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Gas Proportional Valve Calibration in CypCut

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Purpose

The proportional gas valve controls the pressure of the supplied gas (oxygen, nitrogen) through a DAC (DA — digital-to-analog). Calibration builds a lookup table that maps "DAC voltage → actual pressure at the regulator" — without it, CypCut will set incorrect pressure (for example, you set 5 bar, but in reality only 3.7 bar is delivered).

When calibration is needed

  • During first-time machine setup after installation.
  • After replacing the proportional valve, pressure regulator, or BCS/BMC board.
  • If the pressure values defined in the cutting parameter sheet do not match the actual manometer readings.
  • After updating the CypCut controller firmware.

What you will need

  • Access to CypCut with permission for the «Machine Adjust Tools» menu (manufacturer/installer password required).
  • A physical gas pressure manometer on the regulator with a digital or analog dial (units — MPa or bar).
  • A connected and filled cylinder/line of the corresponding gas (O₂ and N₂ are calibrated separately).
  • The gas supply valve on the machine open.

Procedure

  1. Launch CypCut. In the top left corner click «File».
  2. In the left column select «Machine Adjust Tools» — a submenu appears on the right.
  3. In the submenu click «Gas DA Correction». The «Gas DA Adjust» window opens.
  4. In the «Gas DA Adjust» window choose the tab for the desired gas — «Oxygen» or «Nitrogen». Each gas is calibrated separately — the «Affected gas» field at the bottom shows which gas is currently being edited.
  5. Tick «Enable DA correction».
  6. Check the parameters in the window header:
    • Type: Oxygen, DA1 (or Nitrogen, DA2) — channel purpose and DAC number.
    • Max DA: 10.00V — maximum DAC voltage.
    • Max pressure: 10.00 BAR — maximum pressure per the regulator's data sheet.
  7. In the «Group» field set the number of calibration points. The standard value is 10 (ten points from 0 to maximum).
  8. Fill in the «DA Output» column — the DAC voltages in volts at which pressure will be measured. Typical layout for 10 points: 0 — 0.0 V; 1 — 0.5 V; 2 — 1.0 V; 3 — 1.5 V; 4 — 2.0 V; 5 — 3.0 V; 6 — 4.5 V; 7 — 6.0 V; 8 — 8.0 V; 9 — 10.0 V. You can use the «DA Auto Fill» button — it will fill the column evenly automatically.
  9. Starting from row 0, press the «Output» button in the «Do DA output» column for each row in turn. On press, CypCut sends the voltage from the «DA Output» column to the DAC, and the proportional valve sets the corresponding pressure in the line.
  10. After each «Output» press, walk to the physical gas pressure regulator (labelled «O2» or «N2») — the digital manometer will display the actual pressure. For example, when 6 V is sent to the DAC, the O₂ manometer reads 0.513 MPa, which equals 5.13 bar.
  11. Write the pressure value into the «Gas Pressure» (BAR) column of the same row. If the manometer shows MPa — convert it: 1 MPa = 10 bar (so 0.513 MPa = 5.13 bar).
  12. Alternatively use the «Output Next» button — it automatically moves to the next row after pressing.
  13. Repeat steps 9–11 for all 10 rows. You should get a monotonically increasing sequence of pressures (see example: 0 → 0.48 → 1.5 → 2.5 → 3.5 → 4.47 → 5.6 → 6.4 → 6.7 → 6.8 BAR).
  14. When all points are filled, press «*Save» (with asterisk — save into the active profile). The «Save as» button saves to a separate file, «Load from file» loads a previously saved calibration.
  15. Switch to the second gas tab («Nitrogen» if oxygen was just calibrated) and repeat the entire procedure for nitrogen.
  16. Click «Close» — the window closes. Calibration is now applied.

Verification

  • After calibration, set pressure 5 bar in the cutting parameter sheet and start gas delivery — the manometer should read 5 bar ±0.1 bar.
  • If the discrepancy is greater than 0.2 bar — check the mechanical regulator (it may be set to a lower maximum than configured in CypCut's «Max pressure» field) and re-measure the points.
  • The «DA Auto Output» button automatically sweeps all points in sequence — convenient for re-verifying an existing calibration without overwriting it.
  • In the «Pressure Test» section you can output one specific pressure (e.g. 5 BAR) and verify that the valve holds it stably. The «GasOn» button switches gas delivery on.

Important

  • Do not calibrate with an empty gas line — there will be no pressure, and the table will fill with zeros.
  • Do not change «Max pressure» arbitrarily — it must match the actual scale of the installed mechanical regulator (for example, 10 bar or 25 bar).
  • If the proportional valve or regulator has been replaced — recalibrate immediately, otherwise CypCut will set pressure based on the old table.
  • The calibration is stored in the machine configuration file; after a CypCut reinstall or a PC replacement, it must be repeated or restored from a configuration backup.