BCS100 Independent Capacitance

Height Controller
User Manual
 BCS100 Independent Capacitance Height Controller 2

Thank you for using our products!

This Manual describes BCS100 capacitance height controller in

details, including system features, operation, installation instructions etc.

If you want to know more about CypCut laser cutting software that can

improve the performance of height controller while using together, please

refer to the help documents of the software. For any other information,

please contact us directly.

Please read the Manual carefully before using the controller and

relevant devices, so that you can make better use of it in future.

Along with continuous updating of product functions, there may be

some differences between that you received and the Manual. We will

apologize for any inconvenience.

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Contents
Chapter 1 Introduction to Product ...............................................................................................5
1 Introduction ......................................................................................................................5
2 Performance Description ..................................................................................................5
Chapter 2 Operating Instructions .................................................................................................7
1 Description of Keys ...........................................................................................................7
2 Functional Hierarchical Graph ..........................................................................................8
3 Main Interface ..................................................................................................................8
3.1 Hidden Functions of Main Interface .......................................................................9
4 Calibration Interface .......................................................................................................10
4.1 Servo Calibration ...................................................................................................10
4.2 Capacitance Calibration.........................................................................................11
4.3 Self adjustment......................................................................................................13
5 Parameter Interface ........................................................................................................14
5.1 Technical Parameters.............................................................................................14
5.2 Speed Parameters..................................................................................................15
5.3 Origin Parameters ..................................................................................................16
5.4 Jog Parameters ......................................................................................................16
5.5 Mechanical Parameters .........................................................................................17
5.6 Network Settings ...................................................................................................18
5.7 Alarm Settings .......................................................................................................19
5.8 Edge Settings .........................................................................................................20
6 Test Interface ..................................................................................................................20
7 Interface of Advanced Settings .......................................................................................21
7.1 Product Information ..............................................................................................21
7.2 Alarm Information .................................................................................................22
7.3 Restart....................................................................................................................23
7.4 System Settings......................................................................................................23
7.5 Config file ...............................................................................................................23
8 Oscilloscope ....................................................................................................................24
9 Edge Cutting Function.....................................................................................................24
Chapter 3 Description of Accessories .........................................................................................26
1 Introduction to Accessories ............................................................................................26
1.1 List of Standard Accessories ..................................................................................26
1.2 Wearing Parts ........................................................................................................26
1.3 Options .................................................................................................................. 27
2 Preamplifier .................................................................................................................... 27
3 Cutting Head ...................................................................................................................28
3.1 Short Focal Length Type ........................................................................................29
3.2 Common Type........................................................................................................29
3.3 3D Cutting Type .....................................................................................................30
Chapter 4 Installation Instructions .............................................................................................31
1 Wiring Instructions .........................................................................................................31
 BCS100 Independent Capacitance Height Controller 4

1.1 Interface Layout .....................................................................................................31

1.2 Power Interface Instructions .................................................................................31
1.3 Servo connection and setting................................................................................32
1.4 Description of Input and Output Interface ........................................................... 37
1.5 Description of Sensor Interface ............................................................................. 37
2 Debugging Steps ............................................................................................................. 37
3 Installation Size ...............................................................................................................39
Chapter 5 Alarm process and FAQ ..............................................................................................40
1 System alarm analysis .....................................................................................................40
1.1 Z+/Z- limit enable ..................................................................................................40
1.2 Out of Z range ........................................................................................................40
1.3 Z- limit continue enable.........................................................................................40
1.4 Servo alarm ............................................................................................................40
1.5 Encoder moves abnormally ...................................................................................40
1.6 Encoder no response .............................................................................................41
1.7 Encoder deviation large.........................................................................................41
1.8 Capacity is 0 ...........................................................................................................41
1.9 Local capacity small ...............................................................................................41
1.10 Follow deviation large ...........................................................................................42
1.11 Sample capacity large ............................................................................................42
1.12 Expiration of time ..................................................................................................42
2 FAQ ..................................................................................................................................42
2.1 Obvious vibration and mechanical shock in the following movement ................42
2.2 The follower always hits the board during in following movement .....................43
2.3 The following height is different from the actual height ......................................43
2.4 The follower cannot move up to the correct height .............................................44
2.5 It shows that: “Validation error, failed ARM upgrading” when upgrading the
controller ...........................................................................................................................44
2.6 Follower moves up without contacting the board when calibrating the
capacitance .......................................................................................................................44
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Chapter 1 Introduction to Product

