BCL 4562

FSCUT1000S Laser Cutting
Control System
User Manual
Shanghai Friendess Electronic Technology Corporation.，Ltd.
www.fscut.com
Ver 1.1
FSCUT1000S Laser Cutting Control System User Manual 2
Thank you for choosing our products!
This manual gives a detailed introduction to the usage of
FSCUT1000S laser cutting controller, including technical features,
installation instructions, etc. For CypOne laser cutting software
operation, please refer to the Help documentation in the software.
Other matters you can contact us directly.
Operating personnel should read the manual in detail which will
be helpful for a better usage of the product.
Due to continuous updating of product functions, the products
you receive may differ from the statement in this manual in some
respects. We apologize for any inconvenience may cause.

3 FSCUT1000S Laser Cutting Control System User Manual
Contents
第一章 Product introduction..............................................................................................................6
1.1 Brief introduction................................................................................................................6
1.2 System Connection Diagram.............................................................................................. 6
1.3 Technical Reference............................................................................................................8
1.4 Control Card Installation.................................................................................................... 8
1.4.1 Install Steps................................................................................................................8
1.4.2 Troubleshooting......................................................................................................... 9
第二章 Wiring instructions..............................................................................................................11
2.1 Interface description..........................................................................................................11
2.1.1 Interface layout........................................................................................................ 11
2.1.2 Power interface specification...................................................................................11
2.1.3 Servo control port.................................................................................................... 12
2.1.4 Limit signal.............................................................................................................. 35
2.1.5 General input port.................................................................................................... 36
2.1.6 General output port.................................................................................................. 36
2.1.7 Analog output...........................................................................................................37
2.1.8 PWM output.............................................................................................................37
2.2 Wiring diagram................................................................................................................. 38
2.3 Laser wiring diagram........................................................................................................ 39
2.3.1 Max Laser Wiring Diagram..................................................................................... 39
2.3.2 Maxs Series Wiring Diagram...................................................................................40
2.3.3 IPG-YLR series wiring diagram..............................................................................41
2.3.4 Raycus Fiber Laser wiring diagram.........................................................................42
2.3.5 Valley Nuo Laser Wiring Diagram.......................................................................... 42
2.4 Wiring precautions............................................................................................................ 43
2.4.1 Specification for cable layout.................................................................................. 43
2.4.2 Specification for machine tool wiring..................................................................... 46
2.4.3 Product assembly requirements............................................................................... 48
第三章 Platform configuration t......................................................................................................50
3.1 Installation.........................................................................................................................50
3.2 Password........................................................................................................................... 50
3.3 User interface.................................................................................................................... 51
3.4 Machine mechanism config.............................................................................................. 52
3.5 Return origin configuration.............................................................................................. 53
3.6 Laser configuration........................................................................................................... 54
3.6.1 Max Laser Configuration.........................................................................................54
3.6.2 Mars Laser Configuration........................................................................................54
3.6.3 IPG Laser configuration.......................................................................................... 55
3.6.4 Raycus Laser configuration..................................................................................... 55
3.6.5 Valley Nuo Laser Configuration..............................................................................56
3.6.6 Other laser configuration......................................................................................... 56
3.7 Gas configuration..............................................................................................................57
3.8 Focus control.....................................................................................................................58

3.9 Alarm setting.....................................................................................................................59
3.9.1 Warning.................................................................................................................... 59
3.9.2 Emergency stop button:........................................................................................... 59
3.9.3 Custom alarm:..........................................................................................................59
3.10 General input port............................................................................................................. 60
3.11 General output port........................................................................................................... 61
3.11.1 Output port:............................................................................................................ 61
3.11.2 Auto lubricate.........................................................................................................61
3.11.3 Custom output........................................................................................................ 61
3.11.4 Regional output...................................................................................................... 62
3.12 BCS100 height controller................................................................................................. 62
3.12.1 Velocity parameter................................................................................................. 63
3.12.2 Cutting technique...................................................................................................63
3.12.3 Reset Parameter..................................................................................................... 64
3.12.4 Alarm setting..........................................................................................................64
3.12.5 Mechanic Parameter.............................................................................................. 64
第四章 Machine debug and tuning..................................................................................................66
4.1 Input and output signal test...............................................................................................66
4.2 Calculate inertia ratio and machine performance features............................................... 67
4.3 Servo gain adjustment.......................................................................................................68
4.3.1 Basic Requirements................................................................................................. 68
4.3.2 Panasonic Servo Gain Adjustment.......................................................................... 68
4.3.3 Yaskawa Servo Gain Adjustment.............................................................................68
4.3.4 Delta Servo adjustment............................................................................................69
4.4 Motion control parameter adjustment...............................................................................69
4.4.1 Motion Control Parameter....................................................................................... 69
4.4.2 Adjust cutting acceleration...................................................................................... 70
4.4.3 Adjust running acceleration..................................................................................... 70
4.4.4 Adjust work frequency.............................................................................................70
4.4.5 Curve precision and corner precision...................................................................... 71
第五章 FAQ..................................................................................................................................... 72
5.1 System alarm and analysis................................................................................................72
5.1.1 Z axis limit enabled..................................................................................................72
5.1.2 Out of Z range..........................................................................................................72
5.1.3 Z- limit signal is valid..............................................................................................72
5.1.4 Z+ limit signal is valid.............................................................................................72
5.1.5 Servo alarm.............................................................................................................. 72
5.1.6 Encoder abnormally moving....................................................................................72
5.1.7 Encoder has no response..........................................................................................73
5.1.8 Position deviation is too large..................................................................................73
5.1.9 Capacitance is 0....................................................................................................... 73
5.1.10 Local capacitance decrease....................................................................................73
5.1.11 Capacitance abnormally became larger................................................................. 74
5.1.12 Following deviation is too large............................................................................ 74

5.1.13 Use period has expired...........................................................................................74
5.1.14 Move close to board...............................................................................................74
5.1.15 Network Alarm...................................................................................................... 74
5.2 Analysis of common problems......................................................................................... 75
5.2.1 There is obvious shaking and mechanical impact when Z axis in following
movement..................................................................................................................75
5.2.2 Collision in following mode.................................................................................... 75
5.2.3 Following distance different with the actual setting............................................... 76
5.2.4 Lifting height not right.............................................................................................76
5.2.5 Upgrade prompt "Check error, ARM upgrade failed".............................................76
1.1 Brief introduction
FSCUT1000S is an open loop laser cutting control system of high

performance developed by Shanghai Friendess Company. It is widely used in the
field of metal and non-metal laser cutting area which has gained widespread
popularity among the vast number of customers.
Please read through this manual carefully before operation.
FSCUT1000S Laser Cutting System contains the following accessories:

Item Model Qty. Standard Optional
Motion control card BMC1603 1 √
I/O terminal board BCL4562 1 √
Preamplifier BCL_AMP 1 √
Handheld operator WKB V6 1 √
C62-2(2m) 1 √
62-pin cable C62-5(5m) √
C62-10(10m) √
C15-1.5(1.5m) 4 √
Servo cable (one end
C15-2.5(2.5m) √
not welded)
C15-4(4m) √
SPC-140(140mm) 2 √
Radio frequency cable
SPC-180(180mm) √
HC-15(15m) 1 √
Aviation plug cable HC-5(5m) √
HC-20(20m) √
LAN-3X(3m) 1 √
Network cable LAN-7X(7m) √
LAN-17X(17m) √
1.2 System Connection Diagram
BMC1603 card uses PCI interface. Dimension: 213mm*112mm. Motion control

card BMC1603 connected with IO terminal board BCL4562 by a C62-2 cable;

