FSCUT4000 Laser Cutting System User ManualV2.0

1 FSCUT4000 Laser Cutting Control System
FSCUT4000 Laser Cutting System

User Manual
Shanghai Friendess Co., Ltd

www.fscut.com
Ver. 2.0
FSCUT4000 Laser Cutting Control System 2
Thank you for choosing our products!
This manual gives a detailed introduction to the usage of
FSCUT4000 laser cutting controller, including technical features and
installation instructions etc. For CypCut laser cutting software
operation, please refer to the CypCut user manual. For other matters
you can contact us directly.
Operating personnel should read the manual in detail which will
be helpful for a better use of the product.
Due to the 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 it may cause.

Content
1. Product Description ........................................................................................................................6
1.1 Brief Introduction ...................................................................................................................6
1.2 Connection Diagram ..............................................................................................................6
1.3 Technical Reference ...............................................................................................................7
1.4 Control Card Installation .......................................................................................................8
1.4.1 Install steps .............................................................................................................8
1.4.2 Troubleshoot...........................................................................................................9
2. BCL3724 Wiring Instruction .......................................................................................................11
2.1 BCL3724 Description ..........................................................................................................11
2.2 Signal Type ...........................................................................................................................12
2.2.1 Input signal ...........................................................................................................12
2.2.2 Relay output .........................................................................................................14
2.2.3 Thyristor output ...................................................................................................14
2.2.4 Analog output.......................................................................................................15
2.2.5 PWM output .........................................................................................................15
2.3 I/O Specification...................................................................................................................15
2.3.1 External power supply .........................................................................................15
2.3.2 Servo control port ................................................................................................15
2.3.3 Servo drive control signal ...................................................................................17
2.3.4 Origin and limit ....................................................................................................24
2.3.5 Common input .....................................................................................................24
2.3.6 Common output ...................................................................................................24
2.3.7 Analog output.......................................................................................................25
2.3.8 PWM output .........................................................................................................25
2.4 Wiring Diagram ....................................................................................................................26
2.5 Laser Wiring Diagram ..........................................................................................................27
2.5.1 YAG laser .............................................................................................................27
2.5.2 CO2 laser ..............................................................................................................27
2.5.3 IPG-YLR ..............................................................................................................28
2.5.4 IPG_ YLS Germany ............................................................................................29
2.5.5 IPG_ YLS American ............................................................................................30
2.5.6 SPI-500W-R4 .......................................................................................................31
2.5.7 FEIBO MARS ......................................................................................................32
2.5.8 JK/GSI-FL ............................................................................................................33
2.5.9 Rofin .....................................................................................................................34
2.5.10 Raycus ..................................................................................................................35
2.5.11 Max .......................................................................................................................36
3. Machine Config Tool ....................................................................................................................37
3.1 Installation and Operation ....................................................................................................37
3.2 Password ...............................................................................................................................37
3.3 User Interface .......................................................................................................................38
3.4 Mechanism Config ...............................................................................................................39
3.5 Return Origin Config ...........................................................................................................42

3.6 Laser Configuration .............................................................................................................43
3.6.1 CO2 laser configuration ......................................................................................43
3.6.2 IPG laser configuration .......................................................................................44
3.6.3 Feibo/Rofin/SPI/GSI/JK laser configuration .....................................................45
3.6.4 Configuration of other laser type ........................................................................46
3.7 BCS100 Configuration.........................................................................................................46
3.7.1 Use BCS100 as height control unit.....................................................................46
3.7.2 Use external device as height control unit .........................................................47
3.8 Gas System ...........................................................................................................................48
3.9 Alarm Configuration ............................................................................................................48
3.9.1 Warning message .................................................................................................49
3.9.2 Emergency stop button ........................................................................................49
3.9.3 Safety mode..........................................................................................................49
3.9.4 Custom alarm .......................................................................................................49
3.9.5 Allowed dual-drive error .....................................................................................49
3.10 Common input ......................................................................................................................50
3.11 Common output ....................................................................................................................51
3.11.1 Output configuration............................................................................................51
3.11.2 Auto lubricate.......................................................................................................51
3.11.3 Custom output ......................................................................................................52
3.11.4 Regional output ....................................................................................................52
3.12 Find Edge Setting .................................................................................................................52
3.13 BCP5045 Panel.....................................................................................................................53
4. Electrical System Adjustment ......................................................................................................54
4.1 Power Supply Checking.......................................................................................................54
4.2 Basic Machine Motion Config Checking ...........................................................................54
4.3 Hardware Signal Checking ..................................................................................................56
4.4 Basic Motion Test .................................................................................................................57
4.5 CypCut Basic Function Test ................................................................................................57
4.6 Position-Loop PID Self Adjustment....................................................................................57
5. Adjustment Steps ..........................................................................................................................59
6. Common Problems in Close-Loop control .................................................................................60
6.1 Motor Runaway Error ..........................................................................................................60
6.2 Encoder and Speed Check Failed ........................................................................................60
6.3 Position Error Too Large......................................................................................................60
7. Optimize Machine Motion Performance .....................................................................................62
7.1 Calculate Inertia Ratio and Preview Machine Performance Features...............................62
7.2 Motion Control Parameter Adjustment ...............................................................................63
7.2.1 Motion control parameter description ................................................................63
7.2.2 Adjust cutting acceleration ..................................................................................63
7.2.3 Adjust travel acceleration ....................................................................................64
7.2.4 Adjust low pass filter frequency .........................................................................64
7.2.5 Curve precision and corner precision .................................................................65
8. FAQ................................................................................................................................................66
8.1 Cutting is Slow or Jamming ................................................................................................66
8.2 Corner Over Burned .............................................................................................................66
8.3 Laser No Emission ...............................................................................................................66
9. Appendix .......................................................................................................................................68
9.1 Fly Cut Operation Guide......................................................................................................68
9.1.1 Function ................................................................................................................68
9.1.2 Function description ............................................................................................68
9.2 Pitch Error Compensation....................................................................................................69
9.2.1 Pitch error compensation description .................................................................69
9.2.2 Mechanical origin ................................................................................................69
9.2.3 Measure pulse equivalent ....................................................................................69
9.2.4 Mechanic error measure ......................................................................................70
9.2.5 Import measurement data to CypCut ..................................................................71
9.2.6 The operation steps of pitch error compensation ...............................................72
9.2.7 FAQ.......................................................................................................................73
1. Product Description
1.1 Brief Introduction
FSCUT4000 is a high performance laser cutting system of close-loop control

developed by Shanghai Friendess Company. It is widely used in metal and non-metal
laser cutting application, has gained wide popularity among users at home and abroad.
This manual served as installation and operation guide for FSCUT4000 system.
FSCUT4000 system hardware table:
Item Model Qty.
Motion control card BMC1214 1 pcs
I/O terminal board BCL3724 1 pcs
62-pin cable (2m) C62-2 1 pcs
Servo cable (1.5m) C15-1.5 4 pcs
Control software CypCut 1 pcs
Wireless handheld remote WKB 1 pcs
NC panel (optional) BCP5045 1 pcs
1.2 Connection Diagram
BMC1214 card adopts PCI interface. Dimension: 155mm*106mm. The socket

(DB62M) on control card connects with BCL3724 I/O terminal by C62-2 cable. Wiring
diagram shown below:
Computer Case
BMC1214
JP1 PCI Card
Y1 axis drive
Y2 axis drive
X axis drive
W axis drive
C15-1.5
C15-1.5
C15-1.5
C15-1.5
C62-2
BCL3724 I/O Board
1.3 Technical Reference
Analog output of 4 servo axis ports, -10V—+10V.

