Alarms, wiring and interference

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• On the height controller panel press F2 then 6 to open the network settings and confirm the addressing.
  Original record

  在调高器面板按F2再按6检查调高器的网络设置，确定网络设置为

• Make sure no two network adapters share an IP — every adapter has to be checked, not just the obvious one.
  Original record

  请确保不同网卡的IP地址设置没有冲突，每张网卡的IP地址都需要检查过

• Open the platform configuration tool and confirm the configured height-controller IP matches the controller's actual IP.
  Original record

  打开平台配置工具，检查调高器的设置确定IP地址和实际调高器的IP地址一致。

• Unplug the height controller's network cable: the adapter that reports disconnected is the one wired to the controller.
  Original record

  将调高器网线拔出后显示网络断开的网卡对应是连接到调高器的网卡

• Check the IP settings of the adapter that connects to the laser.
  Original record

  检查连接激光器对应网络适配器的IP地址设置是否正确

• Check the PC host's own network configuration.
  Original record

  检查电脑主机的网络连接设置。

• Check the expansion board's supply — the BCL4516E series needs 24 V.
  Original record

  检查BCL4516E扩展板供电是否正常，BCL4516E系列扩展板需要24V供电

• Expansion board IN lamp: steady yellow means physically connected, flashing green means actually communicating. Both are needed.
  Original record

  检查BCL4516E扩展板的IN网灯是否正常，黄灯亮代表连接正常，绿灯闪烁代表通讯正常

• If the network lamp misbehaves, swap in this order: cable, then network adapter, then expansion board.
  Original record

  如果网灯闪烁异常，请依次更换网线、网卡、BCL4516E排查问题

• These expansion boards all sit on the EtherCAT bus — any communication failure shows up as an EtherCAT alarm.
  Original record

  都是基于Ethercat总线的扩展板，如果通讯失败就会出现Ethercat报警。

• If the slave scan errors, connect a single expansion board or a single servo and scan that. If it appears, add slaves back one at a time until the faulty one shows up, then check that slave's settings and power.
  Original record

  如果扫描报错，可以尝试只接一个扩展板或者只接一个伺服去扫描，然后看扫描结果，如果可以扫到就逐个增加从站，直到找到问题从站所在，然后检查从站设置以及供电情况，以伺服为例

• When the scan count does not match, find the missing slave and connect only that one. If it still is not found, check its configuration, wiring and power.
  Original record

  如果不一致就去找哪个从站没有扫到，然后只连接未扫描到的从站，扫描一下，如果还是扫描不到就要考虑检查一下这个从站的设置以及连接以及供电

• If the addressing is correct and the timeout alarm persists, swap the cable, then the adapter, then the height controller.
  Original record

  如果以上配置都无法解决网络超时报警，请依次更换网线、网卡、调高器排查问题。

• Bus network alarm with the cable reported as not connected — physically reseat both ends before anything else.
  Original record

  总线网络报警、网线未连接

• Check whether the PC and the drive network ports have been swapped.
  Original record

  检查电脑、驱动器网口是否接错

• Network cable pins bent, deformed or broken, or the cable body kinked at a sharp angle.
  Original record

  网线插针存在折弯、变形、断裂，或者线身存在大角度折弯情况

• Cable is good: pins straight and intact, no sharp bends. Rule it out and move on.
  Original record

  网线状态良好，插针不存在折弯、变形、断裂，线身也不存在大角度折弯情况

• Enable lamp not lit means communication between the software and the 4562 terminal board has failed. Unplug the leftmost 62-pin cable, inspect the pins for bending, and use a multimeter to check pin-to-pin continuity at both ends.
  Original record

  使能指示灯未正常亮起，说明软件与4562端子板之间通讯出现异常，需要拔下4562端子板最左侧的62芯线，检查针脚是否存在折弯、变形等情况，并用万用表测量62芯线两端针脚是否为一对一导通。

• If the signal does not conduct, the link between the 4562 terminal board and the drive is broken — the enable signal never arrives, so check the servo drive cable.
  Original record