Wiring diagram shown below:
1.3 Technical Reference
3 servo axis ports with high frequency pulse output of

Motor 2MHz, 1 servo axis with analog output
Motion Control 3 servo axis ports with encoder feedback channel,
Control Signal quadruple frequency can reach to 8MHz
Positive& negative limit and servo alarm signal input for
each axis
Servo enable function
Control cycle 1ms
S-type acceleration and deceleration
Motion Velocity look-ahead strategy, intelligent speed control at
Control turning point
Performance Local curvature analysis and speed limitation at small
curves.
Smoothing process at small graphics
Laser Control Signal 1 PWM signal, DIP switch 24V and 5V for option
2 DA 0-10V analog signal
I/O Function 6 general inputs
8 general relay outputs
Work Environment Temperature:0-60 degrees Celsius
Humidity:10%~90% (no condensation)
Power Supply 24V，2A
Requirements
1.4 Control Card Installation
1.4.1 Install Steps

Please wear anti-static gloves to prevent possible electrostatic
damage to the motion control card.
(1) Turn off computer, insert the control card into PCI slot, and fix the control card
with screw;
(2) After start up computer, "Find New Hardware Wizard" pops out and click
"Cancel" button, as shown below. If this dialog box does not appear, indicating
that the card is not inserted properly, please repeat the first step.
(3) Install CypOne software. BMC1603 card driver and dongle driver will be installed
automatically in CypOne installation.
(4) Turn off antivirus software during installation to prevent CypOne identified as
virus and installation failed. Pass all pop-out windows during installation.
(5) Open device manager to confirm installation succeed. If the following image
appears means installation succeed.
1.4.2 Troubleshooting
（1） If "Find New Hardware" dialog box does not pop out after start up computer
or control card does not shown in device manager, indicating that the control
card is not inserted properly. Please replace the PCI slot or computer, insert the
control card and reinstall software.
（2） If the device has a yellow exclamation mark, double-click
to open its attributes page, and select "Detail

Information" as shown below:
（3） If the first half of the "hardware ID" shows:" "means

computer recognize the card properly, software installation might fail. Please
re-install CypOne software. If it still fails, please contact our technicians.
（4） The first half of the "Hardware ID" does not shown as:" ",
indicating that the computer failed to recognize the control card. Shut down
computer and replace PCI slot, insert control card and reinstall the software.
（5） If step (4) still fails, the control card might be damaged please contact our
technicians.
2.1 Interface description
2.1.1 Interface layout

BMC1603 card compatible with BCL4562 IO terminal board. The detailed signal
port layout as shown below:
BCL4562 terminal board uses guide rail or fixed install form. The old version
dimension is 315 mm*120 mm*54 mm and the new version dimension is 315
mm*127.8*60 mm.
2.1.2 Power interface specification
The outer shell of the machine is the negative pole of the capacitance to be
measured. In order to ensure the stable operation of the measuring circuit, the FG foot
of the power interface must be reliably connected to the outer shell of the machine.
The outer shell of the preamplifier must also be well connected to the outer shell of
the machine. The specific index is DC impedance less than 4 ohms, otherwise the
actual follow up performance may be poor.
The power output can only be supplied to limit switch.
2.1.3 Servo control port

There are 4 servo control ports in BCL4562 IO terminal board, 3 ports send pulses
and 1 send analog output.
Pulse control ports use DB15 connecter, signal pin described as below:
Signal pin description of C15-1.5 cable shown as below:
Pin Signal name Pin Signal name

1 Yellow PUL+ (positive 9 Yellow-black PUL- (negative
pulse) pulse)
2 Blue DIR+ (positive 10 Blue-black DIR- (negative
direction) direction)
3 Black A+ (Encoder A 11 Black-white A- (Encoder A
phase phase
positive) negative)
4 Orange B+ (Encoder B 12 Orange-black B- (Encoder B
phase phase
positive) negative)
5 Red Z+ (Encoder Z 13 Red-black Z- (Encoder Z
phase phase
positive) negative)
6 Green SON (Servo 14 Purple ALM (Alarm
enable) signal)
7 Green-black CLR (Alarm 15 Brown-black 0V (Power

clear) ground)
8 Brown 24V (power
output)
+24V、0V： Supply 24VDC power for servo driver.

SON： Servo ON, output servo drive enabling signal;
ALM： Alarm, receiving servo driver alarm signal;
PUL+、PUL-： Pulse (PULS), differential output signal;
DIR+、DIR-： Direction (DIR), differential output signal;
A+、A-、B+、B-、Z+、Z-： Encoder three-phase, input signal.
The servo wiring diagram with Fuji, Panasonic, Yaskawa, Delta etc., shown as
below, recommend to use high frequency pulse connection.
Notes regarding wiring other servo:
(1) Check the SON signal type of the servo if it's active-low (when conducted
with 24V GND turns active);
(2) Make sure set the signal type "pulse +direction" in servo;
(3) Check input of servo if there is external emergency signal, and the active logic
of it;
(4) Before trial run of driver, provide 24V power supply to IO terminal board,
which required by driver;
(5) If driver still can't run, check if the parameter "positive/negative direction
drive inhibit" in driver invalid.
Fuji ALPHA5 SMART PLUS High Frequency Pulse
Parameter Recommended Description

Setting
PA1-01 0 Control mode must select position mode.
PA1-03 0 Select command pulse/direction,
500kHZ-4.0MHZ.
PA1-04 Motor rotation direction
PA1-05 Number of command input pulses per
revolution
PA1-08 Number of output pulses per revolution
PA1-13 13 Recommend to use interpolation operation
mode
PA1-14 Inertia ratio
PA1-15 Auto tuning gain (rigidity)
PA1-54 Position command response time constant
Fuji ALPHA5 SMART Series Wiring Diagram
Fuji ALPHA 5 Series

Setting
PA-101 0 Position control mode
PA-103 0 Pulse + Direction highest frequency 1 Mpps
Panasonic A5 High Frequency Pulse Wiring Diagram
Panasonic A5 Low Frequency Pulse Wiring Diagram

Panasonic A5 Series basic setting

Setting
Pr001 0 Control mode must select position mode.
Pr007 3 Must select "Pulse + Direction" mode
Pr005 1 When using high speed pulse wiring mode,
the parameter setting is 1, and highest pulse
frequency. supports to 3Mpps
When using low speed pulse wiring mode,
the parameter setting is 0, and highest pulse
frequency. supports to 500Kpps.
Yaskawa servo wiring diagram

Yaskawa Σ series basic setting

Setting
Pn000 001X Set position mode
Pn00B The setting is 0100 when use single phase
power input
Pn200 2000H Positive logic: Pulse + direction;0005H
negative logic: Pulse + direction
When pulse frequency is less than 1 Mpps
select mode 0000H
When pulse frequency reaches 1Mpps~4Mpps
select mode 2000H
Pn50A 8100 Forward run allowed
Pn50B 6548 Reverse run allowed
Mitsubishi J3 series wiring diagram

Mitsubishi E Series wiring diagram
Mitsubishi MR-J3-A series basic setting

Setting
PA01 0 Control mode- Position mode
PA13 0011 Negative logic: Pulse + Direction
For Mitsubishi J3 series highest pulse frequency is 1Mpps.
Delta A Series High Frequency Pulse Wiring Diagram
Delta ASD-A series basic setting