Motor control Encoder feedback channel of 4 servo axis ports, 10MHz.
signal Dedicated signal inputs of origin, positive/negative limit
and servo alarm for each axis.
Motion Control
Motion control
Dedicated signal outputs of servo enable and alarm reset

etc., for each axis.
Control cycle 1ms.
S-type acceleration and deceleration with filter.
Motion Velocity look-ahead strategy, intelligent speed control at
control turning point.
performance Local curvature analysis and speed restriction at curves.
Auto smooth corner.
Laser control signal 1 PWM signal, DIP switch(24V/5V as options)
3 analog output ports of 0~10V
1 analog input port of 0~10V
I/O function 12 common input ports.
20 output: 6 relay outputs and 14 thyristor outputs.
Work environment Temperature: 0-55 Celsius degree
Humidity: 5% ~ 90% no condensation
Power supply 24V，2A
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) Power off computer, insert the control card into PCI socket, and fix the control
card tightly;
(2) After start up computer, "Add Hardware Wizard" pops out and click "Cancel"
button, as shown below. If this dialog box does not appear, indicating the card
is in poor connection, please repeat the first step.
(3) Install CypCut software. The driver program will be installed by default option
automatically.
(4) Open windows device manager to confirm installation succeed. Below image
shows the installation is succeed.

1.4.2 Troubleshoot
（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 in good connection with PCI socket. Please replace the PCI socket
or change another computer, insert the control card tightly 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 ‘device instance ID’ attribute is displayed as
it means computer has correctly recognized the motion
control card but software installation might be failed. Try install CypCut
again, if installation still fails, please contact our technical support.
（4） If the first half of ‘device instance ID’ attribute is not , it

indicates computer doesn't recognize the control card. Power off computer and
change PCI socket, install the card firmly and repeat installation again.
（5） If step (4) still fails, the control card might be damaged please contact our
technicians.
P- P+ D1- D2- D3- AD- COM COM COM COM COM COM COM COM COM COM COM COM
X axis Y1 axis Y2 axis W axis
2. BCL3724 Wiring Instruction
FSCUT4000 Laser Cutting Control System
Control Control Control Control

relay relay relay relay 1 2 D1+ D2+ D3+ AD+ IN12 11 10 IN9 8 7 IN6 5 4 IN3 2 1
ON
62-pin socket
OFF
BCL3724
BCL3724 diagram shown as below:
Relay Relay Relay Relay Relay Relay

output output output output output output
BCL3724 Description
X- XO X+ Y1- Y1O Y1+ Y2- Y2O Y2+ W- W0 W+

POWER IN POWER OUT
24V COM 24V 24V 24V COM COM COM COM COM COM COM COM COM COM COM COM NO1CON1 NO2CON2 NO3CON3 NO4CON4 NC5NO5CON5 NC6NO6CON6 O7 O8 O9 O10O11O12 O13O14O15 O16O17O18 O19O20COM
11
2.1
You can either use guide rail or fixed installation to install BCL3724 board, product
dimension 315mm*107mm. DB62M socket connected with JP1 interface of BMC1214
card by C62-2 cable.
4 sockets (DB15M) on top left are for servo control, from left to right is X, Y1, Y2
and W axis port.
The signal terminals on bottom left are positive/negative limit, origin inputs of X,
Y and W axes. All lower terminals are conducted, ground end of COM, 0V.
On bottom right are 20 common output terminals which are thyristor emitter output.
Thyristor output is 24V, common cathode.
Above are PWM signal and 4 DA analog signal terminals.
There is a DIP switch down below PWM:
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 Signal Type
2.2.1 Input signal

The input signals: positive/negative limit, origin, common input. All input
terminals of BMC1214 are low-level active, support NO (normally-open) and NC
(normally-close) input. When set input as normally-open, input signal active when
conduct with 0V; when set input as normally-close, input signal active when disconnect
with 0V.
The polarity of input can be changed by jump-wire, IN10, IN11, IN12 support
jump-wire. There are 2 status of jump-wire, ACT_LOW means low-level active (input
0V active); ACT_HIGH means high-level active (input24V active). The default state is
ACT_LOW.
ACT_LOW
ACT_HIGH
The typical wiring of photo-electric switch shown below, must use NPN 24V type
switch.
BCL3724 Photo-electric switch
COM —
Y- O
24V +
The typical wiring of contact switch shown below.
BCL3724 Contact switch
COM COM
Y+ NO
The typical wiring of magnetic switch shown below, must use NPN 24V type
switch.
BCL3724 Magnetic switch
COM 0V
IN6 o
24V V+
2.2.2 Relay output

There are 6 relay output on BCL3724 terminal board which are OUT1-OUT6.
OUT1-OUT4 only support normally open, OUT5-OUT6 have both NO and NC
options. The maximum load of relay: DC 30V, 8A; AC 250V, 8A. Recommend to
use load under 2A, the inductive load or high power load will reduce the service
time of relay switch.
Wiring between relay output and contact shown below:
BCL3724 Machine
OUT1
Coil power
supply
Digit 24V
2.2.3 Thyristor output

There are 14 thyristor output on BCL3724 from OUT7-OUT20, which can drive
24V DC device directly, drive capacity is 500mA. Wiring diagram shown below:
BCL3724
OUT16
24V DC
Magnetic
valve
COM
2.2.4 Analog output

3 analog output of 0-10V.
Output range 0V~+10V

Maximum output load 50mA
Maximum capacitive load 350pF
Input impedance 100KΩ
Maximum bipolar error +/-50mV
Resolution 10mV
Conversion speed 400us
2.2.5 PWM output

There is one PWM port on BCL3724 for laser average power modulation. There
are 5V and 24V for options. The duty cycle is adjustable from 0%~100%, the highest
carrier frequency 50 KHz. The signal output shown below:
VCC
PWM
PWM+
PWM-
Set PWM signal level, 5V or 24V set by DIP switch.
2.3 I/O Specification
2.3.1 External power supply

BCL3724 requires external 24V DC power supply. The 24V and COM connect
with 24V and 0V of power supply.
2.3.2 Servo control port

The 4 servo ports on BCL3724 are DB15 sockets, signal pin description listed
below:
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
The signal pin description of C15-1.5 cable listed below:
15-pin servo control interface

Pin Description Pin Description
1 DA (-10~10V analog) 9 AGND (analog ground)
2 0S (zero speed clamp) 10 0V (power supply ground)
3 A+ (encoder A phase positive) 11 A- (encoder A phase negative)
4 B+ (encoder B phase positive) 12 B- (encoder B phase negative)
5 Z+ (encoder Z phase positive) 13 Z- (encoder Z phase negative)
6 SON (servo enable) 14 ALM (alarm signal)
7 CLR (alarm clear) 15 0V (power supply ground)
8 24V (power supply)
+24V, 0V: give 24V DC power supply to servo driver;
SON: servo-on output;
ALM: alarm input from servo;
DA, AGND: analog output for motor control;
CLR: alarm reset;
OS: zero speed clamp signal;
A+ 、 A- 、 B+ 、 B- 、 Z+ 、 Z-: Encoder 3-phase input signal, to check
encoder zero point.
The polarity of SON and ALM can be changed by jump-wire;
SON ALM
ACT_LOW ACT_LOW
ACT_HIGH ACT_HIGH
SON signal jump wire to ACT_LOW, output is low-level active (output 0V active);
Jump wire to ACT_HIGH, output is high-level active (output 24V active); Default is
ACT_LOW.
ALM signal jump wire to ACT_LOW, input is low-level active (input 0V active);
Jump wire to ACT_HIGH, input is high-level active (input 24V active); Default is
ACT_LOW.
2.3.3 Servo drive control signal

