Vision VR48 4 Series User manual

© 2015 Vision Engraving and Routing Systems
Vision VR48 Series 4
Router User Manual
Revised: 8/19/2015

All rights reserved. No parts of this work may be reproduced in any form or by any means - graphic, electronic, or
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While everyprecaution has been taken in the preparation of this document, the publisher and the author assume no
responsibility for errors or omissions, or for damages resulting from the use of information contained in this document or
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for anyloss of profit or any other commercial damage caused or alleged to have been caused directly or indirectly by this
document.
Revised: 8/19/2015
Vision VR48 Series 4 Router User Manual
© 2015 Vision Engraving and Routing Systems

3Contents
3
© 2015 Vision Engraving and Routing Systems
Table of Contents
Part I Introduction 6
................................................................................................................................... 71 Disclaimer and Warranty Information
................................................................................................................................... 92 Safety Precautions
................................................................................................................................... 123 Emergency Stop Locations
Part II General Information - Installation 14
................................................................................................................................... 141 Requirements
................................................................................................................................... 172 Wiring Connections
................................................................................................................................... 213 Carriage Ports Description
................................................................................................................................... 224 Installation Layout Diagram - T-Slot Table Models
................................................................................................................................... 235 Installation Layout Diagram - Vacuum Table Models
................................................................................................................................... 246 Vacuum Pump Installation - Vacuum Table Models Only
................................................................................................................................... 267 Mounting the Pendant Holder
Part III Series 4 Contoller and Vision 9 Software
Installation 27
................................................................................................................................... 271 Computer Requirements
................................................................................................................................... 292 Direct Connection to Computer
................................................................................................................................... 363 Network Connection
................................................................................................................................... 394 Using a Network Hub - ONLY
................................................................................................................................... 465 Vision Software Installation
Part IV Router, Engraving and Knife Heads 56
................................................................................................................................... 561 High Frequency Router Head
................................................................................................................................... 582 Engraving Head and Spindles
................................................................................................................................... 613 Cutting Tool Installation
................................................................................................................................... 654 Oscillating Knife
.......................................................................................................................................................... 66Oscillating Knife Operation
Part V Operation 72
................................................................................................................................... 721 The Pendant Controls
................................................................................................................................... 902 Using the Measure Feature
................................................................................................................................... 933 Set Surface Procedures
................................................................................................................................... 964 Set Home Procedure
................................................................................................................................... 975 Sending Jobs to Your Machine
................................................................................................................................... 996 Using the T-Slot Table
................................................................................................................................... 1017 Using the Vacuum Table

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................................................................................................................................... 1028 Vacuum Table Zones
................................................................................................................................... 1049 Dust Collector Operation
Part VI The DACS Camera System 107
................................................................................................................................... 1071 DACS Test File
................................................................................................................................... 1082 Setting Up the DACS Camera System 2
.......................................................................................................................................................... 108Machine ToolsInstallation
.......................................................................................................................................................... 109Ethernet Camera Driver Installation
.......................................................................................................................................................... 111Ethernet Camera Software Setup
.......................................................................................................................................................... 116Camera Adjustments
.......................................................................................................................................................... 119Vision VR48 Machine Configuration
.......................................................................................................................................................... 125Vision Software Setup
................................................................................................................................... 1273 Using the DACS Camera System
Part VII Example Jobs 135
................................................................................................................................... 1361 Level 1 Job Examples
.......................................................................................................................................................... 136Diamond Drag Engraving
......................................................................................................................................................... 137Example Job 1 - Diamond Drag
.......................................................................................................................................................... 147Rotary Engraving
......................................................................................................................................................... 148Example Job 2 - Rotary Engraving
.......................................................................................................................................................... 152Burnishing
......................................................................................................................................................... 154Example Job 3 - Burnishing
.......................................................................................................................................................... 163Profile Cutting
......................................................................................................................................................... 165Example Job 4 - Profile Cutting
................................................................................................................................... 1772 Level 2 Job Examples
.......................................................................................................................................................... 177Reverse Engraving/Color Filling
......................................................................................................................................................... 177Example Job 5 - Reverse Engraving
.......................................................................................................................................................... 186Deep Engraving Sign Foam
......................................................................................................................................................... 186Example Job 6 - Deep Engraving
.......................................................................................................................................................... 205Profile Cutting Dimensional Letter - Metals
......................................................................................................................................................... 205Example Job 7 - Dimensional Letter in Metals
.......................................................................................................................................................... 213Profile Cutting Dimensional Letter - Non-metals
......................................................................................................................................................... 213Example Job 8 - Dimensional Letters in Non-Metals
................................................................................................................................... 2213 Level 3 Job Examples
.......................................................................................................................................................... 221ADA Signs
......................................................................................................................................................... 221Example Job 9 - Acrylic ADA Signage
.......................................................................................................................................................... 250Control Panels
......................................................................................................................................................... 250Example Job 10 - Plastic Control Panel
................................................................................................................................... 2814 Feeds and Speeds
Part VIII Vectorizing Images in Vision 9 Pro 283
Part IX Creating Multiples and Serialization in Vision
9 Expert and Pro 312
Part X Maintenance 331
................................................................................................................................... 3311 General Cleaning
................................................................................................................................... 3322 Electronics Maintenance