Setting
P1-00 1102H Position control mode, negative logic pulse +
direction.
Setting is 1102H unlocks high speed
differential signal mode, the highest pulse
frequency can reach to 4Mpps；
Setting is 0102H unlocks low speed pulse
signal mode, the highest pulse frequency up to
500Kpps.
P1-01 00 Position control mode controlled by external
instructions.
P2-10 101 DI1 select SON servo enable, logic is
normally open.
P2-14 102 DI5 set ARST alarm reset, logic is normally
open.
P2-22 007 DO5 set Alarm, logic is normally open.
Delta B Series High Frequency Pulse Wiring Diagram

Setting
direction.
500Kpps.
P1-01 00 Position control mode controlled by external
instructions.
normally open.
open.
Sanyo R Series Servo Wiring Diagram
Sanyo R Series Basic Setting

Setting
SY08 00 Set position mode
Gr8.11 02 Select pulse signal type: Pulse + direction;
Gr9.00 00 Forward run allowed
Gr9.01 00 Reverse run allowed
Schneider 23D High Frequency Pulse Wiring Diagram
Schneider Lexium 23D Series Basic Setting

Setting
direction.
500Kpps.
P1-01 X00 Select position mode controlled by external
instructions.
P2-10 101 Set IN1 as SON in servo
P2-11 0 IN2 invalid
P2-13~P2-17 0 IN4~IN8 invalid
Notice:
The above parameters setup and correct wiring can only guarantee the basic
motion function cannot ensure the control accuracy. To optimize motion effect,
please adjust rigidity, gain, Inertia ratio and other parameters.
Servo control terminal and PIN description on BCL4562 as shown below:
Signal pin description of C15-1.5 cable shown as below:
Pin Signal name Pin Signal name

1 Yellow DA (-10~10V 9 Yellow-black AGND (analog ground)
analog)
2 Blue 0S (ZEROSPD) 10 Blue-black 0V (Power ground)
3 Black A+ (Encoder A 11 Black-white A- (Encoder A phase
phase positive) negative)
4 Orange B+ (Encoder B 12 B- (Encoder B phase
phase positive) Orange-black negative)
5 Red Z+ (Encoder Z 13 Red-black Z- (Encoder Z phase
phase positive) negative)
6 Green SON (Servo 14 Purple ALM (Alarm signal)
enable)
7 Green-black CLR (Alarm 15 Brown-black 0V (Power ground)
clear)
8 Brown 24V (power
output)
+24V、0V： Supply 24VDC power for servo driver.

DA、AGND： Analog output provides speed signal for the driver.
0S： Zero-speed clamp is used to suppress zero drift of servo system.
SON： Output signal enable servo
ALM： Receive servo driver alarm signal.

A+、A-、B+、B-、Z+、Z-： Encoder three-phase, input signal.
Precautions when connecting the driver:

(1) Make sure the servo supports velocity control mode. For example, Panasonic
A5 series servo must choose full-function type, not pulse type.
(2) All IO ports in BCL4562 are active-low type, servo should be active-low.
(3) Check if servo equipped with motor brake. Strictly connect the signal pin and
set parameters as user manual instructions.
(4) The shielding layer of servo cable connect with servo shell and make sure
servo unit well grounded.
Fuji ALPHA 5 SMART PLUS Series Wiring Diagram
Fuji ALPHA 5 SMART PLUS Series Servo Parameters

Setting
PA1-01 1 Velocity control mode
PA1-04 Motor rotate direction

PA1-08 2500 Number of output pulses per revolution
PA1-15 20 Auto tuning gain
PA3-03 2 Zero clamp
PA3-31 6 Speed command scale matches with
500r/v/min in BCS100 controller
PA3-51 14 Brake timing
Panasonic servo wiring diagram
Panasonic A5 servo parameter set

Setting
Pr001 1 Control mode must be velocity mode.
Pr002 3 Real-time auto-gain tuning setup select
vertical axis mode
Pr003 17 Servo stiffness, recommended range 14-20.

Pr302 500 Input gain of speed command
Pr315 1 Enable speed zero-clamp function
Pr504 1 Setup of over-travel inhibition input
Panasonic A4 series servo parameter setup

Setting
Pr02 1 Control mode must be velocity mode.
Pr21 4 Real-time auto-gain tuning setup select
vertical axis mode
Pr22 7 Servo stiffness, recommended range 5-10.
Pr50 500 Input gain of speed command
Pr06 1 Enable speed zero-clamp function
Pr04 1 Setup of travel limit inhibition input
Yaskawa servo wiring diagram
Yaswaka Σ-V series servo parameter setup

Setting
Pn000 00A0 Speed control mode with zero-clamp function
Pn00B Null The setting is 0100 when use single phase
power input
Pn212 2500 The number of output pulses per motor
revolution, match the parameter "pulses per
rev 10000" in BCS100
Pn300 6.00 Correspond to the speed gain 500r/v/min in
BCS100.
Pn501 10000 Zero-clamp value
Pn50A 8100 Forward run allowed
Pn50B 6548 Reverse run allowed
Delta A Series servo wiring diagram
Delta ASD-A series servo parameter setup

Setting
P1-01 0002 Control mode must select velocity control
mode.
P1-38 2000 Set the largest value of zero-clamp
P1-40 5000 Match the "speed gain 500 r/v/min" in
BCS100
normally open.
P2-11 105 DI2 set CLAMP, logic is normally open.
P2-12 114 Set speed command as external analog control
open.
Delta B series servo wiring diagram

Setting
P1-01 0002 Control mode must select velocity control
mode.
P1-38 2000 Set the max value
P1-40 5000 Match the parameter speed gain 500 r/min/v in
BCS100.
normally open.
P2-11 105 DI2 set CLAMP, logic is normally open.
open.
TECO servo wiring diagram
TECO JSDEP Servo parameter setup

Setting
Cn001 1 Control mode must select velocity control
mode.
Cn002.2 1 Auto-tuning gain (Note: This is parameter
no. 2 of Cn002.)
Cn005 2500 The number of output pulses per motor
revolution, match the parameter "pulses per
rev 10000" in BCS100.
Cn026 4 Rigidity, you can sue default level 4.
Sn216 4000 Speed gain, match with 500r/v/min in
BCS100 controller
Mitsubishi servo MR-J30A wiring diagram
Mitsubishi MR-J30A Series

Setting
PA01 2 Control mode is speed mode
PA15 10000 Number of encoder pulses per revolution x
4
PC12 5000 Corresponding to the speed gain in BCS100
500r/v/min.
PC17 0 Not use zero-clamp function(use ST1 port)
Schneider Servo Lexium 23D Wiring Diagram
Schneider Lexium 23D servo parameter setup

Setting
P2-10 101 Set IN1 as SON in servo
P2-11 0 IN2 invalid
P2-12 5 Servo IN3 set as zero speed signal.
P2-13~P2-17 0 IN4~IN8 invalid
P1-38 2000 Zero speed range setting is 200rpm.
P1-01 2 Set speed mode
P1-40 5000 Speed command scale matches with
500r/v/min in BCS100 controller
P1-46 2500 Match with pulses per rev 10000 in
BCS100
P2-68 1 User does not need to re-trigger SON to
enable motor
Sanyo R Series Wiring Diagram
Sanyo R Series Servo parameter setup