The wiring diagram with Panasonic, Yaskawa, Sanyo and Schneider provided here.
For servo driver parameter setting you can take reference from ServoTools calculation.
If you have any question please contact our technical support.
For other brand servo wiring please take notice of following items:
(1) Make sure the servo supports velocity control mode. For example, Panasonic
A5 series servo must choose full-function type, cannot use pulse type;
(2) Check if SON signal is low-level active (SON is active when conducted with
GND of 24V);
(3) Check if there is external emergency stop in servo I/O;
(4) Before trial run of driver, provide 24V power supply to IO terminal board, the
24V power supply provided by BCL I/O board;
(5) If driver still can't run, check if the parameter 'positive/negative direction drive
inhibit' in driver is disabled.
Panasonic servo wiring diagram

FSCUT DB15 servo control MINAS-A 50P
Signal Pin Shielding layer Pin Signal

DA 1 14 SPR/TRQR
AGND 9 15 GND
A+ 3 21 OA+
A- 11 22 OA-
B+ 4 48 OB+
B- 12 49 OB-
Z+ 5 23 OZ+
Z- 13 24 OZ-
24V 8 7 COM+
SON 6 29 SRV-ON
0V 10 36 ALM-
ALM 14 37 ALM+
0V 15 41 COM-
Panasonic A5 reference setting
Parameter Description Recommended value

Pr0.01 Control mode 1
Pr0.02 Real time auto tuning 0
Pr0.04 Inertia ratio You can calculate the inertia ratio by
Panasonic servo software
Pr0.11 Encoder output pulse Set by mechanism feature, the pulse equivalent
per motor revolution should be among 1000-2000. For example, if
the linear distance is 10mm on machine load
per motor rotation, the pulse per revolution
should be 10000, and Pr0.11 set 2500.
Pr1.01 1st gain of velocity 75.0Hz
loop
Pr1.02 1st time constant of 9.0ms
velocity loop
integration
P r1.04 1st time constant of 0.3ms
torque filter
P r3.02 Input gain of speed Set by maximum motor speed. If maximum
command motor speed is 4000rpm, set 400 here.
Yaskawa servo wiring diagram

FSCUT DB15 servo control YaskawaΣ50P

DA 1 5 V-REF
AGND 9 6 SG
A+ 3 33 PAO
A- 11 34 /PAO
B+ 4 35 PBO
B- 12 36 /PBO
Z+ 5 19 PCO
Z- 13 20 /PCO
24V 8 47 +24 VIN

SON 6 40 /S-ON
0V 10 32 ALM-
ALM 14 31 ALM+
0V 15 1 SG
Yaskawa Sigma 5/7 reference setting

Pn000 Control mode 0000
Pn100 Velocity loop gain 75.0Hz
Pn101 Velocity loop integral 9 .00 MS
constant
Pn103 Inertia ratio Set by calculation result of Yaskawa
servo software SigmaWin. Or you
can set by calculation result of
ServoTools.
Pn170 Adjustment-free 1400
Pn212 Differential pulse output Set by mechanism feature, the pulse
per motor revolution equivalent should be among 1000-2000.
For example, if the linear distance is
10mm per motor rotation, the pulse per
revolution should be 10000, and Pr0.11
set 2500.
Pn300 Input gain of speed 0.01V/rated speed
command
Pn401 Torque command filter 0.30 MS

time constant
Pn50A Input signal 8100
Pn50B Input signal 6548
Sanyo R series wiring diagram

FSCUT DB15 servo control Sanyo R2 50P

DA 1 21 V-REF
AGND 9 20 SG
A+ 3 3 A0+
A- 11 4 A0-
B+ 4 5 B0+
B- 12 6 BO-
Z+ 5 7 ZO+
Z- 13 8 ZO-
49 OUT-PWR
24V 8 50 CONT-COM
SON 6 37 CONT1
0V 10 24 OUT-COM
ALM 14 46 OUT8
Sanyo R2 reference setting

SY09 Control mode 01
Gr0.00 TUNMODE, tuning mode selection. 02
Gr1.12 KVP, velocity loop proportional 75H z
gain
Gr1.13 TVI, velocity loop integral time 9ms
constant
Gr1.14 Inertia ratio Input the value calculated by Sanyo
servo software, you can also
calculate by Friendess ServoTools.
Gr8.29 VCGN, analog velocity command Set by the maximum motor rpm. For
gain example, if the maximum motor
speed is 4000rpm, set this parameter
as 4000.
G r9.00 F-OT, forward over travel 00
Gr9.01 R-OT, reverse over travel 00
G r9.27 VLPCON, velocity loop 00
G rB.13 Hold brake delay 00
G rB.14 Release brake delay 00

G rC.04 Differential pulse output Set by mechanism feature, the pulse
equivalent should be among 1000-2000.
For example, if the linear distance on
machine load is 10mm per motor
rotation, the pulse per revolution should
be 10000, and Pr0.11 set 2500.
Schneider Lexium 23D wiring diagram

FSCUT DB15 servo control Schneider Lexium 23D

DA 1 42 V-REF
AGND 9 44 GND
A+ 3 21 OA
A- 11 22 /OA
B+ 4 25 OB
B- 12 23 /OB
Z+ 5 50 OC
Z- 13 24 /OC
24V 8 11 COM+
SON 6 9 SON
0V 10 45 COM-
ALM 14 28 DO5+
0V 15 27 DO5-
Schneider 23D reference setting

P1-01 Control mode 0002
P1-37 Inertia ratio Input inertia ratio calculated by
Schneider servo software, you can also
use Friendess ServoTools to calculate the
inertia ratio.
P1-40 VCM, maximum command Set by maximum RPM of motor. For
rotation speed example, if the maximum RPM of motor
is 4000rpm, set same value for this
parameter.
P1-46 ENCOUTRES, encoder output Set by mechanism feature, the pulse
pulse per motor revolution equivalent should be among 1000-2000. For
example, if the linear distance is 10mm per
motor rotation, the pulse per revolution
should be 10000, and Pr0.11 set 2500.
P2-04 KVP, velocity control gain 565rad/s
P2-06 KVI, velocity integral 108rad/s
compensation
P 2-32 ATMODE, automatic 0

adjustment
2.3.4 Origin and limit

X-: negative limit of X axis, dedicated input, low-level active;
XO: origin of X axis, dedicated input, low-level active;
X+: positive limit of X axis, dedicated input, low-level active;
COM: ground, the common end of above three signal ports.
Y1-: negative limit of Y1 axis, dedicated input, low-level active;

Y1O: origin of Y1 axis, dedicated input, low-level active;
Y1+: positive limit of Y1 axis, dedicated input, low-level active;
Y2-: negative limit of Y2 axis, dedicated input, low-level active;

Y2O: origin of Y2 axis, dedicated input, low-level active;
Y2+: positive limit of Y2 axis, dedicated input, low-level active;
W-: negative limit of W axis, dedicated input, low-level active;

WO: origin of W axis, dedicated input, low-level active;
W+: positive limit of W axis, dedicated input, low-level active;
You can change input polarity of origin and limit signals via machine config tool.
See details in chapter 3 machine config.
2.3.5 Common input

There are 12 common input IN1-IN12. You can assign common inputs as user-
defined software button or alarm input. See details in chapter 3 machine config.
2.3.6 Common output