1 Introduction
BCS100 independent capacitance controller (hereinafter referred to as BCS100) is
a high-performance control device that can dominate the laser cutting capacitance
follower by way of closed-loop control method. Apart from control methods similar to
that of other products, BCS100 also provides a unique Ethernet communication (TCP /
IP protocol) interface, and thus easily achieves many functions with CypCut laser
cutting software, such as automatic tracking of height, segmented punching,
progressive punching, edge cutting, leapfrog, arbitrary setting of lift-up height of
cutting head and flying light path compensation. Its response rate is also improved
greatly. Especially in servo control aspects, its running speed and accuracy should
obviously be better than that of similar products in the world, owing to dual closed-loop
algorithm of speed and position.

2 Performance Description
 Sampling rate: 1,000 times per second.
 Static measurement accuracy: 0.001 mm.
 Dynamic response accuracy: 0.05 mm.
 Following range: 0-10 mm.
 The upper limit of moving speed depends on the upper limit of servo motor
speed and screw lead. 5 mm screw and 3,000 rev / min servo, the highest
moving speed can be up to 375 mm / sec.
 The signal will not decay with strong capacity of resisting when the length of
signal transmission cable is up to 100m.
 Support network communications and U disk online upgrade.
 Adapt to any cutting head and nozzle, with self-adaption capacitance
parameters.
 Support alarm while hitting the board and beyond the edge.
 Support edge detection and automatic inspection.
 Automatic calibration process, with fast and easy operations.
 Support leapfrog and segmented punching; the lift-up height can be set
arbitrarily.
 Support oscilloscope functions to detect the changes of capacitance and
height in real time.
The comparison between the performances of BCS100 and foreign products are as
shown below:
Performance German American BCS100
indicator product product
Sampling rate 500HZ 200HZ 1000HZ
 BCS100 Independent Capacitance Height Controller 6

Fastest moving speed 300mm/s 200mm/s 500mm/s

Dynamic response 0.05mm 0.1mm 0.05mm
accuracy
Static measurement 0.01mm 0.02mm 0.001mm
accuracy
Calibration mode Manual Manual Automatic
Parameter setting mode Potentiometer Toggle switch LCD / keyboard /
Ethernet
Signal processing mode Analog signal Analog signal Digital signal
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Chapter 2 Operating Instructions

1 Description of Keys
Keyboard Function
Functional F1 F2 F3 F4
Achieve the functions prompted by the
key
interface.

1 2 3
Number
key 4 5 6
Decimal
point 7 8 9
Backspace
. 0
key : Used for digital input, and mainly for parameter
input

变速
SHF
Arrow key

: Used for switching cursor and inching follower, and

the key of “SHF” can switch the jog speed.

跟随关 跟随快 跟随高 停止 确定

SHUT FAST +0.1 STOP ENT

跟随开 跟随慢 跟随低 回原点 取消

FOLLOW SLOW -0.1 ORG ESC
：
<SHUT> : The cutting head will automatically rise to the stop position
while shutting the follower.
Control key
<FOLLOW>: Open the following function.
<FAST> and <SLOW>: Used for adjusting the following gain level.
<+0.1> and <-0.1>: Used for adjusting the following height.
<STOP>: Immediately stop all movements.
<ORG>: Immediately implement the movement to go back to the origin
and correct mechanical coordinates.
<ENT>: Confirm the current operation.
<ESC>: Cancel the operation and go back.
 BCS100 Independent Capacitance Height Controller 8