Setting
SY08 01 Velocity control mode
Gr0.00 00 Self-tuning
Gr8.25 5000 Maximum speed (r/min) of motor correspond to
10V analog output.
Gr9.00 00 Positive side allowed turn
Gr9.01 00 Negative side allowed turn
Gr9.26 00 Disable gain switch
Brake delay from servo on switch to servo off
GrB.13 0
state
Brake loosen delay from servo on switch to servo
GrB.14 0
off state
GrC.05 2500/32768 Match with pulses per rev 10000 in BCS100
2.1.4 Limit signal

X-： X - Limit, dedicated input port, low level effective;
X+： X+ Limit, dedicated input port, low level effective;
Y-： Y- Limit, dedicated input port, low level effective;

Y+： Y+ Limit, dedicated input port, low level effective;
Z-： Z- Limit, dedicated input port, low level effective;

Z+： Z+ Limit, dedicated input port, low level effective;
COM： Ground, the common end of the above three signals.
Limit input logic can be switched in config tool. If set limit input normally open,
Input signal is valid in conduction with 0V if set limit input normally closed, input
signal is valid when disconnected with 0V.
See details in chapter 4 configuration tool.
The typical wiring diagram of optoelectronic switch as shown below, required

NPN 24V type.
The typical wiring diagram of magnetic switch as shown below, required NPN
24V type.
2.1.5 General input port

There are 6 inputs from IN1~IN6.You can assign the 6 inputs as customized
button or alarm in config tool.
The typical wiring diagram of contact switch as shown below.
2.1.6 General output port

There are 8 relay outputs from OUT1~OUT8, the first 4 output ports are only NO
contacts, the last 4 can switch to NO and NC contact. You can assign the 8 relay
outputs controlling laser, cutting gas etc.
The load capability of the relay outputs in BCL4562: The maximum load current
is 1.5A, not allowed to carry 220V directly. It can directly control 24V load. If you
need to carry high power load, please connect external relay/ contactor.
2.1.7 Analog output

There are two 0~10V analog relay outputs in BCL4562.You can set DA1 and
DA2 for controlling laser peak power and proportional valve in config tool.
Output range 0V~+10V

Maximum load 50mA
Maximum bipolar error +/-20mV
Resolution 2.7mV
Conversion speed 400us
2.1.8 PWM output

There is 1 PWM output in BCL4562 IO terminal board to control average laser
power PWM signal level is 24V or 5V as option. The duty cycle is adjustable from
0%~100%, the highest carrier frequency 50KHz.The output of the signal is shown in
the following figure:
There is a DIP switch at the lower left of PWM port to switch 5V and 24V
voltage:
Switch P1 and P2 to set PWM voltage
P1 P2 Description
On Off PWM voltage is 24V
Off On PWM voltage is 5V
2.2 Wiring diagram

2.3 Laser wiring diagram
2.3.1 Max Laser Wiring Diagram
Notice:
1. PD+, PD- is laser alarm output, connect to any input port in BCL4562 and set
a customized laser alarm in "Config tool-- alarm--customized alarm”;
2. PWM select 24V control (DIP switch: P1 ON, P2 OFF)
2.3.2 Maxs Series Wiring Diagram
Note:
PWM select 24V control (P1ON, P2 OFF)
2.3.3 IPG-YLR series wiring diagram
We recommend you choose RS232 or network control if laser supports this

communication mode, which can control laser realize the function including laser
emission, turn on/off guide beam, set peak power, etc., and no need to control peak
power by analog DA port.
Recommend to use network communication for IPG-YLR series.
Note:
1. Remote start-up button is not necessary, it might cause laser error when laser
device is not well grounded.
2. PWM 24V control (DIP switch: P1 on, P2 off).
2.3.4 Raycus Fiber Laser wiring diagram
Note:
1. RayCus's latest products use 24V PWM, the old version use 5V PWM. And
the key switch to REM then RS232 is available, while the old version switch to ON.
Laser PWM port will indicate 24V or 5V control; No sign indicates voltage means
using 5V.
2. PWM 5V control (DIP switch: P1 off, P2 on).
3. PWM 24V control (DIP switch: P1 on, P2 off).
2.3.5 Valley Nuo Laser Wiring Diagram

Here take the example of NT-3200SM model.
Note:
Part of CO2 laser also supports PWM control mode, wiring can take reference
from Max laser.
2.4 Wiring precautions
2.4.1 Specification for cable layout

1. When releasing the cable from the coil, it is necessary to prevent the cable from
twisting (it needs to be laid along the tangent direction) and to straighten the cable.
This work should be carried out before laying the cable, providing a period of
stress release for the cable. Because the manufacturing process cannot fully
guarantee that the cable is straight and without any distortion, the printed
markings on the cable surface rotate along a tiny spiral.
Correct example Error example
2. The cable is not allowed to twist when it is installed in enclosed space. The twist
during installation may lead to premature damage of the core strand. This effect is
gradually strengthened in the operation of the cable, resulting in the phenomenon
of back-twisting, which eventually leads to core breakage and failure.
3. Cables must be laid side by side in the towing brackets. Isolating pieces should be
used to separate cables as far as possible. The gap between cable and isolator,
separator or its adjacent cables should be at least 10% in diameter.
4. The cables should be installed symmetrically according to the weight and size of
the cables. The larger diameter cables should be placed outside. Smaller and
lighter cables should be placed inside. Cables can also be placed from inside to
outside in order of decreasing size. One cable should be laid on the other cable
without the use of isolation panels.
5. For vertical suspension tow chains, more free space must be left in the vertical
bracket because the cable will be lengthened during operation. After a short period
of operation, it is necessary to check whether the cables are running along the
central area and adjust them if necessary.
6. For self-supported drag chain structure, cables are fastened to moving points and
fixed points. It is necessary to use the appropriate cable support provided by the
towing chain supplier. When operating at high acceleration, the applicability of
cable strapping is very limited. It should be prevented to tie multiple cables
together. Cables should not be fixed or tied to the movable parts of the tow chain
in any way. The gap between fixed point and bending motion should be wide
enough.
7. For sliding towing chains, we suggest that cables should only be fixed on moving
points. Setting a small cable protection area at a fixed point (refer to the assembly
instructions of the tow chain supplier).
8. Make sure that the cable moves along the center area under the required bending
radius. Do not apply tension to the cable (do not pull too tight), otherwise the
friction inside the tow chain will lead to cable sheath wear. Do not let the cable
loose too much in the tow chain, otherwise it will easily lead to wear and tear
between the cable and the inner wall of the tow chain, or entanglement with other
cables.
9. If the cable is not running smoothly, you can check whether there is any distortion
along the longitudinal axis during operation. The cable should rotate slowly at a
fixed point until it runs smoothly.
10. In view of the absolute size of cables and towing chains, their length variation
characteristics are quite different. In the first few hours of operation, the cable
stretched naturally. For towing chains, it takes many hours to run this phenomenon.
Such a big difference can be solved by regularly checking the installation location
of cables. We recommend regular inspections, once every three months in the first
year of operation, and then at each maintenance time. The contents include
checking whether the cable is completely free to move within its proper bending
radius and adjusting it if necessary.
2.4.2 Specification for machine tool wiring