There are 20 common output OUT1-OUT20. Common output can be assigned as
user-defined signal output for laser, gas, indicator lamp controlling etc. See details in
chapter 3 machine config.
2.3.7 Analog output

3 channels analog output of 0-10V, DA1, DA2 and DA3. Analog output can be
assigned for laser peak power and gas valve control.
2.3.8 PWM output

For fiber laser configuration in CypCut machine config, PWM will be activated
automatically for laser average power regulation. For other type laser, there is no signal
output from PWM port.
2.4 Wiring Diagram
DB15 socket
DB62 socket
X servo
X xis
24V power +24V
supply COM
X- limit
Y1 servo
X-
DB15 socket
X origin
Y1 axis
X0
X+ limit
X+
COM
Control relay
Y1- limit
Y1-
Y1 origin
DB15 socket
Y2 servo
Y10
Y2 axis
Y1+ limit
Y1+
COM
Y2-
Y20
DB15 socket
W servo
W axis
Y2+
COM
W-
W0
W+ PWM PWM- Laser
COM output PWM+ modulation
Analog GND
OUT1 Analog DA1- Laser
Analog voltage
output1 DA1+
contact
NO type
Analog GND
Analog DA2- Proportion
Relay output
output2 DA2+ Analog voltage

al valve
OUT4 Analog DA3-

output3 DA3+
Analog GND
Analog AD1- Gas pressure
NO/NC type
Analog voltage valve

input1 AD1+
contact
OUT5
OUT6 IN12
IN11
IN10
IN9
Thyristor output
OUT7 IN8
IN7
IN6
output
DC 24V
IN5
IN4
OUT20 IN3
IN2
COM IN1
Custom input
COM
2.5 Laser Wiring Diagram
2.5.1 YAG laser

Assign an output for laser emission and connect with laser.
2.5.2 CO2 laser

Here take example of NT-3200SM CO2 laser.
BCL3724_V2.0 Terminal Board OVNT CO2 laser 24P
Analog output DA1- 6 Laser power

(DA1 laser power control) DA1+ 7 Analog 0V
Thyristor output
OUT11 digital shutter OUT11 10 Digital shutter
OUT13 laser mode1 OUT13 8 EP pulse
OUT14 laser mdoe2 OUT14 9 SP pulse
COM 19 Switching value 0V
Assign one relay

NO 11 Optical shutter
output as mechanical
shutter CON 12 Optical shutter
Note: mechanical
shutter response is
not necessary.
Assign one input for IN 16 Shutter response
mechanical shutter response COM 18 Passive CON
Note:
Some of CO2 laser also supports PWM control mode, wiring can take reference
from Max laser.
2.5.3 IPG-YLR
IPG_YLR Laser 25P
1 Safety interlock1
2 Safety interlock2
3 Safety interlock2
Computer RS232 DB9
4 Safety interlock1
1
6 2 5 RS232 Rx
7
3 6 RS232 Tx
8 4 7 RS232 COM
9
5
BCL3724_V2.0 I/O Board
DIP switch PWM PWM- 15 Modulation+

ON output PWM+ 16 Modulation-
1 2
It's recommended to use serial communication (RS232) or network

communication under serial or Ethernet communication, CypCut can monitor laser
status in real time and control laser of emission, aiming, peak power without DA analog
output.
Recommend to use network communication for IPG-YLR series.
Note:
1. Remote start-up button is not necessary and not recommended for it might cause
laser malfunction when laser is not well grounded.
2. Select 24V for PWM (DIP switch: PIN1 ON, PIN2 OFF).
2.5.4 IPG_ YLS Germany
BCL3724_V2.0 I/O Board IPG-Germany YLS Laser

64Pin XP1
thyristor output
OUT11 Laser ON OUT11 C1 Laser ON
OUT12 Laser Request OUT12 A1 Laser Request
OUT13 Program Start OUT13 A2 Program Start
OUT14 Aiming OUT14 A5 Guide Laser On
COM A16 Common
+24V A6 Anolog Control ON

Power output B15 24V
+24V
COM B16 0V
24V reply
Assign an input as IN B2 Emission ON
Emission Status） COM
25Pin XP2
DIP switch
ON PWM PWM-
output A1 Modulation+
1 2 PWM+
A2 Modulation-
C1 Safety interlock1
7Pin XP4
Analog output DA1- A1 0~10V

（DA1 for laser power control） DA1+ A2 AGND
Note:
1. B2 'Emission ON' in XP1 interface is not necessary for CypCut, set 'Emission
Status' as '0' in machine config, CypCut will not check laser emission status.
2.5.5 IPG_ YLS American
BCL3724_V2.0 I/O Board IPG-American YLS Laser

64Pin XP1
Thyristor output
OUT11 Laser Request OUT11 A1 Laser Request
OUT12 Program Start OUT12 A2 Program Start
OUT13 Aiming OUT13 A5 Guide Laser On
COM A16 Common
+24V A6 Anolog Control ON

Power output B15 24V
+24V
COM B16 0V
24V relay
IN B2 Emission ON
Assign a output
Emission Status COM
DIP switch 25Pin XP2

ON PWM-
PWM output Modulation+
1 2 PWM+ A1
A2 Modulation-
A8 Remote Mode
A9 Remote Mode
Assign an output for NO C5 Power On
Laser On CON C6 Power On
7Pin XP4
Analog output DA1- A1 0~10V

DA1 laser power cotrol DA1+ A2 AGND
Note:
1. B2 'Emission ON' in XP1 interface is not necessary for CypCut, set 'Emission
Status' as '0' in machine config, CypCut will not check laser emission status.
2.5.6 SPI-500W-R4
SPI-500W R4 Laser Systems
InterLock
1 Interlock 1
2 Interlock 2
4 Interlock 2
Computer 5 Interlock 1
RS232 DB9
RS232 Comms Port
1
6 2 2 RS232 Rx
7
3 3 RS232 Tx
8 4 5 RS232 COM
9
5

Mod Input TTL
DIP Switch
ON PWM PWM- Modulation+
output PWM+
1 2 Modulation-
Note:
1. When use MODINPUTTTL for laser modulation, select 5V for PWM (DIP
switch: PIN1 OFF, PIN2 ON).
2. When use PIN1 of I/O interface for laser modulation, select 24V for PWM (DIP
switch: PIN1 ON, PIN2 OFF).
2.5.7 FEIBO MARS

Computer RS232 DB9 FEIBO MARS-500W Laser System
D-SUB 9
1
6 2 2 RS232 Rx
7
3 3 RS232 Tx
8 4 5 RS232 COM
9
5

D-SUB 15
DIP Switch
ON PWM PWM- 3 Modulation+
output PWM+ 6
1 2 Modulation-
8 +5v
9 INTLK
Note:
Select 24V for PWM (DIP switch: PIN1 ON, PIN2 OFF).
2.5.8 JK/GSI-FL
JK/GSI-500W-FL
SK11
Computer RS232 DB9 1 Interlock

2 Interlock
PL1
1 5 Interlock
6 2 6 Interlock
7 2 RS232 Tx
3 7 Interlock
3 RS232 Rx
8 4 15 Interlock
5 RS232 COM
9 14 Interlock
5
13 Interlock
10 Interlock
9 Interlock

