data:
179
Graphics:
180
181
EXAMPLE 15
EXAMPLE 15 - HOLES
In this example, which is similar to the previous one, the HOLE 2 INTERSECTION ANGLE
is in the opposite direction and has a CENTERLINE OFFSET. The CENTERLINE OFFSET is
a negative number because the hole is moved toward the operator.
0 X ANGLE
0 X ANGLE
Y-AXIS
END 1
HOLE 1
HOLE 2
INTERSECTION
ANGLE = -45
HOLE 2
END 2
BRANCH
OPERATOR
0 AXIAL ANGLE
HOLE 1
INTERSECTION
ANGLE = 90
HOLE 2
HOLE 2
INTERSECTION
ANGLE = -45
HOLE 1
HOLE 2
CENTERLINE
OFFSET = -2.500
Y-AXIS
END1
END 2
OPERATOR
BRANCH
-20.000
-50.000
OPERATOR
182
BRANCH
Input Data:
183
Graphics:
184
185
APPENDIX E WINDOWS 2000 KEYBOARD SHORTCUTS
186
APPENDIX F WinMPM DIRECTORY AND FILES STRUCTURE

WinMPM parent directory:
WinMPM.exe
Calcs3K.dll
GCL52FW.dll
Error.txt
ErrorLog.txt (WinMPM will create this)
NewVersion.exe
WinMPM.ini (WinMPM will create this)
WinMPM.in2 (WinMPM will create this)
DAT subdirectory:
DOWNLOAD.PMC
DOWNRETR.PMC
DOWNZERO.PMC
HELP subdirectory:
EndTypes.txt
Ivars.txt
PlcStatus.txt
Top.gif
.wmf images: Crown, Elbow, EndSlots, HoleRound, HoleSawCut, HoleSquare,
Miter1, Miter2, Saddle1, Saddle2, Straight, Top, Transition1,
Transition2
PMC subdirectory:
ConsoleMpm.PLC
DdfsMPM.plc
GCODE.PRG
InitMPM.pmc
McodeMPM.prg
POSITION.plc
Setup.plc
THMB.plc
ZHOME.plc
TBL subdirectory:
Feedrate.TBL
PDELAY.TBL
NC subdirectory:
Contains NC (.NC) files. Must exist but can be empty
PMP subdirectories:
Contains Pipe Machine Program (.pmp) files. Must exist but can be empty.
187
Index
A
abort.............................................................................................................................................53, 64, 65, 94
alignment ........................................................................................................................................................ 7
axial angle.......................................................................................................................................29, 30, 104
B
baseline offset.......................................................................................................................................28, 104
bevel correction factor...........................................................................................................................94, 100
branch member ............................................................................................25, 28, 29, 32, 104, 105, 106, 107
C
calculations................................................................................................................................32, 62, 73, 100
centerline offset..............................................................................................................................28, 31, 104
computer............................................................................ 1, 5, 13, 14, 15, 16, 28, 54, 60, 62, 73, 86, 90, 100
contour carriage .......................................................................................................................................10, 11
conveyors .......................................................................................... 1, 2, 5, 6, 7, 8, 9, 10, 11, 12, 87, 88, 105
cut quality ..........................................................................................................................................52, 63, 98
D
data ................................................................ 15, 19, 22, 25, 30, 31, 32, 37, 41, 52, 53, 55, 60, 69, 73, 85, 90
disk drives ...............................................................................................................................2, 60, 62, 81, 90
display ................................................................................... 14, 15, 16, 51, 53, 59, 64, 65, 70, 73, 90, 91, 98
dry run ............................................................................................................................................................ 2
F
feed rate ...................................................................................................................................................81, 83
foundation............................................................................................................................................5, 6, 7, 8
G
gates.........................................................................................................................................................10, 12
H
handwheel............................................................................................ 14, 28, 29, 31, 51, 54, 97, 99, 104, 107
HELP............................................................................................................................................................ 20
holes ..........................................................................................................................................30, 31, 52, 104
home ............................................................................................................................................14, 65, 69, 98
hydraulics ..........................................................................................................................5, 6, 8, 9, 10, 87, 93
I
installation .........................................................................................................................................6, 7, 8, 87
intersections..................................................................................... 19, 28, 29, 30, 31, 57, 104, 105, 106, 107
K
kerf ..................................................................................................................................................62, 94, 100
L
length of cut..5, 9, 11, 16, 25, 28, 29, 31, 51, 57, 62, 63, 64, 65, 73, 94, 97, 98, 100, 104, 105, 106, 107, 108
limits................................................................................................................................16, 25, 69, 91, 92, 99
listing data .................................................................................................................................2, 6, 34, 43, 44
loads, maximum ............................................................................................................................................. 5
188
M
main member..................................... 2, 6, 11, 28, 29, 32, 33, 37, 44, 52, 87, 96, 99, 100, 104, 105, 106, 107
maintenance.............................................................................................................................................73, 86
N
NC programming.......................................................................................................34, 37, 41, 43, 44, 60, 81
O
OD.....................................................................................................................................28, 30, 57, 105, 106
offsets .................................................................................................. 14, 28, 29, 31, 51, 54, 97, 99, 104, 107
operating system............................................................................................................................................. 2
P
part number................................................................................................................................................... 37
pivot point .....................................................................................................................87, 94, 97, 98, 99, 100
plasma................................................................................................................13, 52, 58, 61, 62, 63, 81, 105
power box ................................................................................................5, 6, 8, 11, 16, 69, 73, 81, 86, 90, 93
programming .........................................................................................................2, 16, 19, 22, 37, 81, 83, 85
R
retrace ........................................................................................................................................................... 53
return to program start .......................................................................................................................14, 37, 52
S
sensors ...............................................................................................................11, 14, 51, 81, 92, 98, 99, 100
servo drives......................................................................................................................11, 16, 73, 87, 91, 92
single step ..................................................................................................................................................... 52
T
tilt 10, 12
transition cut ..........................................................................................................................28, 57, 105, 106
trouble shooting.......................................................................................................................................90, 93
V
vertical carriage ....................................................................... 7, 8, 10, 11, 13, 51, 69, 82, 88, 92, 97, 99, 100
V-Assist.................................................................................................................................................... 20
189