2 Functional Hierarchical Graph

The functional hierarchy of BCS100 is as shown below:
Servo calibrate

Calibrate Capacitance calibrate

Self adjust

Technic

Speed

Origin
Main Parameter
Jog

Mechanic

Net

Alarm

Edge

Test

Version

Alarm info
Advanced
Restart

System set

3 Main Interface
It will automatically enter<main interface>after the system is powered on and the
initialization is completed, as shown below:

Dynamic Error Follow level 1~9 Function

Current State
Follow height
Z coordinate
Current Capacity

Jog Speed
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The displays on the main interface include:

Current status: display the current motion state of the following system. The
motion states are as follows:
A. Stopped: Z-axis is in an idle state.
B. Decel: There will be a very short transition state for slow stop after receiving a
stop instruction in motion state. It will change into “stop” state after completely
stopping.
C. Moving: It is the movement of Z-axis while lifting up during processing.
D. Follow: The follower follow the board while conduct punching and cutting
operations.
E. Origin: Go back to the mechanical origin of Z-axis.
F. Jogging: Manually jog Z-axis.
G: Lift up: It is the process to shut the follower off, and lift it to the stop position.
Following gain level: The level of following gain ranges from 1 to 30. The large
level is, the smaller average error is, the quicker follow acts, and the stronger slope
move ability is. But if gain is too high, there may be self-oscillation. It is recommended
to set this parameter by self adjustment.
Following height: The actual following height can be adjusted with a step of
0.1mm after pressing the button<+0.1> and <-0.1>. The following mode can be
changed through pressing <SHUT> and <FOLLOW>. After pressing “SHUT”, the axis
will automatically raise to the stopping coordinates (it defaults to the position of Z= 0;
the stopping coordinates can be modified after pressing <F2> to enter the parameter
interface).
In addition, in the Ethernet control mode, the following height is set by CypCut
software.
Dynamic error: In the following state, this value reflects the real-time error
during following movement.
Distance H between follower and board surface: Within the capacitance
measurement range (calibration range), the distance between follower and board
surface is “following height” plus “dynamic error”. When exceeding the measuring
range, “set following height” plus “dynamic error” is identically equal to the calibration
range.
Current Z-axis coordinates: After homing to origin, a mechanical coordinate
system is established at Z-axis. The coordinate will increase when moving down.
Current capacitance value C: The principle of systematical sampling is to get
the distance through measuring the capacitance between the follower and polar plate.
The closer the follower is to the board, the greater the capacitance value is. The
capacitance will change to Zero while the follower hits the board.
Jog speed of Z-axis: <L> represents low jog speed and <H> represents high jog
speed. The jog speed stalls can be switched through pressing the button <SHF>. You
can press the buttons <↑> and <↓>to jog.

3.1 Hidden Functions of Main Interface

Key Functions
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<3> Set follow parameters.

<4> Real-time following error oscilloscope.
<5> Real-time monitor oscilloscope of capacitance.
<6> Capacitance-distance curve.
<7> Record the current capacitance.
<8> Simulate the signal of input port 1 and begin to follow.
<9> Start the follower of edge cutting.
<0> Set the current Z-axis coordinates to be 0.

4 Calibration Interface
In the main interface, press the key <F1> to enter<calibration interface>, as shown
below:

After BCS100 was installed and sued as first time, do servo calibration first.
Then return origin, do capacitance calibration. At last, do self adjustment. At the next
time, do capacitance calibration is enough.

4.1 Servo Calibration

The purpose of servo calibration is to eliminate the zero drift of servo motor. Press
the key <1> to enter the interface of<servo calibration>, as shown below:

During servo calibration, the motor vibrates back and forth with small amplitude,
so it is required to first jog the motor to the mid-travel, and thus prevent from exceeding
the travel range while vibrating. And then press <ENT> to begin calibration.
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The system will return to the previous interface after completing the automatic
calibration.