  信号未正常导通说明从4562端子板到驱动器之间的连接异常，4562端子板发送的使能信号未能正常给到驱动器这边，需要检查伺服驱动器线。

• If the signal does not conduct, the servo drive cable between the height controller and the drive is faulty — the enable signal never arrives.
  Original record

  信号未正常导通说明从调高器到驱动器之间的伺服驱动器线连接异常，调高器发送的使能信号未能正常给到驱动器这边，需要检查伺服驱动器线。

• If the signal conducts but the drive still will not enable, the wiring is fine and the problem is supply-side: measure the 4562 board's input voltage for stability.
  Original record

  信号正常导通说明从4562端子板到驱动器之间连接正常，信号正常给到了驱动器这边。驱动器依然上不了使能需要先检查4562端子板供电，可以用万用表测量电源输入端电压是否稳定。

• No continuity between pin 6 and pin 15 means the height controller's servo output is faulty. Unplug everything except the power supply from the back of the controller and measure pins 6 and 15 again.
  Original record

  号针脚和15号针脚之间不导通，说明调高器伺服输出口异常，将调高器背面除了供电电源线之外的其他线后拔掉，然后再测量6号针脚和15号针脚之间是否导通。

• Continuity between pins 6 and 15 means the enable output is good — next check the enable signal at the drive end of the servo cable.
  Original record

  号针脚和15号针脚之间导通，说明调高器伺服使能信号输出正常，下一步检查伺服驱动器线连接驱动器一端的使能信号是否正常。

• If it still does not conduct with everything unplugged, power-cycle the height controller and measure its supply for stability. If the supply is stable and pins 6-15 still show no continuity with output 6 lit in the test screen, the controller itself has failed — raise a service case.
  Original record

  如果拔掉之后依然不导通，则对调高器进行断电重启，并用万用表测量调高器的供电电源输入电压是否稳定。如果调高器的供电电源输入电压稳定，并且断电重启后在测试界面6号输出口点亮的情况下再次测量6号针脚和15号针脚之间依然处于不导通状态，则可能是调高器存在故障，联系柏楚售后工程师。

• Inspect the 62-pin cable for abnormal pins.
  Original record

  检查62芯线是否有针脚异常

• Check whether the encoder feedback pair in the 15-pin cable was ever soldered.
  Original record

  检查15芯线的编码器反馈信号是否未焊接

• Check the 15-pin cable for dry joints.
  Original record

  请检查15芯线是否有虚焊

• Likely poor contact in the servo cable or a dry joint at the axis connector. Change the servo cable first, then the drive.
  Original record

  可能是伺服线接触不良或者轴口虚焊。建议客户往这个方向排查，更换伺服线，或者驱动器。

• Read the white label on the servo drive cable: if the brand or the control type printed there does not match what is actually installed (closed-loop), the cable is wrong — swap it.
  Original record

  检查伺服驱动器线身上的白色小标签，看上面标注的伺服驱动器品牌是否与现场实际相对应，控制类型是否是为闭环控制。如果不相符则联系我司售后人员进行更换。

• On a semi-finished servo drive cable the customer solders themselves, re-check every pin definition and look for dry joints and shorts.
  Original record

  驱动器线为我司提供的需要焊接的非成品伺服驱动器线重新检查各针脚定义，并检查焊接是否存在虚焊、短路等情况。

• For any non-finished cable, verify each pin is soldered correctly with no dry joint or poor contact.
  Original record

  对于非成品线，检查各针脚焊接是否正确，是否存在虚焊或者接触不良的情况。

• Check whether the drive is showing a non-bus alarm such as overload or encoder fault — that changes the whole diagnosis.
  Original record

  检查驱动器是否有非总线通讯类的报警，比如过载、编码器异常等等

• Check that the servo type is configured correctly; a wrong type mimics a wiring fault.
  Original record

  检查伺服类型是否设置正确

• If jogging works, the servo receives the motion command but no encoder signal comes back — the fault is inside the drive, not the command path.
  Original record