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VERNON TOOL COMPANY

4 and 5-AXIS MICROPROCESSOR PIPE

4.3.3 Programming End 1 (<F1>, <F2>) ............................................................... 32

Home Offsets (<F6>, <F5>) ............................................................................ 71

Appendix F WinMPM Directory and File Structure

Most microprocessor pipe machines consist of three parts - an entrance conveyor,

Typical Vernon System

The lifter conveyor system (4)

This page intentionally left blank.

INSTALLATION AND SETUP

250 lbs. per foot to a maximum loading of 5,000 lbs.

100 degrees (F)

2.2 Assembly of the Vernon MPM machine:

Machine Shipment Arrival.

under the machine.

Conveyors. If more than 1 machine bed is being used continue to the

2.3 Installation of the conveyors

2.4 Hydraulic System

2.5 Locate the Power Box.

2.6 Install the new Operators Console.

2.7 Install the Y-axis carriage on the Y-axis track.

Installation, Testing, Commissioning, and Training Schedule:

The cutting machine is made up of several functional components as described in the

The machine conveyor (sometimes called the lifter-conveyor) allows pipe to be

Machine conveyor lifter

Vertical Carriage and Motor

A-Axis (5-axes (MPM5) only)

Contour Carriage Control Box

CONTROL (OPERATORS) CONSOLE

Left and Right pushbuttons

First the conveyor or conveyors to be moved

Loading Rack Controls

The contour torch is the torch that

Cutoff Torch (optional)

Marking Torch (optional)

The sensor pushbuttons are used to

Keyboard and Display

MAIN MENU DISPLAY

are display to the left of X Degree.

Optional Straight Cut Off Carriage.

This page intentionally left blank.

USE OF THE KEYBOARD

WinMPM Users Manual

V-Assist (Vernon Electronic Assistance)

V-Assist (Vernon Electronic Assistance) sets up an interactive internet session

CUT PROGRAMMING (<F1>)

Setting WinMPM Options

The Production mode is a fully function operating system to run

Remember window position between runs:

Load last Pipe Machine Prog at startup:

Print cut info with cut sheets

Error alarm sound:

Status font size (points):

Pipe Data (<F1>, <F1>)

Programming End 1 (<F1>, <F2>)

Editing End 1 (<F1>, <F1>, <F1>)

Programming Midsection (<F1>, <F3>)

Programming End 2 (<F1>, <F4>)

Calculating a Pipe Machine Program (.PMP) (<F1>, <F7>)

Listing and Editing a Pipe Machine Program (.PMP) (<F1>, <F5>)

Saving a Pipe Machine Program (.PMP) (<F1>, <F9>)

Pipe Machine Program Data (.PMP)

Loading a Pipe Machine Program (.PMP) (<F2>)