SK101
PWM PWM- Modulation+

output PWM+ Modulation-
Note:
1. The interlock in SK11 interface
2. When use SK101 as modulation, select 5V for PWM (DIP switch: PIN1 OFF,
PIN2 ON).
3. When use Pin-16 in PL5 as modulation, select 24V for PWM (DIP switch: PIN1
ON, PIN2 OFF).
2.5.9 Rofin
BCL3724_V2.0 I/O Board Rofin Fiber Laser
X710
Thyristor output
OUT11 Mission ON OUT11 3 Mains on
OUT12 Fault Reset OUT12 1 Program Start
OUT13 Stand By OUT13 4 Stand By
OUT14 Aiming OUT14 8 Guide Laser On
OUT15 Gate OUT15 10 Gate
COM 9 Ext GND
DIP switch 13 Gate GND
ON PWM PWM-
1 2
output PWM+ 15 Ext Pulse 5V
16 Ext Pulse GND
X720
22 Interlock
23 Interlock
24 Interlock
25 Interlock
26 Interlock
27 Interlock
28 Interlock
29 Interlock
30 Interlock
31 Interlock
32 Interlock
33 Interlock
X704
Analog output DA1- 1 Analog+

DA1 laser power control DA1+ 14 Analog-
Note:
1. Take related reference for wiring of interlock in X720;
2. Select 5V for PWM ((DIP switch: PIN1 OFF, PIN2 ON; one of PIN3 or PIN4
ON and the other OFF).
2.5.10 Raycus
RayCus Fiber Laser

InterLock
b Interlock1
c Interlock1
Computer RS232 DB9

COMMAND RS232
1
6 2 2 RS232 Rx
7
3 3 RS232 Tx
8 4 5 RS232 COM
9
5

INPUT MOD
PWM PWM- Modulation+

output PWM+ Modulation-
Note:
1. Raycus's latest products use 24V PWM, the old versions use 5V PWM. For
latest Raycus laser, key switch turns to REM under serial communication, while for
old versions key switch turns to ON position under serial communication. Laser
PWM port will indicate its 24V or 5V control. No specific description indicates 5V
PWM control.
2. 5V PWM control (DIP switch: PIN1 OFF, PIN2 ON).
3. 24V PWM control (DIP switch: PIN1 ON, PIN2 OFF).
2.5.11 Max
Max Fiber Laser

InterLock
1 Water chiller interlock

19 Water chiller interlock
Max Fiber Laser
DIP Switch
ON PWM PWM- 3 Modulation-
output PWM+
1 2 15 Modulation+
OUT17 17 Aiming+
Assign thyristor output as 16
Emission on and Aiming
OUT18 Emission on+
COM 21 Emission on-
22 Aiming-
Analog output DA1- 5 AGND

DA1 laser power control DA1+ 12 0~10V
Assign one input as IN 18 PD+

laser alarm COM 23 PD-
Note:
1. PD+/PD-(laser alarm output) connect to any input port in BCL3724 I/O board,
then in 'machine config>alarm>custom alarm' setup the laser alarm (normally-open);
2. The ground end of aiming laser and laser emission can connect to any COM
port in BCL3724 board.
3. 24V PWM control (DIP switch: PIN1 ON, PIN2 OFF; one of PIN3 and PIN4 is
ON, the other is OFF).
3. Machine Config Tool
3.1 Installation and Operation
CypCut default installation contains machine config program.
In Windows Start > All Programs > CypCut open machine config program .
'CypCut laser cutting system' is software name which might be different of OEM
version.
3.2 Password
You have to input password to start config tool.
Initial password 61259023.
Note:
All settings in machine config must setup by actual mechanism structure. Wrong
settings will cause severe unknown problem! In machine config, all input are yello w
color, and all output are green color.
3.3 User Interface
The first page open machine config is machine config overview. Click tab in top
and left bar will open each parameter setup page for different machine module. For
example, above three are entrance for laser, height control and gas system setting page.
Click 'file location' will locate to folder of config data.
Click button in overview page will also open the parameter setting page of each
module. Click 'Machine tool' will enter ' Machine' page.
Click 'import' to finish machine config setting by existing file. Click 'save' save the
setting.
Note:
1. Data folder contains all config files of CypCut.
2. Data backup is in CypCut > File > Backup.
3.4 Mechanism Config
Config mechanism structure, single drive Y axis or dual-drive Y axis, also config
rotary axis.
X axis range: the maximum travel range under software limit protection function,
also the width of white frame in CypCut drawing board.
Y axis range: the maximum travel range under software limit protection function,
also the length of white frame in CypCut drawing board.
Pulse equivalent: pulse output per 1mm linear distance on machine load. You can
calculate by ServoTools.
Servo alarm: set the triggered polarity of alarm signal is normally open or close.
Max speed: maximum user speed and acceleration restricted by CypCut.
Pitch compensation: compensation method for mechanic error including backlash
and offset error data from interferometer.

Squareness: this is to offset the error when X and Y mechanic is not orthogonal.
X/Y check: used for motor runaway risk checking.
Motor runaway check: to check if the motor rotation direction same with encoder
feedback. For example: send voltage+ for motor rotation+. If encoder feedback pulses
increase in positive value, it indicates motor rotation polarity same with encoder
feedback. Otherwise, it cannot create a close loop control when motor rotation polarity
different with encoder feedback, under this situation motor will never reach the target
position and controller keep sending command signal, machine load will rush out, this
scenario called 'motor runaway'. (Note: if doesn't pass motor runaway test, cannot open
CypCut for machine spindle adjust).
The sequence of motor runaway check:
30rpm
100ms
t
100ms 50ms
-30rpm
Close-loop jog: check the option and jog X axis, observe the motor rotation and
encoder feedback polarity.
Open-loop jog: check the option controller only send analog output, doesn't
compare with feedback. Dual-drive axis doesn't recommend this function.
Reverse X: if machine load direction not same with jog direction, click
to reverse it and doesn't need to change setting in servo driver.

Pulse check: check if encoder feedback pulses match with controller command.
3.5 Return Origin Config
Enable soft limit: check this option, software limit function will force start all the
time.
Prompt user at start: prompt message when open CypCut to inform user execute
return origin operation.
Origin direction: select return origin direction needed. Return origin direction
decides which coordinate quadrant system runs with. For example, return origin
direction of X and Y are both in negative direction, system runs in first quadrant
coordinate.
Origin signal: FSCUT4000 must use origin switch, cannot take limit as origin.
ORG measure: measure the installation distance between limit and origin switch.
Z-phase signal: whether or not capture Z-phase signal results different return
origin process. The return origin process of each mode will display in picture. Dual-
drive gantry synchronize function only available when capture Z-phase signal return
origin.
Low speed: fine positioning speed, recommend to set 10mm/s.

High speed: course positioning speed, recommend to set 50mm/s.
Rollback: the distance motor rolls back after reach origin switch.
Limit logic: the polarity of limit and origin signal active.
3.6 Laser Configuration
CypCut programmed standard configuration for YAG, CO2, IPG, Raycus, SPI and
many other brand laser, select laser type and there are different parameter settings under
each page.
3.6.1 CO2 laser configuration
Mechanic shutter: the output for mechanic shutter.