1. Wiring specification for power supply
（1） Strong electricity
a) Strong and weak electricity is strictly separated.
b) The power line is selected according to the size of the power line
diameter. The attached is the cable diameter and power comparison
table.
Wire and Cable cross 25℃ Single phase Three phase

cable section copper 220V load 380V load
specificatio (mm2) current power (W) power (W)
ns (mm2) carrying
capacity
(A)
1.5 1.38 15 3300 9476.8
2.5 1.78 25 5500 13163.2
4 2.25 32 7040 16848.8
6 2.85 45 9900 23693.6
10 7*1.35 60 13200 31591.2
16 7*1.7 80 17600 42121.6
25 7*2.14 110 24200 57917.6
c) Strong current plus short-circuit protector, filter and other auxiliary

devices.
（2） Weak current (take DC24V as an example)
a) The power positive and negative pole wiring colors are distinguished,
for example: The red line is connected to the positive pole, and the
blue line is connected to the negative pole.
b) Larger interference loads, such as servo and solenoid valves, are
supplied separately from the controller.
2. Specification for earth wire connection

（1） The ground wire adopts standard yellow green double color line.
（2） There are some high frequency signals (PWM, pulse, encoder, capacitance
signal, etc.) in the laser cutting machine tool. It is suggested to use
multi-point grounding.
（3） Galvanized earthing screws for machine tools and earthing with special
earthing wires. The resistance between the grounded metal main body and
the main grounding point should not exceed 0.1 ohms.
3. Specification for signal (control) wiring

（1） Signal line color: Such as black.
（2） The signal line is selected according to the power size.
（3） DC 24V solenoid valve is recommended. Absorption circuit is added at
both ends of solenoid valve, that is, a continuous current diode (attention
direction, current resistance value, voltage resistance value) is connected
in parallel at both ends of solenoid valve, as shown in the following
figure:
（4） It is recommended that the digital signal (PWM) shield layer be grounded
at two ends and the analog signal (DA) shield layer be grounded at one
end. Single ended grounding can avoid low frequency current noise on
shielding layer. Double-terminal grounding can effectively eliminate
high-frequency interference. If the transmission cable is long, multi-point
grounding is recommended to ensure that the shielding layer is
equipotential.
（5） The resistance of the cutting head connected by the amplifier to the shell
of the machine tool is not more than 1, and the resistance of the grounding
point to the electric cabinet is not more than 6.
4. Other specifications
（1） Each wire is marked and marked clearly and accurately.
（2） Line and line are arranged in parallel. No crossover is allowed. The
arrangement of wiring harness and line pipe should be straight.
（3） When choosing Friendess wires, choose the appropriate type of wire
according to the layout space, do not accumulate hovering.
（4） All wiring must be reliable and not loose to prevent ignition.
（5） Wiring avoids formation of loops and prevents antenna effects. A current
loop consisting of a signal source, a transmission line, a load is equivalent
to a magnetic field antenna. As shown in the figure below, the wrong way
is on the left side and the right connection is on the right.
（6） The recommended connection is star connected, and serial connections

are not recommended.
2.4.3 Product assembly requirements

Please take care of it. Before contacting the circuit of the control card
or inserting/unplugging the control card, wear anti-static gloves or
contact with effectively grounded metal objects to discharge the
human body, so as to prevent possible electrostatic damage to the
motion control card.
Except the USB interface, the other interfaces are not allowed to plug,
and the plug may cause the internal components to burn down.
Please take it carefully, forbid external pressure to press the card.

Pressing the card may cause bending of the card, resulting in damage
to the function of the card.
3.1 Installation
Configuration tool will be installed automatically in CypOne software

installation.
Click "start" menu- "All programs"-"CypOne laser cutting system"-"Config tool"
to startup config tool . "CypOne laser cutting system" is software name, which
differs from different OEM software version.
3.2 Password
You have to input password to start config tool.
Initial password 61259023.
Notice: Parameter setup must accord with the actual mechanism structure, wrong
setting will cause unknown serious consequences!
3.3 User interface
The main page of config tool is machine structure. Click the icon at top bar to
enter different parameter model. You can config signal assignment of limit switch,
laser, gas etc. You can click "config file" locate to Data file folder.
Users can click "Import" to load the config file. "Save" button is used to save the
settings.
Note: Data folder contains all configuration information of CypOne.

3.4 Machine mechanism config
Select single drive or dual by the actual X/Y axis structure.
The travel range of X axis: The maximum travel range of X axis when use
software limit function, and define the width of the white square in CypOne main
page.
The travel range of Y axis: The maximum travel range of Y axis when use
software limit function, and define the length of the white square in CypOne main
page.
Pulse equivalent: Command pulses controller send to servo every 1mm linear
distance on machine bed. The linear distance can set to 5 decimal places, pulse
equivalent= pulses/linear distance.
Servo alarm: Select servo alarm signal logic.
Verticality correction: When X/Y axis not mounted perpendicular in 90°, you
can set this parameter to correct the deviation.
3.5 Return origin configuration
Soft Limit: Enable this function will force open the soft limit function, users
can't turn off on CypOne software.
Prompt go origin at start: Display go origin message in main page to remind
user.
Return origin direction: You can set different return origin direction according
the axis structure. Return origin direction decides the quadrant of the machine
coordinates. For example, return origin direction of both X and Y is negative direction,
then machine coordinate is in the first quadrant.
Z phase signal: Whether use Z phase signal decide the two different process of
return origin. The corresponding process image will be displayed at lower position.
High speed: Coarse positioning section shown as blue color recommended speed
50mm/s.
Low speed: Fine positioning section shown as green color, find origin signal in
slow speed, recommended 10mm/s.
Roll-back distance: The distance can keep machine origin not too close to origin
switch.
Limit logic: Set limit signal logic of X/Y axis.
3.6 Laser configuration
CypOne provides configuration parameter for Max laser, Mars, IPG, RayCus,
Valley Nuo and other type, each laser type has corresponding configuration parameter.
3.6.1 Max Laser Configuration
Guide beam output: Set output to control guide beam.

Laser enable: Set output to control laser emission.
DA port: There are 2 analog DA ports on BCL4562 terminal board, choose either
of them to control laser power
DA voltage range: The analog signal voltage range to control laser power.
3.6.2 Mars Laser Configuration

Mars Laser supports serial communication.
3.6.3 IPG Laser configuration

DA port selection: There are 2 analog DA ports on BCL4562 terminal board,
choose either of them to control laser peak power. When use RS232 or network
control doesn't require DA port.
IPG Laser Configuration:
Remote start-up button:
When switch key to remote control mode, you can startup laser by remote button.
Select this option you have to assign the output port for remote control button.(It is
not recommended to use this function, which might cause laser error)
IPG remote control:
After enable remote control function, CypOne can send command to laser by
network or RS232 communication to realize the functions including laser emission
control, guide beam and set laser peak power etc. When you use network or RS232
control laser, DA setting won't take effect.
3.6.4 Raycus Laser configuration

DA port: There are 2 analog DA ports on BCL4562 terminal board, choose
either of them to control laser power.

RayCus laser supports serial communication.
3.6.5 Valley Nuo Laser Configuration
Mechanical emission gate: Output port to control mechanical emission gate.

Electronic gate: Output port to control electronic emission gate
3.6.6 Other laser configuration
Reserved configuration, not support serial and network communication. It must

use DA to control peak power.
3.7 Gas configuration
Valve: Output to turn on/off cutting gas.