5Contents
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................................................................................................................................... 3343 Motion SystemCleaning and Lubrication
................................................................................................................................... 3404 Vacuum Pump Maintenance
Part XI Optional Accessories 342
................................................................................................................................... 3421 UNIST Misting System
................................................................................................................................... 3452 Vacuum Chip Removal System
................................................................................................................................... 3463 Hold Down Clamps
................................................................................................................................... 3484 Fixtures
................................................................................................................................... 3515 Clamping Vises

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© 2015 Vision Engraving and Routing Systems
1 Introduction
About This Manual
Thank you for your purchase of the Vision VR48 Large Format Engraving and Routing System. To fully
take advantage of your system, be sure to read this guide completely before using your system. This
manual is designed to provide you with information about your VR48 machine. Beginning with ing the
machine and continuing through installation, operation and maintenance, this manual does not attempt
to teach the user howto become an expert in engraving, computer usage, or engraving software
usage. Some previous knowledge of engraving terms and the engraving process is certainly
beneficial. For information on the Vision Engraving Software, see the Vision Engraving
Software manual. For more information on your individual computer system, see your computer's
user manual or contact your computer distributor.
To begin, locate the White/Blue Dongle or Orange Dongle or USB
Stick included with your machine in the Accessories Box
Important Note:
The Vision software is available in two versions; one with a dongle, and one
that is "dongle-less" and is loaded on to a USB Memory stick.
If your machine was delivered with, or you currently have the white/blue or
orange software dongle, DO NOT LOSE IT!
The Vision software will NOT run without the dongle plugged into the
computer.

Introduction 7
© 2015 Vision Engraving and Routing Systems
1.1 Disclaimer and WarrantyInformation
Limits of Liability / Disclaimer of Warranty
The information contained within this manual has been carefully checked and is believed to be accurate,
however, Vision makes no representations or warranties for this manual, and assumes no responsibility
for inaccuracies, errors, or omissions that may be contained within this manual. In no event shall Vision
be liable for any loss of profit including (but not limited to) direct, indirect, special, incidental,
consequential, or other damages resulting from any defect or omission in this manual, even if previously
advised of the possibility of such damages.
In the interest of continued product development, Vision reserves the right to make improvements to this
manual and the products it describes at any time, without notice or obligation.
Limited Warranty:
Vision Computerized Engraving and Routing Systems
Vision Computerized Engraving and Routing Systems (Vision) warrants that for a period of one year
fromthe date of shipment to the original purchaser of the VR48 Router (the System), that the System
will be free from defects in material and workmanship under normal use and service. Upon written
notification, we will transfer the remaining warranty to a new customer. This warranty shall cover all
elements except for items covered by separate manufacturer’s warranties and consumable items.
“Consumable” items include, but shall not be limited to, belts, brushes, lubricants, and cutters furnished
with the System, for which no warranty is provided.
In the event a defect is discovered during the warranty period, within thirty days of discovery, but no
later than the last day of the warranty period as described above, the user shall contact Vision for
instructions regarding disposition of the problem. Vision shall, at its option, either (1) repair the affected
product with new or refurbished parts, or (2) provide a replacement. Any incidental costs, including the
cost of shipment from the user’s location to the point of repair and return, and any installation performed
by the user, shall be at the expense of the user.
This warranty covers normal use only and shall be void in the event that the System is altered or
modified without authorization by Vision, or is subject to abuse, neglect, or other misuse by the user.
The warranties for Third-Party Hardware and Third-Party Software shall run directly from the
manufacturers of such hardware and software to the user. Vision makes no warranties, expressed or
implied, with regard to Third-Party Hardware or Third-Party Software.