  可以点动说明伺服接受到了系统发出的运动指令，但是没有接受到伺服传输回来的编码器信号，后面排查驱动器本身的问题。

• Encoder feedback is abnormal — treat that as the root cause rather than a symptom.
  Original record

  基本可以判断是编码器反馈异常导致的。

• Take the axis motor off and spin it free: if the alarm persists, it is electrical, not mechanical.
  Original record

  轴电机拆下来空转，是否还有报警

• If the ejector pin is straight, reseat the 62-pin cable; if the X-axis servo alarm remains, the unit has to go back for repair.
  Original record

  如果顶针不歪，重新拔插62芯线，X轴仍伺服报警，需要走返修流程。

• If everything above checks out and homing still misbehaves, open the platform configuration tool and untick the Z-phase signal as a test.
  Original record

  上述问题都排查正常后，如回原点还是异常。请到平台配置工具，不勾选Z相信号作测试。

• The origin and limit switches reach the control card correctly — now confirm the signal actually toggles while the machine is moving.
  Original record

  原点、限位开关到控制卡的信号传输正常。请检查机床在运动过程中是否能触发原点、限位开关的信号变化。

• If the limit input port itself is faulty, replace the adapter board.
  Original record

  如果限位输入口异常，请更换转接板。

• Cut mains power to the servos and the laser, then start the software again — this clears a whole class of stale-state faults.
  Original record

  给伺服，激光器等断强电后再开软件

• If a restart does not clear it, the network port is probably being disturbed from outside: tidy the cabinet wiring and check machine earthing and mains interference.
  Original record

  重启无法解决多半是外部干扰了网口，可以从新理一下电气柜环境，排查整机接地，强电干扰等。

• That places the interference at the servo or another external load: check their earthing, fit a magnetic ring on the servo motor power cable, and earth the FG terminal of the height controller's supply.
  Original record

  则说明干扰来自于伺服或外部用电设备，检查伺服电机或外部用电设备的接地是否良好，伺服电机的动力可以套磁环，调高器电源输入端口的FG接地，接地案例见下图

• After enabling the motors, mains interference reaches the IPC's USB port and the keyboard/mouse receiver stops getting through.
  Original record

  可以判断是，开软件后给电机上使能后，强电干扰工控机的USB口，导致鼠标键盘的接受器传输指令被干扰。

• The PC is smooth until the cutting software starts, then the mouse stutters or freezes — look at USB interference and service load, not at the PC.
  Original record

  不开切割软件时，点电脑运行流畅，鼠标滑动流畅，切割软件开启之后，鼠标就非常的卡顿，甚至失灵。

• Nominal maximum is around 24 V — set the meter range accordingly before measuring.
  Original record

  正常电压最高为24V左右，注意量程

• Check that the licence dongle driver is installed correctly.
  Original record

  请检查机密狗驱动是否安装正常

• A licence-expired prompt means the registered code needs re-entering; restart the software afterwards and it runs again.
  Original record

  会提示许可证到期。输入注册码，重启软件后就能恢复使用。

• No licence found, or the licence has expired — same fix as above.
  Original record

  提示没有找到许可证或许可证已过期

• Software reports no motion control card detected — check the card seating and the PCIe slot before reinstalling anything.
  Original record

  打开软件提示没有检测到运动控制卡

• If it will not clear, try a different PCI slot, then a different PC.
  Original record

  如无法解决请更换PCI插槽或者更换电脑。

• If that still fails, replace the motion control card.
  Original record

  如无法解决，请更换运动控制卡。

• If it still will not clear, replace the network cable, then the 4562 card.
  Original record

  仍不能解决请依次更换网线、4562卡。

• If it still will not clear, work through the network adapter, the PC host and the camera in that order.
  Original record

  如果还是不行，建议依次更换网卡，电脑主机，摄像头来进行排查故障。

• That software version cannot talk to the slave at all — update to a newer version rather than fighting the wiring.
  Original record