Air: Output to turn on/off air
Oxygen: Output to turn on/off oxygen
Nitrogen: Output to turn on/off nitrogen
DA Gas Control: An output port to control proportional valve
3.8 Focus control
Focus control function must be realized by BCL4516E terminal board. Connect in the
BCL4516E in config tool-extend IO.
Focus range: Set software limit and travel range.
Focus position at org position: The focus scale at origin position
Pulse rate: Command pulses send to servo correspond with focus moving
distance.
Return origin direction: Negative direction is upward, positive direction is
downward.
Origin signal: Sampling signal can comes from limit or origin switch as your
selection.
High speed: The speed to find origin switch.
Low speed: The speed to relocate the origin switch after first receive the switch
signal.
Rollback distance: Reverse direction motion distance after complete fine
location.
Jog speed: Jog speed of focus
Locate speed: Focus switching speed.
3.9 Alarm setting
3.9.1 Warning
Display the warning message of yellow color when machine is running. You can
edit the warning message.
3.9.2 Emergency stop button:

Assign the input port and signal logic of emergency button. Controller will send
emergency stop alarm once the input signal is valid.
3.9.3 Custom alarm:

Users can add customized alarm and edit alarm name, assign signal pin and select
signal logic. The commonly used alarms are low-pressure, water temperature
over-high, and laser head collision.
Note: All alarm status will be removed in 2 seconds automatically after alarm
signal eliminated.
3.10 General input port
Click function button you can select port number and set signal logic. The signal port
can't be reapplied.
3.11 General output port
3.11.1 Output port:

Lasering: If this port configured, the indicator will light when laser is firing.
Working: If this port configured, the indicator will light when machine in cutting
process.
Alarm light: If this port configured, the indicator will light when there is alarm
detected.
Alarm bell: If this port configured, the indication bell will ring when
corresponding alarm triggered.
Lights flashing/ bell intermit: Enable this function you can customize the
interval time of output open and close to realize the effect of indicator flash.
3.11.2 Auto lubricate

After this port assigned, program starts time count and activate related output and
maintain a setup time then close.
3.11.3 Custom output

Setup a customized output it will displayed as a button in CypOne main
page-CNC module. The output signal can select lock or contact control.
3.11.4 Regional output

Regional output is used for dust collection. When laser is firing, the output in the
region where laser head is in will open. If laser head move from region 1 to region 3,
then output in region 1 close and output in region 3 open.
Close delay: The output will close in a delay time when laser head switch to
another region.
3.12 BCS100 height controller
Height control unit of FSCUT1000 system is integrated in BCL4562 IO

terminal board communicate by Ethernet network.
BCL4562 is directly connected to computer box. Parameter setup of BCS100 in
CypOne-CNC- module. Click parameter config :
Read follower parameter: Read in the parameter of current connected height

control unit.
Open the existing config: Open Ifg file (BCS100 parameter backup file). Select
"read follower parameter", click "Ok" will prompt the parameter page:
3.12.1 Velocity parameter

The parameter description shown in below list:
Parameter Description
name
The follower move down and lift up speed. Recommended to
Moving speed setup a value when motor maintain a rated rotating speed to
guarantee the efficiency and stable operation.
Moving
Follower follow down and lift up acceleration.
acceleration
Jog low speed Setup Jog low speed
Jog high speed Setup Jog high speed
3.12.2 Cutting technique

name
When finish cutting, laser head will lift up and park at this
Dock position
position.
The travel range of the Z axis. If soft limit enabled, once Z
Z range axis exceed this range will stop immediately and send alarm
"exceed Z range"
3.12.3 Reset Parameter

name
Org speed Speed of Z axis return to origin
Org when If return org when power on. Set "Yes" after finish machine
power on tuning and debug.
Return dock
If Z axis park in dock position after return origin
position
3.12.4 Alarm setting

name
The maximum following tolerance allowable in
Follow BCS100.When laser head follows to target position,
deviation meanwhile plate vibration or other vibration caused deviation
will generate the alarm.
The filter time of deviation alarm. Larger value allows longer
Follow
duration of deviation and stronger ability of filtering the
deviation delay
disturbance.
When system stops, the laser head will lift up automatically
Hit board and output alarm signal if duration of touching the panel
delay reached the critical value. Set the value as 0, the Tip Touch
alarm will not be triggered when system stops.
3.12.5 Mechanic Parameter

name
The screw lead per revolution. Theoretically the larger lead is
Lead screw the faster speed Z axis can reach. Recommend to use 5~10mm
screw ball lead
The maximum speed of motor. Generally no more than 4500
Max RMP
rpm.
Speed-voltage The motor revolutions per voltage. This parameter must be
gain same with the value in servo, recommended 500rpm/V.
Pulses per Pulses feedback every revolution. This parameter must be

revolution same with the value in servo.
Support Panasonic/Mitsubishi, Yaskawa/Delta, Teco JSDEP
these three types servo. The zero-clamp signal logic, input and
Servo type
output logic as well as related parameters in controller are
different with different types of servo.
Servo direction The motor rotate direction.
Encoder
Direction of feedback pulses.
direction
When soft limit protection enabled, Z axis cannot Jog under
Soft limit negative coordinates or following height to prevent collision.
Soft limit protection only works in the BCS100 main page.
Limit logic Limit input port (Z+, Z-) logic, default normally open.
Export parameter: Backup and export the parameter setup data, user can restore the
parameter setup by "open the existing config" option.
Write in: Write in current parameter to BCS100.
4.1 Input and output signal test
After finish the wiring of electric circuit, you can start machine debug and
tuning:
(1) Connect terminal board and control card with C62-2 cable, and supply 24V
power to terminal board. Check LED indicator of input port on IO terminal board: If
limit switch is normally close, then X-/Y- LED is light. Manually trigger limit switch,
if LED lights off, it means wiring is correct. If limit switch is normally open, the LED
should be in off state. Manually trigger the limit switch if lights on, it means wiring is
correct. Check the other input port in the same way to make sure all the wiring are
correct and save time for machine debug.
(2) Start-up computer and CypOne software, enter in "BCL4562 monitor” page:
You can check all input and output status, manually change the output status.
Light in grey means signal port is inactive, when signal active the light will turn green.
When limit signal active the light will turn red.
When X, Y or Z axis servo enabled, the signal port turns in green, and turns blue
means controller sending pulses to the servo. Press X, Y and Z button to manual
enable or disable the servo. You can send command pulses in positive or negative
direction to the servo and test if pulses equivalent setting right.
You can also check all the custom input and output name set in config tool.
(3) Close monitor page enter in CypOne main interface. At the right side in
control panel manual jog Z axis up and down, press gas, laser and aiming beam, set
laser power to text the machine function.
4.2 Calculate inertia ratio and machine performance features
The inertia ratio is a key indicators of machine performance features. You can
calculate the inertia ratio of each axis by a Servo Tool. You can download Servo Tool
on http://downloads.fscut.com/.As shown below:
The inertia ratio is less than 200% machine in light load can reach high speed
cutting.
The Inertia ratio is in 200% to 300% machine in medium load, cutting precision
is declined compared with light load in high speed, you need to lower the cutting
speed and low pass filter.
The ratio of Inertia is in 300% to 500% machine in heavy load cannot reach high
speed cutting.
Inertia ratio is more than 500%. There are serious design defects. Servo tuning is
hard to complete in a short time.
You can calculate the max cutting speed, max running speed and max
acceleration which can be used set in CypOne motion control parameters.
Experienced users can also calculate the Inertia ratio accurately through servo adjust
tool.
Note: Servo parameters calculated by servo only can be used in FSCUT4000.
4.3 Servo gain adjustment
4.3.1 Basic Requirements

This required professionals who are experienced with servo tuning tools.
PANATERM servo tuning tool for Panasonic servo, SigmaWin+ for Yaskawa servo,
experienced with servo tool can simplify the process.
4.3.2 Panasonic Servo Gain Adjustment