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© 2015 Vision Engraving and Routing Systems
Vision does not warrant any product, component, or part not manufactured by Vision that was not
supplied by Vision. (Third-party items, including but not limited to software, are subject to their own
manufacturer’s warranties.) Vision does not warrant defects caused by a failure to provide a suitable
environment for the system, by unauthorized attachments, by modifications or repairs other than by
Vision, by use of the Systemfor other than its original intention, or by other misuse or abuse of the
System.
Extended Warranty
An Extended Warranty may be purchased which extends the terms of the original equipment Warranty
in 1 year increments for a period of up to 30 days after the original equipment Warranty expires. An
Extended Warranty may also be purchased for a period of up to 30 days after an existing Extended
Warranty expires. Extended Warranties cannot be purchased on any equipment that is 7 or more years
old, or if there is a Lapse of Warranty. Age of equipment is determined fromthe date of shipment to the
original buyer.
Lapse of Warranty
If an Extended Warranty is not purchased within 30 days of the expiration of the original equipment
Warranty, or within 30 days of the expiration of an existing Extended Warranty, the equipment will be in
Lapse of Warranty. An Extended Warranty can never again be purchased for any equipment that is in
Lapse of Warranty. It is the responsibility of the purchaser of the equipment to maintain accurate
records and to knowthe expiration date of any Warranty.
The above and foregoing is the only warranty of any kind, either expressed or implied, by statute or
otherwise, regarding the System, its fitness, quality, merchantability, or otherwise. Any warranties
implied by laware hereby expressly disclaimed. No oral or written information or advice given by Vision,
its Dealers, Distributors, Agents, or Employees shall create a warranty or in any way increase the
scope of this warranty. Neither Vision, nor anyone else who has been involved in the creation,
production, or delivery of the System shall be liable for any direct, indirect, consequential, or incidental
damages (including damages for loss of business profits, business interruption, loss of business
information, and the like) arising out of the use of, or inability to use, the product.
Any software supplied by Vision in conjunction with the purchase of the System for use therewith shall
be governed by its own separate software license and warranty agreement.
Terms and Conditions are subject to change
For Warranty Service Call: [phone]
Please have your machine serial number ready before calling.
Vision Engraving & Routing Systems is owned and operated by Western Engraver's Supply, Inc.
Phoenix, Arizona, USA

Introduction 9
© 2015 Vision Engraving and Routing Systems
1.2 SafetyPrecautions
WARNING: Do not attempt to operate this equipment until you have read thoroughly and
understood completely the instructions contained in this User's Guide! Failure to comply may
result in damage to the equipment and/or inflict serious personal injury!
Only trained personnel should operate the VR48 system. All individuals operating this system should
have read and understand this complete User's Guide.
Use of this equipment by unauthorized or untrained personnel may result in damage to the equipment
and/or inflict serious personal injuries.
Never use this machine in a Hazardous environment. Do not store or use this machine outdoors. Do
not run this machine in an extremely hot environment.
Place the equipment in a location with low humidity and a minimumof dust. Avoid placing the
equipment in direct sunlight or in locations with excessive heat.
Do not expose the equipment to rain or use it near water. You can clean the controller with a damp
cloth, but be sure to unplug the unit first.
Follow the maintenance instructions for proper cleaning of the controller air filter.
There are no user serviceable parts inside the controller. Please contact qualified service personnel
for service issues.
Openings are provided in the controller box for ventilation. Do not cover the openings or place the
controller in an environment where the openings may become blocked.
Never insert anything into the ventilation openings. Doing so may create a danger of electric shock.
Always stop the machine before making any adjustments.
Keep hands clear of the bottom of the spindle during operation.
Do not operate the equipment with the covers removed.
Use extreme caution when inserting or removing cutters.
Before any servicing, disconnect the power cord.