  说明该版本的软件不支持与从站通讯，建议更新新版本的软件

• If the firmware upgrade still fails, open the network adapter list and check for multiple active ports.
  Original record

  仍升级失败，打开网络适配器，检查是不是多个网口

• If a network upgrade is not possible, upgrade from a USB stick instead.
  Original record

  如无法进行网络升级，请使用U盘进行升级

• Copy the upgrade file to the root of the USB stick, not into a folder on it — the controller only looks at the root.
  Original record

  文件，将此文件复制到U盘中，注意不要复制到U盘的文件夹里，直接复制到U盘的根目录下。

• System delay is measured from File, then Diagnostic tools, then Axis monitor, then System delay measurement.
  Original record

  文件-诊断工具-轴监控-系统延时测定

• Find the axis or axes whose delay is out of line and pull them back towards the others. If Z sits at 7999 while the rest are near 5500, bring Z down to about 5500.
  Original record

  先确定是哪个轴或哪几个轴延时偏差过大，将它的延时拉到和其他轴基本一致即可，如图举例，Z轴延时为7999与其余轴相差较多，则把Z轴延时拉到5500左右即可。

• A delay that is too large is reduced by raising the servo's speed feedforward; a delay that is too small needs it lowered.
  Original record

  以图为例，Z轴7999过大，需降低延时，则将Z轴伺服的速度前馈适当提高即可

• Check the speed gain against the drive parameters. Yaskawa example: with the height controller set to 500 r/min/V, Pn300 should be 6.
  Original record

  检查速度增益是否和驱动器参数匹配以安川举例，调高器中速度增益设置500r/min/V时，Pn300应为6

• Check the pulses-per-revolution setting against the drive. Yaskawa example: with 10000 set in the height controller, Pn212 should be 2500.
  Original record

  检查每转脉冲数是否和驱动器参数匹配以安川举例，调高器中每转脉冲数设置10000时，Pn212为2500

• The parameter must match four times the servo's single-turn feedback pulse count, then be corrected for the actual screw lead.
  Original record

  参数与伺服单圈反馈脉冲数的4倍相匹配。然后根据实物的螺杆导程，修改

• Check that Pn000 is set to speed control with zero-point clamp, and that the Pn501 zero-clamp value is normal.
  Original record

  系列伺服为例，检查Pn000是否为带零位固定功能的速度控制，Pn501零位固定值是否正常。

• Zero-speed clamp differs between servos — the principle, the I/O signal logic and the control parameters all change with the brand.
  Original record

  不同的伺服，零速箝位的原理、输入输出信号的 逻辑及系统控制参数均不同。

• Where rows of relays sit side by side, leave 20 cm between them or separate them completely — inductively coupled coils are a classic interference source.
  Original record

  右侧多排继电器，建议间隔20公分或彻底分开

• Add earth wires at several points on the bed — near the Y-axis origin of the tube section, mid-bed, and near the middle chuck. On badly disturbed machines 4 to 5 wires at each of those points is what actually brings the interference down.
  Original record

  分别在靠近切管部分的Y轴原点位置附近、床身中段和中卡盘附近的床身上增加地线数量，注意采取各部位设置多根地线的方式。某些干扰特别大的设备需要在这几处位置附近分别设置4~5根地线才能较好的降低电磁干扰。

• Bond the tube-cutting and plate-cutting sections of the bed and the feet together with plate and copper wire, using multiple contact points. Strip paint or powder coating at each contact first — a bonded connection through paint does nothing.
  Original record

  利用金属板、铜线等在切管和切板部分的床身、地脚等多个部位进行有效连接，注意是多部位多接触点连接。如果接触部位表面被油漆、喷塑粉末等覆盖，则需要先对接触部位打磨露出金属层后再进行有效连接。

• A DIF value above 30 on the tube section proves interference there. Check whether the plate-cutting section shows it too before you start adding earths.
  Original record

  值大于30表明切管部分存在电磁干扰。首先排查平板切割部分是否也存在电磁干扰。