Step 1: Open PANATERM [Gain tuning] page. Open the [Real time auto-gain
tuning] to calculate the inertia ratio.
Step 2: Set rigidity as a conservative value. For example, start from level 13.Then
Jog the axis in high speed by CypOne software. Watch if there are abnormal noise or
vibration. Then slowly rise the rigidity level. When axis stated to have noise and
vibration lower the rigidity 1~2 level to ensure axis motion stability. The final rigidity
recommended within 10~20.For synchronous axis you need to change the parameters
of both axis then test the motion function.
Step 3: when you finish measure the servo rigidity of X/Y axis, recommend set
the same rigidity to both X/Y axis to make sure XY axis response speed is uniform.
The final rigidity should be in accordance with the smaller level. For example, X axis
servo rigidity is level 19, Y axis 16, final level should be 16.
Step 4: Close [Real time auto-gain tuning] and save the setting.
4.3.3 Yaskawa Servo Gain Adjustment

Yaskawa servo adjustment process is similar with the Panasonic, the difference is:
 No inertia ratio and auto-gain tuning function in SigmaWin+.You can
roughly calculate the inertia ratio by Servo Tool download in our web
www.fscut.com.Experienced users can manually calculate the inertia ratio by
the torque variation and acceleration time during an acceleration motion.
 It is recommended to close Pn140 function.
 It is recommended to close Pn170 function.
 There is no concept of servo rigidity in Yaskawa servo. You can set the
parameter take reference in Panasonic servo rigidity level table:
Pn102 --correspond with Panasonic Pr100
Pn401 -correspond with Panasonic Pr104

 The table as below please notice the unit and decimal point. The unit of
Pn101 parameter in Yaskawa is 0.01ms, while in Panasonic Pr102 unit is
0.1ms.
4.3.4 Delta Servo adjustment

Delta servo adjustment can also refer to Panasonic servo rigid table. Reference
methods are as follows:
P2-00 KPP is equivalent to Panasonic Pr100. For example, when P2-00 = 90, it is
equivalent to Panasonic Pr100 = 900.
4.4 Motion control parameter adjustment
4.4.1 Motion Control Parameter

In FSCUT 1000S system you can set limit to speed, acceleration and low pass
filter to control motion performance, and program will optimize the other motion
related parameters automatically. The three parameter described as below:
Item Description
Move speed Maximum running speed, recommended 60m/min for FSCUT1000
system.
Move Maximum running acceleration, recommended 0.5G for
acceleration FSCUT1000 system.
Cut Maximum cutting acceleration directly determines the time of
acceleration ACC/DEC in corner motion, which adjusted by torque curve in

servo tool.
Work Smaller value will improve the vibration suppression but extend the
frequency ACC/DEC time.
Curve Larger value will smooth the curve and improve the speed but also
precision reduce the precision. It does not represent actual accuracy.
Corner Larger value will smooth the path and improve the speed but also
precision reduce the precision. It does not represent actual accuracy.
4.4.2 Adjust cutting acceleration

Jog axis at a high speed, 500mm/s for example, make sure axis move a long
distance and reach the set speed.
Monitor the torque curve in servo tool when jog the axis, increase the work
acceleration if peak torque under 80% or reduce work acceleration if peak torque
larger than 80%.
4.4.3 Adjust running acceleration

You can set this value according the result calculated by the ServoTool. Or larger
than work acceleration by 1.5~2 times of it. When axis running without load, servo
torque should be within 150%, and there is no mechanical deformation and vibration
under this acceleration.
4.4.4 Adjust work frequency

Adjust low-pass filter by cutting a sample. Set a small laser power marking on
plate and observe the cutting path. The sample graphic could be small circle in
different sizes, hexagon, dodecagon, star shape and rectangle. As shown in the
following figure:
Increase the low pass filter as much as possible without affecting the cutting
precision. The reference standard of test cutting is no waves around the corner in
rectangular, star type cutting. You can setup as the experiential value in below table.
Or you can setup the cutting acceleration then adjust the low pass filter frequency up
and down within 2 levels. The cut acceleration and low pass filter frequency must
match, does not setup a large value and the other too small.
4.4.5 Curve precision and corner precision

Only under special circumstances to adjust the parameters in a small extent
around the default value, otherwise not recommend to modify these two parameters.
If curve precision parameter set too large and cutting precision is not good, you
can lower the curve precision which will limit the cutting speed at curves. If sharp
corner precision is not good, lower the corner precision will limit the cutting speed at
sharp corner. The value set too large the sharp corner will turns to a round corner.
5.1 System alarm and analysis
5.1.1 Z axis limit enabled

Limit sensor being triggered will send this alarm. Under this case check the items
below:
 Check the wiring.
 Check if the "Limit logic" correctly set as "normally open" or "normally
closed".
 Check if the limit sensor actually detected the object and sent valid level
signal.
 Check if the sensor damaged or polluted by dust or oil.
5.1.2 Out of Z range

When Z axis oversteps the Z axis travel range will trigger this alarm. If it's false
alarm, check if execute Z axis goes origin and built correct coordinates, if travel range
parameter set correctly and encoder response proper.
5.1.3 Z- limit signal is valid

When controller executes Z go origin, axis trigger the sensor and not reverse back
from sensing zone of limit switch, this alarm will be produced.
5.1.4 Z+ limit signal is valid

When controller executes Z go origin, axis trigger the sensor then roll back and
exceed the limit+ range, this alarm will be produced. When this alarm turns out, check
the "return distance" and "dock position" in BCS100 if set too large.
5.1.5 Servo alarm

Servo alarm is generated in software when alarm signal pin 14 detected active.
The high/low level logic of alarm is unlike with different servo, "servo type" must be
set correctly in BCS100.Below circumstances may cause "servo alarm" in BCS100:
 "Servo type" parameter in BCS100 not setting right.
 Wiring not right.
 Servo itself goes alarm.
 Interference (low probability for BCS100 has input filter).
5.1.6 Encoder abnormally moving

When BCS100 in static condition but detected encoder feedback different, this
alarm will be produced. Possible reasons include:
 Axis shaking caused by external force.

 Signal pin terminal not fixed and zero speed clamp signal is invalid.
 Servo rigidity is too weak.
 There is interference to the encoder cable. Check if the cable well ground and
add ceramic ring.
5.1.7 Encoder has no response

When controller sent analog signal to servo but no response returned from
encoder, this alarm turns out. Possible reasons include:
 Signal wiring not right, analog signal not sent into the servo, or zero speed
clamp signal keeps activating, or encoder feedback not returns to BCS height
controller.
 Wrong servo type setting. Servo should have velocity control mode.
 Servo setting not switch to velocity mode.
5.1.8 Position deviation is too large

When target position is different with feedback position controller will generate
this alarm. This alarm indicates that servo cannot follow up the controller's instruction
of position loop. Possible reasons include:
 Encoder direction reverse. Controller not receive feedback from position loop,
you need to modify related parameters.
 Wiring error and interference disturb the encoder feedback.
 Z axis is stuck or locked that increases torque instantly but not located in
target position.
5.1.9 Capacitance is 0
Possible reasons include:
 Laser head touches the plate.
 Water cause short circuit in laser head.
 Local capacitance of laser head too large and exceed the sensing range.
 Amplifier damaged.
 Poor connection of amplifier/laser head.
 Short circuit between nozzle (positive) and laser head shell (negative).
5.1.10 Local capacitance decrease

Local capacitance decrease value exceed threshold will generate the alarm.
Possible reasons include:
 Laser parts connection changed or replaced, or material properties change
will cause this alarm. Calibrate the capacitance will solve the problem.
 Scattered laser raise the nozzle temperature and cause temperature drift.
 Gassing pressure changes the gap between nozzle (positive) and laser shell
(negative).
 Bad contact in nozzle and amplifier cable.
 Calibration range set too small in BCS100 (3D smaller than 10mm, 2D
smaller than 15mm), might cause the alarm.