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To avoid electric shock or equipment damage, connect the power to this machine according to the
suggestions in this guide and in compliance with all applicable regulations. Make sure the machine is
properly grounded.
Never operate the equipment with damaged or frayed power cords, loose connections, or exposed
extension cords where the cord could create a tripping hazard.
Be sure to hold the plug, not the cord, when disconnecting the equipment from an electrical socket or
power source.
Keep work area clean. Remove adjustment tools from the machine prior to start-up. Keep workbench
clean. Cluttered work areas can increase the potential for an accident.
Safety Glasses should be worn at all times while machine is running. While machine is running, chips
or other debris may become airborne.
Avoid loose clothing, neckties, gloves, rings, bracelets, or jewelry which may get caught in moving
parts.
If your equipment does not operate properly; in particular, if there are any unusual sounds or smells
coming fromit, immediately unplug it and contact a service technician or your local distributor.
Unplug the machine when it is going to be left unused for an extended period of time.
Operators should inspect the machine daily for damage or modifications. Under no circumstances
should the machine be operated if there is any doubt about the machine condition. If there are any
questions call the Vision Engraving Systems technical support team at 602-439-0600.
Keep a safe distance away from machine while its running.
Keep children away fromwork area at all times. Visitors should be at least 3 feet or more away from
working area.
Do not operate this or any machine while under the influence of drugs or alcohol.
Keep hands away fromthe spindle at all times when spindle is rotating and/or machine is moving.
Always wait for spindle to stop rotating completely before attempting to insert or change a tool. Do not
try to stop the spindle manually with your hands or other devices. Failure to comply with these
instructions may result in serious personal injury!
Never leave the machine running unattended.

Introduction 11
© 2015 Vision Engraving and Routing Systems
Press any Emergency Stop switch to stop the machine immediately.
Be familiar with the location of all emergency stop switches. In the case of an emergency you can
push the nearest one.
Make sure workpiece is properly fastened to table before starting job.
Turn on vacuum table or make sure clamps and other fixtures are tightly fastened. If workpiece moves
during operation you can damage the machine, the workpiece, and serious personal injury may
occur to the operator.
Only use the machine and its attachments for the applications they were designed for. Forcing the
machine or its attachments to do work it was not intended to do may cause permanent damage to the
machine and serious injury may occur to the operator. If there are any questions about the abilities of
your machine, please call the Vision Engraving Systems technical support team at 602-439-0600.
Do not force the machine to work at excessive speeds. The machine will work safely under normal
permissible speeds which are material and application dependent. Using excessive speeds may
damage tooling, material, the machine, and may cause serious personal injury.
Avoid powering on the machine when servicing the machine.
Avoid powering on the machine when installing or replacing parts and/or accessories.
Turn power to the machine OFF when not in use.
Perform required maintenance at the recommended intervals.
Use the general maintenance guidelines to properly maintain your machine.
A disciplined approach to preventative maintenance can extend the useful life of any Router/Engraver,
improve cut quality, and reduce repair costs. Keep records of what and when you perform
maintenance duties.

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1.3 EmergencyStop Locations
There are 4 emergency stop buttons on the VR48. One is on each side of the gantry, one is on the front
panel and the last one is on the Pendant. Refer to the belowdiagram and pictures to identify the
emergency stop locations.
Users should be familiar with EmergencyStop locations before
using the machine. Failure to do so can result in serious injuryor
damage to the machine!

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2 General Information - Installation
2.1 Requirements
Electrical Connections
1. A qualified and licensed electrician must be used to complete all wiring and grounding of the
machine according to all state, local, and national electrical codes.
2. Make sure all Junction Boxes and Outlets are mounted according to all state, local and national
electrical codes.
3. Junction Box#1 (50 Amp, 220 VAC, Single Phase) will power the router table, spindle, and controls.
It is typically mounted on Wall A, approximately 36 to 48 inches above the floor surface. The box
should be level with the left edge of the router table. (Refer to Installation Layout Diagrams).
4. Junction Box#2 - for machines equipped with Vacuum Tables ONLY - (40 Amp. 220 VAC, 3 Phase)
will power the Vacuum Pump. Mounting should be on Wall A and between 36 inches and 48 inches
above the floor surface. If locating the vacuum pump as shown (Refer to Installation Layout
Diagram), locate Junction Box#2 no greater than 4 feet fromJunction Box#1.
5. Outlet #1 (20 Amp, 220 VAC, Single Phase or 25 Amp, 110 VAC) should be mounted on Wall A as
shown (Refer to Installation Layout Diagram- Section 2.1). This can also be another Junction Boxif
the Dust Collector is to be direct wired to its electrical source. The dust collector is approximately 2
feet x3 feet and is on wheels.
6. Outlet #2 (15 Amp, 110 VAC, Single Phase) should have multiple standard three prong sockets for
the computer. It is typically located near the bottom left corner of the router table (home position) as
shown (Refer to Installation Layout Diagram).
7. Wiring needs to be completed to the junction boxes, outlets, etc. before the scheduled first
installation/machine orientation day.