Digital shutter: the output for digital shutter.
Response input: response input when open mechanic shutter.
Laser form: laser form can be set as continuous wave, gate pulse and high power
pulse by mode 1 and mode 2 output.
DA port: there are three DA analog output, select one of them for laser power
control.
DA range: set the analog voltage range.
Minimum power: the minimum laser power.
3.6.2 IPG laser configuration
PWM enable: select a relay output in BCL3724 board as switch of PWM signal.
Relay output can avoid laser leakage.
DA output: there are 3 DA ports of analog output, select one of them for laser
power control. When use RS232 or network control doesn't require DA port.
IPG Fiber Laser Configuration:

Remote start button:
When key switch turns to remote control mode, you can startup laser by remote
button. If use remote start button, you need to setup the output port for the button.
(Remote start up button is not recommended, for it's easy to cause laser malfunction).
IPG remote control:

When use IPG remote control, CypCut will monitor laser status in real time, then
communicate and control laser emission, guide beam and peak current etc. When use
remote control mode, doesn't require DA analog port.
IPG remote control supports serial and network communication, user can set IP or
COM port as needed. When laser and BCS100 both select network communication with
PC, take notice that the network segment of each IP cannot be same. For example, IP
segment of BCS100 is 10.1.1.x while laser IP set 192.168.1.x. Recommend to use
network communication which is more stable. If use serial communication, the
shielding layer and outer shell of the connected device must be well grounded.
3.6.3 Feibo/Rofin/SPI/GSI/JK laser configuration
Feibo, Raycus and SPI laser are similar with IPG laser configuration, and support
serial communication.
Debug mode: when enable this mode, CypCut log window will display the
communication code with laser.
3.6.4 Configuration of other laser type
Shutter enable: output to open laser shutter.
3.7 BCS100 Configuration
3.7.1 Use BCS100 as height control unit
Use BCS100 as height control unit, set IP address in machine config same in
BCS100.
Details of setting IP address please check in BCS100 user manual P2.5.6.
3.7.2 Use external device as height control unit
CypCut supports I/O control mode for height controller of other brand. User can
assign output with basic functions of lift, hold, up and down etc.
Start follow: output to start follow.

Lift/stop follow: output of stop follow and lift up.
Stop/hold: output of stop follow and hold still.
Jog up: output of jog Z axis up.
Jog down: output of jog Z axis down.
Follow in place: input signal of follow reached position.
Active level (follow in place input): active level of follow in place signal.
Note: If the port number set '0', means this port not in use. If this port not assigned
to any signal, doesn't set any port number, otherwise it might cause error.
3.8 Gas System
Valve (H/L): master valve of high pressure or low pressure gas channel.
Air: set output for air switch.
Oxygen: set output for oxygen switch.
Nitrogen: set output for nitrogen switch.
Gas alarm: to set alarm check for each gas channel or master valve.
There are 3 DA ports of analog signal can be assigned for gas pressure regulation.
3.9 Alarm Configuration

3.9.1 Warning message

Display the warning message of yellow color when machine is running. You can
edit the warning message.
3.9.2 Emergency stop button

When this signal port active will trigger emergency stop alarm.
3.9.3 Safety mode

Safety mode used for machine maintenance mode, under which machine speed and
laser power will all be restricted to preset safety range.
3.9.4 Custom alarm

User can assign any input port as alarm, edit alarm description and active level of
signal port, and select allowed machine actions in alarm status.
3.9.5 Allowed dual-drive error

Maximum dual-drive position error allowed, the threshold to trigger alarm.
3.10 Common input
Click button and select controlled function and active level of input
signal.
3.11 Common output
3.11.1 Output configuration

Aiming: output to control guide laser.
Lasering: system will send an output signal for indicator lamp when laser in
emission.
Working: system will send an output signal for indicator lamp when laser in
production.
Alarm lamp: system will send an output signal for alarm lamp when alarm
triggered.
Alarm bell: system will send an output signal for alarm bell when alarm triggered.
Ready: after machine axes returned origin, system will send an output.
3.11.2 Auto lubricate

After this I/O is assigned for auto lubrication, CypCut will start time/running
length counting and turn on/off lubrication when reach preset time/mileage interval.
3.11.3 Custom output

Assigned I/O will display software button under CypCut CNC tab. Custom I/O
can select contact or self-lock control method.
3.11.4 Regional output

Regional output used for automatic dust extracting. When machine in production,
laser head works in region A, output in region A will active and turn on dust extractor.
When laser head works from region A to region B, output 12 turns off and output 15
turns on.
Turn-off delay: when laser head works from one region to another one, output of
last region will turn off after preset delay.
3.12 Find Edge Setting
CypCut supports find workpiece edge by capacitance sensing and photo-electric

senor. Photo-electric sensor must be Omron E3Z-L61 model. Capacitance sensing
realized by BCS100 height controller.
3.13 BCP5045 Panel
Enable BCP5045 panel in this page. In stand-alone environment, CypCut will

connect to BCO5405 Mac address. In LAN environment, input ID of BCP5045. There
are 12 custom buttons which can be assigned for machine function like PLC control or
pallet control.
4. Electrical System Adjustment
4.1 Power Supply Checking
Connect BCL3724 I/O terminal board and BMC1214 control card by C62-pin
cable, give 24V power supply to BCL3724 board. Make sure power supply in right
wiring and no short circuit before power up.
Note: Do not hot plug BMC1214 card and C62-pin cable!
4.2 Basic Machine Motion Config Checking
Motor runaway risk exists in close-loop control, you need to do some checking
points before first-time running.
First, confirm some basic settings in 'machine config tool' in below image: motor
type, servo alarm signal polarity, pulse equivalent, encoder feedback, input gain of
speed command, for dual-Y drive structure you also need to confirm rotation direction
of master motor and slave motor in case of mechanic twisting (Take notice that servo
drive parameters should be same settings for dual-Y axes).
Second, check motor direction and feedback pulse direction from encoder. Click
open ‘motor axis checking’ page.
1. Click to start motor runaway test.
2. Click option, then jog motor in both directions, if motor motion
direction not same with command direction in CypCut, click to
reverse it.
3. Pulse check. This is to ensure encoder feedback pulses and input gain of speed
command set right.
4.3 Hardware Signal Checking
Startup computer and open CypCut software. Open File tab > Diagnosis > IO
Monitor.
Check each signal one by one: positive limit/negative limit/origin switch of each
motor axis, DA signal, PWM signal, servo enable signal and all other input and output
signal.
4.4 Basic Motion Test
First, set conservative PID value in servo driver. And set conservative value of
motion control parameter in CypCut. In CypCut 'Layer' > 'Global Parameter' shown as
below:
Test single motor axis make sure pulse equivalent set right.
After all limit and origin signal tested to work normally, execute each motor axis
return origin to build mechanical coordinate.
4.5 CypCut Basic Function Test
On CypCut control panel(right side on screen), click direction button to jog

control axes, lift up/down Z axis, turn on/off gas blow, open/close aiming laser,
change laser burst power etc. to test each part function well. Confirm system can
control laser, BCS100 height controller, gas and other devices function well.
4.6 Position-Loop PID Self Adjustment
In CNC tab > Auto adjust, to adjust position-loop PID parameter.

5. Adjustment Steps
1.Select velocity control mode;
2.Set input gain of speed command;
3.Set encoder differential pulse
output per motor revolution;
Servo drive 4.Velocity loop gain 75hz,time
setting integral 9ms and set velocity loop
rigidity level,
5.Confirm select external enable
signal, doesn't set deadband signal,
doesn't set rotation restriction.
1.Set motor type;

CypCut machine 2.Set pulse equivalent;
3.Set encoder pulse output per motor
config revolution;
4.Set max motor rotation speed to
10V.
Motor runaway
check
Encoder
feedback check
Self adjustment
6. Common Problems in Close-Loop control
6.1 Motor Runaway Error
Error source: system doesn't receive feedback pulse or receive abnormal pulses from
encoder.
Checking points:
（1） Check the wiring, make sure servo enable signal, speed command signal and
encoder signal are wired with correct signal pin;
（2） Check servo driver parameter: if set external enable, do not set deadband(neutral
zone), and set zero offset value properly;
（3） Check PID parameters in velocity loop and current loop, servo rigid level cannot
be too low.
6.2 Encoder and Speed Check Failed
Error source: in process, program detected received encoder pulses and
maximum speed doesn't match with preset value.