4.2 Capacitance Calibration

The purpose of follower calibration is to measure the corresponding relationship
of capacitance and position between the follower and board. Press <2> to enter the
interface of<follower calibration>, as shown below.

If no setting has been conducted before, press <F4> to set calibrated parameters.

Parameter Description
It is required to record the capacitance data within the range for
Calibration
calibration, and the default is 15mm. When the travel of Z-axis is too
range
short, users can appropriately reduce the value.
Board
Set the material of the following object.
material
Press <ENT> to save the parameters and return to the previous interface.
Before calibration, first fog the follower and make it close to the board (larger than
1mm from the board), and keep the board still without vibrations. Then press <ENT> to
begin calibration.

The calibration process can be done automatically within ten seconds. Users can
press the <Stop>button to forcibly terminate the calibration. After the calibration is
complete, there are two standards, and four grades of “excellent”, “good”, “not good”
 BCS100 Independent Capacitance Height Controller 12

and “poor” are respectively set for each standard. The automatic calibration steps are
as below:
(1). Head moves down slowly and checks if board is hit.
(2).After head hits the board, moves up for 2 mm, checking the stability.
(3). Head moves down slowly and checks if board is hit for the second time.
(4).If board is hit, head moves up for the calibrate range, checking the smoothness
and the capacitance characteristic.
If one of the steps is not executed, and there is alarm after calibration, hardware
or connection problem should be considered. An easy way to check the problem is:
touch the spray by metal and see if capacitance changes. If the change is low(in 200)
or the capacitance is always 0, hardware or connection problem is proved. In addition,
considered to safe and static electricity factor, touch the spray by hand when system is
powered is not recommended.
The meaning of calibration result is as below:
Stability: It reflects the static characteristics of the capacitance. If the standard is
not ideal after calibration, the reason may be due to the vibration of the board or strong
external interference.
Smoothness: It reflects the dynamic characteristics of the changes in capacitance
during calibration.
These two standards at least should be “medium”, or the system may not be able to
be used normally. In relatively ideal conditions, the two standards should be “excellent”
or “good”.
After pressing <ENT> to save the calibration results, capacitance-distance curve
will be displayed. Normal curve should be smooth, as shown below:

If the curve is not smooth with downs or glitches, the results are not ideal and
re-calibration is required. If the results are still not ideal after repeated calibration, users
should reexamine the hardware installation and wiring of the system. In addition, users
can view the calibrated curve after pressing button<6> on the main interface.
If calibrate failed, alarm is as shown below:
Alarm Description
When calibrating, if the cutting head moves down and
check no board is hit in long time, there will be this
alarm. How to check what happened? First, ensure the
Hit board over time
head is near the board before calibration (in about 5mm).
Next, check if the hardware and connection are right.
Last, try to do calibration again. If the head does not
 BCS100 Independent Capacitance Height
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move when calibrating, maybe the resolution ratio of

analog voltage output is not enough. You should try to
modify the speed-voltage gain less.
First check if the hardware and connection are right.
Leave board
Second check the hit board capacitance parameter is
overtime
rightly set. If the board is metal, set it to 0.
Sample overtime Do calibration again.
Always hit board Please refer to “Leave board overtime” alarm.
Capacity changes Do calibration again. Take care jog near the board at
abnormally about 1~5mm before calibration.

4.3 Self adjustment

Press <3> to enter the interface of<Self adjustment>, as shown below:

Before adjustment, it should be confirmed as below:

 Servo calibration is done.
 Origin is done.
 Capacitance calibration is done.
 There is a board below the head to be followed.
The course of adjustment is follow again and again to optimize the internal
parameter. The optimization result is as shown below:

Press <ENT> to save the parameters. The meaning is as shown below:

Parameter Description
The larger it is, the faster head follows. Too large level will
Follow down result in large deceleration. This parameter can be only set by
gain lv self adjustment. And follow level parameter is also set at the
time after adjustment.
The default value is 40. Different machine has different best
Differential
value. The less the parameter is, the more overshoot when
time const
head follows, and the faster head reach to destination. It is
 BCS100 Independent Capacitance Height Controller 14

recommended to set this parameter by self adjustment.