General Information - Installation 15
© 2015 Vision Engraving and Routing Systems
Locating the Router
1. A doorway of at least 80 inches wide and 80 inches high is required in order for the router to be
moved into your facility.
2. Locate machine indoors on a flat surface and on a solid foundation.
3. Temperature must remain between 40°F and 85°F.
4. Do not expose machine to direct sunlight, rain, vibration, dampness, or explosive environments.
5. A forklift is required to remove the crate from the shipping truck and to locate the equipment in the
building. The forklift must have a minimumcapacity of 6,000 lbs and 6' or longer forks.
6. A pallet jack is required to level the router table.
7. The router table footprint is approximately 6.7 feet x10.7 feet. A designated work area of at least 5
feet is strongly recommended around all sides of the machine to ensure ease of operation, material
handling, cleaning, maintenance and safety.
8. Typically, the vacuum pump is between the router table and Wall A (Refer to Installation Layout
Diagram - Section 2.1). Please note the orientation of the pump and motor.

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© 2015 Vision Engraving and Routing Systems
Leveling the machine
1. Make sure the machine has been properly located at your work-site.
2. It is not necessary to bolt your machine to the floor in your facility. However, a solid, stable
foundation is required to support the machine's weight.
3. There should be a leveling bolt in each of the four machine legs.
4. Place a precision leveling gauge on the machine's table top and adjust the leveling bolts until the
machine is level in both the horizontal and vertical directions.
Scheduling the Installation
1. Please schedule an electrician for the morning of the first day of installation/machine orientation to
connect the router table, vacuum pump motor, and dust collector to the junction boxes and outlets.
2. If an electrician is not available for the installation, please call Vision ASAP in order to reschedule
installation/machine orientation. If Vision personnel arrive and the electrical connections are not
ready and the electrician is not present, there will be an additional charge $750/day while waiting.
WARNING:
The first time the Vacuum Pump is turned on, check that the direction of rotation is correct. Turn it on,
then off, observing the direction of rotation. It should match the arrowon the pump near the motor. If
necessary, swap any two of the three power leads to change the rotation to the opposite direction.
Prolonged usage of the vacuum pump when rotating in the incorrect direction can cause permanent
damage to the pump.

General Information - Installation 17
© 2015 Vision Engraving and Routing Systems
2.2 Wiring Connections
The Main Power Switch is located on the left side of the VR48.
The main power supply is connected to the Main Electrical Boxon the left side of the VR48. Remove
the cover and make the connections as shown below. Ground is connected to the bare wire and
common leads are connected to the two shielded wires. The supply for this connection is Junction Box
#1 (220 VAC, Single Phase).
Note: The picture below is for illustration purposes only. The power cable should enter the Main
Electrical Boxthrough the hole in the left side of the boxas shown in the above picture.

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On the front of the control box for VR48 Router, there are four connection ports; One is an Ethernet
port used to connect your computer or network to the on-board Series 4 Controller, the second is for
the Pendant, the third is another Ethernet port used to connect a computer to the optional DACS
Camera System, and the fourth is to connect the Remote Start Switch for the Dust Collector System.
Plug the network cable (or the crossover cable) into the BOTTOM Ethernet port on the VR48, then either
plug the network cable into your network (or hub), or using the crossover cable, plug into the network
port on your computer. Plug the Pendant cable into the Pendant and Pendant Port on the VR48.
Connections for the DACS Camera System are detailed in a separate section of this manual. Connect
the Dust Collector Remote Start Cable to the Remote Start Port using the supplied cable.
NOTE: The crossover cable is colored gray.

General Information - Installation 19
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The Dust Collector Remote Start Switch will need to be connected. For ease of operation, a remote start
switch and cables can be used to turn on the dust collector automatically when a job is being run. The
supply for this connection is fromOutlet #1 (220 VAC, Single Phase, 20 Amp or 110 VAC 25 Amp).

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Wiring for this switch is shown below. The input and output wires should be connected as shown. Both
input and output ground wires can be connected to the single GND location shown. The switch can be
wall mounted at a location convenient for the user.
The Remote Start Cable is connected to the Remote Start Port on the front of the machine's control box.