Checking points:
（1） If test results remain same error value in repeated testing, check servo driver
parameter if command speed gain and feedback pulses match the setting in
CypCut machine config;
（2） If test results are different error value in repeated testing, encoder signal might
be disturbed. Check in electrical cabinet if separate the wiring of strong current
from weak current.
6.3 Position Error Too Large
Error source: the feedback position different with command position.

Checking points:
（1） Open CypCut machine config, and execute make sure the
checking passed;
（2） If this error came after increasing acceleration in CypCut, might be caused by
motor torque being restricted. Driver settings restrict motor torque or motor
itself is of low torque type;
（3） If this error came after increasing speed in CypCut, motor speed might be
limited. Servo parameter might limit motor speed, or exceed motor maximum
speed;
（4） If this type error always exist when setting acceleration and speed from high to
low level, it indicates servo system is of low rigid. Mechanic or driver inner
loop is low rigid.
7. Optimize Machine Motion Performance
7.1 Calculate Inertia Ratio and Preview Machine Performance
Features
The inertia ratio is a crucial indicator of machine performance features. You can
calculate inertia ratio of each motion axis of machine by ServoTools. Download link
is http://downloads.fscut.com/. ServoTools interface shown below:
When inertia ratio is smaller than 200% machine runs in light load can reach
high speed cutting.
When the inertia ratio is between 200% to 300% machine runs in medium
load, cutting precision is declined compared with light load in high speed, cutting
speed and low-pass frequency should be lower.
When inertia ratio is between 300% to 500% machine runs in heavy load and
cannot reach high speed cutting.
When inertia ratio is larger than 500% indicating serious defect in machine
design, servo system cannot complete adjustment in short time.
You can calculate a rough value of machine maximum cutting speed, travel
speed, and acceleration by ServoTools. The calculation results can be set in
CypCut > Global Parameter > Motion Control parameter. Experienced users can
calculate more accurate inertia ratio by servo tuning tool.
Note: The servo parameters calculated by ServoTools only for FSCUT system of
close-loop control card. Open loop control card should set servo parameter by
position loop control mode.
7.2 Motion Control Parameter Adjustment
7.2.1 Motion control parameter description

Speed, acceleration, low-pass filter frequency, corner and curve precision in
FSCUT4000 system are available for users to adjust, other parameters related with
motion control are optimized automatically. Parameter description listed below:
Name Description
Travel Speed The maximum travel speed. You can calculate by ServoTools and
input calculated value directly.
Travel The maximum travel acceleration. You can calculate by
Acceleration ServoTools and input calculated value directly.
Cutting The maximum cutting acceleration which directly influences
Acceleration speed in cutting curve or corner path. You need to observe the
torque curve in servo tuning tool to adjust acceleration in cutting.
Low-Pass The filter frequency to suppress machine vibration. Suppression
Frequency works stronger under smaller low-pass frequency value.
Curve Precision Curve cutting precision. Smaller value works higher curve control
precision and lower speed.
Corner Precision The precision of NURBS curve fitting corner path. Smaller value
works more pointed corner cutting but also slow the speed.
7.2.2 Adjust cutting acceleration

Jog axis at high speed, 500mm/s for example, make sure axis move enough
distance to reach the pre-set speed.

Monitor the torque curve in servo tool when jog control the axis, increase the
cutting acceleration if peak torque is under 80% of rated value, lower the cutting
acceleration if peak torque is below 80% of rated value.
Adjust the acceleration until peak torque reaches to 80% of rated value when jog
the axis in high speed. The acceleration lead screw structure can bear is usually under
0.5G. For rack gear structure is under 2G.
7.2.3 Adjust travel acceleration

You can calculate maximum travel acceleration by ServoTools. Or directly set a
value 1.5~2 times larger than cutting acceleration. When machine running without
load, motor peak torque should be under 150% of the rated value, and there should be
no mechanism deformation or vibration under this acceleration. The acceleration lead
screw structure can bear usually is under 0.5G. For rack gear structure is below 2G.
7.2.4 Adjust low pass filter frequency

You can adjust low-pass filter frequency (LPF) by cutting a part. Lower laser
power and make a marking cut on workpiece. Observe the quality of marking contour.
The marking graphic could be small circles in different sizes, hexagon, dodecagon,
star shape and rectangle etc. As shown in the below image:
Setup low pass filter frequency as high as possible as long as not reducing
marking contour precision. The standard of contour precision should be no waving at

corner position in cutting star, rectangular or polygon etc. You can setup by
experiential value in below table. Setup the cutting acceleration then adjust LPF 2
levels around. The cutting acceleration has to match with LPF, you cannot setup one
of them too larger than the other one.
Level 1 2 3 4 5 6 7 8 9 10
Cutting 0.1 0.2 0.3 0.4 0.5 0.6 0.8 1 1.5 2
Acceleration
(G)
LPF (HZ) 2 3 4 5 5.5 6 6 6 7 8
7.2.5 Curve precision and corner precision

It's recommended to use the default value. If it's really needed, you can fine tune
the value a little bit around the default value.
If curve cutting precision doesn't reach requirement, you can lower the value,
meanwhile cutting speed at curve also be reduced. Speed reduction is more obvious
under smaller precision value. If corner cutting precision is not satisfied, you can
lower the value, meanwhile cutting speed at corner also be reduced. Sharpe corner
will turn to round corner under a large precision value.
8. FAQ
8.1 Cutting is Slow or Jamming
 In CypCut, open 'node mode' to view the drawing, if graphic contour made of
a lot nodes, please optimize and smooth the graphic before cutting.
 Check the cutting parameter setting see if there is improper setting of time
delay, or mixed time unit set 200ms to 200s for example.
 If Z axis jamming in lifting actions, check the BCS100 firmware version. If it's
BCS100 V2.0, make sure firmware update to V802 and later version.
 If it takes a long time for laser to start emission, check the serial
communication of laser.
8.2 Corner Over Burned
 Raise the low pass filter frequency to reduce the acceleration and deceleration
time at corner.
 Raise the corner precision in global parameter to smooth the corner path.
 Modify the drawing, for example, change the corner path like below image.
 In layer parameter setting window, open speed-power regulating curve

function, lower the laser power at low speed position.
 Apply cooling point technique at corner position to cool off the heated zone
then resume cutting.
8.3 Laser No Emission
1. Check Laser Setting in Machine Config

 Check the laser type selection, for example, IPG YLS American version is
different with Germany version.