 Bad contact in nozzle and amplifier cable.
 The plasma cloud impact. Plasma cloud often formed in cutting stainless
steel especially with film. For stainless steel with film, it should defilm then
cut, do not cut with film. Make sure the machine is well grounded. Following
height shouldn't be smaller than 0.5mm, increase the following height could
improve the issue; properly increase the gassing pressure.
5.1.11 Capacitance abnormally became larger

When current capacitance is larger than the initial calibration value or setup
threshold will generate the alarm. The possible reasons include:
 Laser head touches the plate.
 Water enters in laser head.
 Scattered laser raise the nozzle temperature and cause temperature drift.
 Gassing pressure changes the gap between nozzle (positive) and laser shell
(negative).
5.1.12 Following deviation is too large

When the controller is in following mode, if there is instant distance deviation
detected will generate the alarm. Possible reasons include:
 Laser head moving out of the plate.
 Sharpe shaking of plate.
5.1.13 Use period has expired

Registered available time of system has expired.
5.1.14 Move close to board

When laser head is too close to the plate system will send this alarm to prevent
the collision.
5.1.15 Network Alarm

Alarm Description
Data frame length Data frame length error in network transmission
error
Data frame Data frame direction error
direction error
Single instruction Single instruction length error
length error
Single instruction Instructions not in the system instruction category.
category error
Data buffer full Instructions sent too frequently, buffer filled.
Parameter CypOne read and write parameter error in network
read/write error communication.
Instruction ID CypOne send wrong instruction ID.

error
5.2 Analysis of common problems
5.2.1 There is obvious shaking and mechanical impact when Z axis in

following movement.
 Bad contact between amplifier shell/controller FG pin with machine frame.
Machine frame is the negative pole of capacitance, the impedance is very
strong when amplifier shell is in bad contact with machine frame. This will cause
measurement error. You can add copper wire between amplifier shell with
machine shell to reduce the impedance. Specific indicators to achieve DC
impedance less than 10 ohms.
 Servo rigidity level set too large
Servo rigid level set too large will cause axis shaking and mechanical shock.
Panasonic MINAS A5 series servo, for example, it is recommended that rigid
settings should not exceed level 19.
 Follow speed level set too large
If follow speed level set too large will cause axis shaking in motion,
recommended level is from 3~7.
 Capacitance calibration not good
When BCL4562 collected capacitance-position curve not smooth, vibration
comes in following movement. Re-calibrate the capacitance until the sampling
result turns in excellent or good level.
 You can lower the "follow gain level" when there is strong interference.
5.2.2 Collision in following mode

 Calibration range setting is too small or Z axis speed too large.
If calibration range set too small and Z axis speed too large, slowing down
distance is too short for Z axis to stop after follow to target position. Z axis speed
larger than 100mm/s, calibration range should within 15mm.Z axis speed larger
than 250mm/s, calibration range should within 20~25mm.
 Servo rigid level too small
Servo rigidity level set too small will cause servo response speed lag than
controller command cause collision. If Panasonic MINAS A5 series servo,
 Capacitance calibration problem
When capacitance record in BCL4562 is significantly different with the
current capacitance might cause laser head collision with plate in following
movement. This happens when nozzle temperature rise or loosen contact. Under
this scenario locate and solve the problem sources then re-calibrate the
capacitance.
 No preheating
Please preheat 2-5 minutes and wait for the sampling capacitance stable
before further operations.
 Ceramic nut not tightened
Ceramic nut not tightened may lead to unstable capacitance.
5.2.3 Following distance different with the actual setting

 No preheating
Preheat the amplifier for 2~5 minutes before operate BCL4562 controller.
The capacitance will change by the temperature, you need to preheat the amplifier
for 2~5 minutes till the capacitance becomes stable.
 Calibration problem
Above errors occur usually when you change the nozzle and not doing
capacitance calibration.
 Laser scattering on nozzle or gassing not working right will lead to abnormal
temperature rise(above 100℃) and affect the capacitance.
 The nozzle does not touch the plate in calibrating, following distance is
larger than actual setting.
5.2.4 Lifting height not right

The lifting height is lowering in cutting process. Check if there is machinery
slippery or improper mechanical connection.
5.2.5 Upgrade prompt "Check error, ARM upgrade failed"

Upgrade file might be damaged or infected by virus.

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FSCUT1000S Laser Cutting

Shanghai Friendess Electronic Technology Corporation.，Ltd.

Thank you for choosing our products!

This manual gives a detailed introduction to the usage of

FSCUT1000S laser cutting controller, including technical features,

installation instructions, etc. For CypOne laser cutting software

operation, please refer to the Help documentation in the software.

Other matters you can contact us directly.

Operating personnel should read the manual in detail which will

be helpful for a better usage of the product.

Due to continuous updating of product functions, the products

respects. We apologize for any inconvenience may cause.

3.8 Focus control.....................................................................................................................58

5.1.12 Following deviation is too large............................................................................ 74

1.1 Brief introduction

FSCUT1000S is an open loop laser cutting control system of high

FSCUT1000S Laser Cutting System contains the following accessories:

1.2 System Connection Diagram

BMC1603 card uses PCI interface. Dimension: 213mm*112mm. Motion control

card BMC1603 connected with IO terminal board BCL4562 by a C62-2 cable;

1.3 Technical Reference

3 servo axis ports with high frequency pulse output of

1.4 Control Card Installation

1.4.1 Install Steps

appears means installation succeed.

to open its attributes page, and select "Detail

（3） If the first half of the "hardware ID" shows:" "means

2.1 Interface description

2.1.1 Interface layout

2.1.2 Power interface specification

2.1.3 Servo control port

Signal pin description of C15-1.5 cable shown as below:

Pin Signal name Pin Signal name

7 Green-black CLR (Alarm 15 Brown-black 0V (Power

+24V、0V： Supply 24VDC power for servo driver.

Fuji ALPHA5 SMART PLUS High Frequency Pulse

Parameter Recommended Description

Fuji ALPHA5 SMART Series Wiring Diagram

Fuji ALPHA 5 Series

Panasonic A5 High Frequency Pulse Wiring Diagram

Panasonic A5 Low Frequency Pulse Wiring Diagram

Panasonic A5 Series basic setting

Yaskawa servo wiring diagram

Yaskawa Σ series basic setting

Mitsubishi J3 series wiring diagram

Mitsubishi E Series wiring diagram

Mitsubishi MR-J3-A series basic setting

Delta A Series High Frequency Pulse Wiring Diagram

Delta ASD-A series basic setting

Delta B Series High Frequency Pulse Wiring Diagram

Parameter Recommended Description

Sanyo R Series Servo Wiring Diagram

Sanyo R Series Basic Setting

Schneider 23D High Frequency Pulse Wiring Diagram

Schneider Lexium 23D Series Basic Setting

Servo control terminal and PIN description on BCL4562 as shown below:

Signal pin description of C15-1.5 cable shown as below:

Pin Signal name Pin Signal name

+24V、0V： Supply 24VDC power for servo driver.