 If use serial or Ethernet communication, check in PC if select correct
communication port.
 If use analog signal to control laser peak power, check if select right DA port.
 Check if PWM and 'Laser on' signal select right I/O port.
2. Check PWM and DA Output Signal

 In CypCut > File > Diagnosis > Card Monitor input different DA and PWM
value, then measure the voltage output at DA and PWM port in BCL3724 I/O
terminal board.
 If measured voltage is under pre-set value or no voltage output at all, try
change another PWM or DA port then measure output voltage again.
 If it's confirmed hardware error, please contact technical support.
3. Check the Wiring

 Check the wiring of PWM, DA, serial cable and other signal wiring with laser
control.
 Serial cable must have shielding layer and pin 2, 3 are crossed.
4. Check Laser Status

 Check laser status with laser software, test laser emission for trouble shooting.
 When use serial communication, it's not allowed to use multiple software to
communicate with laser at same time.
 If serial communication failed, use debug mode to check command and laser
response.
9. Appendix
9.1 Fly Cut Operation Guide
9.1.1 Function
There are new functions for CypCut later than V6.3.495: ‘fly cut’ also named
‘scan line cut’ in CypCut. This function applied in thin sheet cutting, used to cut
arrayed parts of standard shape in high speed to improve production efficiency.
Function entry shown as below.
9.1.2 Function description

Linear Fly Cut: select the rectangular array and create fly cut path. The fly cut
path will be along same direction and laser head will not lift traveling between cut
paths, meanwhile machine always maintain high speed in cutting.
Circular Fly Cut: select arrayed circles and create fly cut path. The cutting will
follow continuous path, laser head will not lift traveling between cut paths, meanwhile
machine always maintain high speed in cutting.
9.2 Pitch Error Compensation
9.2.1 Pitch error compensation description

The mechanical error in ball screw and gear rack is an absolute existence, so the
actual mechanic character is different with its nominal character. For application of
high precision, it requires to measure mechanical error by measuring instrument like
interferometer, then offset measured data via cutting control system to reduce
mechanical error.
CypCut laser cutting software designed complete compensation functions to
create required machine actions for measuring device capturing data and offset error
measurement data from interferometers of Renishaw, API, Agilent, OptoDyne etc.
You can also set backlash error compensation directly if there is no interferometer
measured data.
9.2.2 Mechanical origin

Before measure mechanical error must return axes to mechanical origin to build
correct coordinate. CypCut takes origin point as reference to offset pitch error data. If
the origin position is different before and after pitch error measuring, then pitch error
offset cannot serve its purpose to reduce error even work in opposite effect.
Use 'Z phase' signal to improve return origin precision. FSCUT4000 system
provides encoder feedback channel for each motor axis to ensure control precision.
Set return origin direction of X/Y axis by machine design. Return origin direction
results in which coordinate quadrant machine runs with. If return origin towards
negative direction, then machine runs in positive range of coordinate. If return origin
direction towards positive direction, then machine runs in negative range of
coordinate.
You can repeat return origin and measure origin precision by interferometer. The
error of each origin should be no more than 5μm.
9.2.3 Measure pulse equivalent

The theoretical pulse equivalent is different with actual value due to mechanical
error. Precise pulse equivalent can be measured by interferometer.
9.2.4 Mechanic error measure

In CypCut > CNC > Path function is to setup and create motion path for
interferometer to capture and record measurement data. Machine runs and pauses in
preset distance and time interval, meanwhile interferometer measures and records the
actual position at each pausing point. After measurement complete will generate a
data table of comparison between theoretical position and actual position.
Most interferometers in market, take Renishaw for example, has to setup travel
range, travel interval and time duration at each stop, like stop 1 sec every 30mm.
Interferometer capturing data or not is decided by the interval distance and stop
duration. First you have to setup several parameters:
Range: the range to be measured, usually a little smaller than maximum machine
travel range.
Interval: by theory, shorter measure interval will get more precise offset result.
Shorter measure interval will come with more stop points to be measured also take
more time for a whole measurement process. Recommended interval is
10mm~100mm.
Stop time: the minimum stop duration for Renishaw is 2 seconds.

Make sure the zero point of interferometer and machine origin

in same position.
Check in CypCut machine config, pitch compensation function
should be disabled while still in measuring process.
9.2.5 Import measurement data to CypCut

The measurement data file can be imported in CypCut. CypCut can read
measurement file generated by Renishaw, API, Agilent, OptoDyne interferometer
software. If the measurement file of interferometer you are using cannot read by
CypCut, please contact our technical support. Below is where to import measurement
file:
Open CypCut machine config, in Machine > Pitch Compensation > Interferometer.
Click will open below window.

Click to import measurement file of X axis, click to import

measurement file of Y axis. Imported file will be shown in data table and graph.
If the coordinate polarity in data table is different with return origin direction, then
compensation invalid.
9.2.6 The operation steps of pitch error compensation

1. Execute 'return origin' via CypCut;
2. Setup the parameter in Interferometer software;
3. Setup travel path in CypCut > CNC > Path;
4. Execute measurement program for interferometer to capture data;
5. Import measurement file to CypCut machine config;
6. Execute 'return origin' via CypCut;
7. Execute measurement program via interferometer again to check compensation result.

9.2.7 FAQ
1. Pitch error doesn't change after compensation
You need to execute return origin after import compensation file to let
compensation data take effect.
If the pulse equivalent is too small, for example, less than 200 pulses per 1mm, the
compensation file doesn't work.
2. Backlash larger after compensation

If backlash gap became larger or even doubled, position error data might be offset
in wrong direction. Click to switch over positive and negative data

group.
This happened most likely when polarity of interferometer measure range and
machine travel range not same.
3. Data curves are symmetrical

If the data curves of positive and negative direction are symmetrical in opposite
direction, the polarity symbol of one of the data groups is wrong. This is rare
situation, you can manually reverse the polarity symbol of positive or negative
position error data group, then import file again. Or contact technical support.

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1 FSCUT4000 Laser Cutting Control System

FSCUT4000 Laser Cutting System

Shanghai Friendess Co., Ltd

Thank you for choosing our products!

This manual gives a detailed introduction to the usage of

FSCUT4000 laser cutting controller, including technical features and

installation instructions etc. For CypCut laser cutting software

you can contact us directly.

Operating personnel should read the manual in detail which will

be helpful for a better use of the product.

Due to the continuous updating of product functions, the products

respects. We apologize for any inconvenience it may cause.

3.5 Return Origin Config ...........................................................................................................42

1.1 Brief Introduction

FSCUT4000 is a high performance laser cutting system of close-loop control

1.2 Connection Diagram

BMC1214 card adopts PCI interface. Dimension: 155mm*106mm. The socket

1.3 Technical Reference

Analog output of 4 servo axis ports, -10V—+10V.

Dedicated signal outputs of servo enable and alarm reset

1.4 Control Card Installation

1.4.1 Install steps

Please wear anti-static gloves to prevent possible electrostatic

shows the installation is succeed.

（2） If the device has a yellow exclamation mark, double-click to

it means computer has correctly recognized the motion

（4） If the first half of ‘device instance ID’ attribute is not , it

Control Control Control Control

Relay Relay Relay Relay Relay Relay

X- XO X+ Y1- Y1O Y1+ Y2- Y2O Y2+ W- W0 W+

2.2 Signal Type

2.2.1 Input signal

The typical wiring of contact switch shown below.

BCL3724 Contact switch

2.2.2 Relay output

2.2.3 Thyristor output

2.2.4 Analog output

Output range 0V~+10V

Maximum capacitive load 350pF

Input impedance 100KΩ

Maximum bipolar error +/-50mV

Conversion speed 400us

2.2.5 PWM output

Set PWM signal level, 5V or 24V set by DIP switch.

2.3 I/O Specification

2.3.1 External power supply

2.3.2 Servo control port

The signal pin description of C15-1.5 cable listed below:

15-pin servo control interface

2.3.3 Servo drive control signal

Panasonic servo wiring diagram

Signal Pin Shielding layer Pin Signal

Panasonic A5 reference setting

Parameter Description Recommended value

Yaskawa servo wiring diagram

Signal Pin Shielding layer Pin Signal

24V 8 47 +24 VIN

Yaskawa Sigma 5/7 reference setting

Pn401 Torque command filter 0.30 MS

Sanyo R series wiring diagram