5 Parameter Interface
On the main interface, press <F2> to enter <parameter interface>, as shown
below:

Users must correctly set the parameters above when using BCS100 for the first
time. Especially, “mechanical parameters” should be set correctly, or the system cannot
work normally.

5.1 Technical Parameters

Press <1> to enter the interface of <technical parameters>, and the first page is as
shown below:

The descriptions of parameters are as shown below:

Parameter Description
Punching Set the spacing distance between the follower and board during
height punching movement.
Aligning Set a coordinate, and move to the coordinate through pressing<←>
coordinate and<→>on the main interface.
Dock Set the target location of the follower after completely processing the
coordinate program.
Set Z-axis travel. Immediately stop when exceeding the travel during
Z-axis travel
running, and give an alarm of “exceeding Z-axis travel”.
When the cursor selects the parameter of “stopping coordinate” or “Z-axis travel”,
there will be one more menu for [F1]. And press [F1] to set the current parameters by
jog mode.
Press <ENT> for the following page, and continue to set process parameters. The
second page is as shown below:
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These parameters are mainly used in IO control mode. These parameters will not
take effect in Ethernet control mode.
The descriptions of the parameters are as shown below:
Parameter Description
IN1 following When input port 1 is effective, direct following mode is used, that
mode is, punching-delay-following.
Punching delay Delay time during punching.
Progressive
Speed when progressively follow to the cutting height.
speed
When dropping to the punching position, output port 4 will give a 200ms of
effective signal. When dropping to the cutting height, output port 1 will give a constant
effective signal.

5.2 Speed Parameters

Press <2> to enter the interface of “speed parameters”, as shown below:

The descriptions of parameters are as shown below:

Parameter Description
name
Up/Down Speed of Follower: The recommended setting is that the ser
vo motor should run close to rated point, so as to improve efficiency a
nd ensure stable running of system. In addition, it is required to increa
Moving
se calibrated range accordingly at a larger moving speed for keeping e
speed
nough deceleration separation from hitting the board while moving do
wn. If above 250mm/s, the calibrated range of speed should be greater
than or equal to 15mm.
Acceleration Set the acceleration of follower for following and moving.
Please do self adjustment after speed parameters be modified.
 BCS100 Independent Capacitance Height Controller 16

5.3 Origin Parameters

Press <3> to enter the interface of <Origin parameters>, as shown below:

The descriptions of parameters are as shown below:

Parameter Description
Whether to origin after Set whether to automatically reset after power-on, and set
power-on the option to be Yes after debugging.
Whether to return to Set whether to go back to the set dock position after
dock position completing reset.
Origin speed Set the fast movement speed to go back to the origin.
Set the return distance after touching the origin switch. This
Return distance
location is coordinate zero.

5.4 Jog Parameters

Press <4> to enter the interface of <jog parameters>, as shown below:

The descriptions of parameters are as shown below:

Parameter Description
Jog speed low Set the speed of Gear L during jog movement.
Jog speed high Set the speed of Gear H during jog movement.
Determine whether or not to enable the soft limit while setting jog. If
used, the soft limit should not jog to the position of negative
Software limit coordinate or below the following height, so as to avoid hitting the
limit or board during jog movement. Soft limit protection function
only becomes effective on the main interface.
Only the jog function on the interface of<test>is open-loop controlled. The jog
function on the functional testing interface will not be affected when encoder signal is
abnormal.
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5.5 Mechanical Parameters

Press <5> to enter the interface of <mechanical parameters>, and Page 1 is as
shown below:

Press <ENT>, Page 2 is as shown below:

Press <ENT> again, Page 3 is as shown below:

The descriptions of parameters are as shown below:

Parameter Description
Set the travel of the transmission mechanism per revolution, such
as screw pitch (lead). In theory, the greater the screw lead, the
Lead screw pitch
faster the running of Z-axis, and it is recommended to use the
ball screw with a lead of 5mm.
Set the number of pulses fed back by the encoder of servo motor
Pulses per round per revolution. The number should be consistent with the
parameters in the driver.
Set the actual rotational speed corresponding to each volt. The
Speed-voltage speed should be consistent with the parameters in the driver, and
gain the recommended value is 500 rev / min corresponding to each
volt.
Set the allowable upper limit of rotational speed of servo motor
Max RPM(rotate
according to the characteristics of motor and load. Generally, it
speed per minute)
does not exceed 4,500 rev / min.
Direction of servo Set the rotation direction of servo.
 BCS100 Independent Capacitance Height Controller 18

Direction of
Set the direction of pulse feedback of encoder.
encoder
0 represents the servo of Panasonic A5 or Mitsubishi J3 series. 1
represents the servo of Yaskawa Σ-V or Delta ASDA series. 2
Servo type represents the servo of Teco JSDEP series. The principles of
zero-speed clamp, logic of input and output signals and system
control parameters are different when the servos are different.
Logic of limit Set the logic of limit input port (IN5~6) (0: normally opened / 1:
input normally closed).
Logic of universal Set the logic of universal input port (IN1~4) (0: normally opened
input / 1: normally closed)
Set whether to use input port IN3 as a separate lift-up signal
interface. If it is set to be 0, the follower will move down when
Enable lift-up IN1 is enabled, while the follower will shut when IN1 is
signal disabled. If it is set to be 1, after IN1 become disabled, the
follower can move up only after setting IN3 to be enabled. (The
parameter is ignored when using network communication)

5.6 Network Settings

Press to enter the interface of <network settings>, as shown below:

When using CypCut laser cutting software of our company, lift up by arbitrary
height, leapfrog, segmented punching; flying light path compensation and other
advanced functions can be easily achieved through the network. See the manual for
CypCut software for details. When not using CypCut software, please shut down the
network, or start-up process will become slow.
When using the network functions, it is recommended to directly connect PC and
BCS100 by crossed wire. IP address of PC should be in the same network segment with
BCS100 (10.1.1.xxx, which cannot be same to BCS100). The gateway should be set in
the same network segment, and the last number should be 1, such as 10.1.1.1. As shown
below:
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Note: When the computer is connected to other network equipments concurrently,

such as IPG fiber laser (network connection mode), and each equipment should be set
in different network segments. For example, the equipments can be respectively set to
be 10.1.2.x and192.168.1.x.
2. After the IP of network card is reset, please disable-enable the network card
again, so as to make the IP settings of the network card to take effect.

5.7 Alarm Settings

Press <7> to enter the interface of <alarm settings>, as shown below:

Parameter Description
name
When the follower hits the board and the duration reaches the time
Hit board
limit, the follower will automatically move up for protection and
delay
output alarm signal.
It is the maximum allowable following error of BCS100. After the
cutting head is in place, the controller will give an alarm for too
Max follow
large following error if the following error exceeds the set alarm
deviation
value due to the movement beyond the plate boundary or severe
vibrations of board.
Set the filter time of following error alarm. The greater the value,
Max follow
the slower the response and the stronger the ability to filter out
delay
interference.
Limit alarm When it is set to be 1, upper and lower limit alarm function will be
 BCS100 Independent Capacitance Height Controller 20

started. The follower will automatically move up when

encountering upper / lower limit and then give an alarm signal.
When it is set to be 0, alarm function is disabled.

5.8 Edge Settings

Press <8> to enter the interface of <edge settings>, as shown below:

Parameter name Description

Saturation speed The max speed to follow down after head cutting out of board
to prevent deep drop damage.
Cut in check When check the H is lower than this parameter, the head start
follow.
Cut out check If it is checked that H position is larger than cut “cut out check”
Cut out delay and last more than “cut out delay”.
Through cut height Set the Z position to locate to before following.

6 Test Interface
On the main interface, press <F3> to enter the interface of <functional test>, as
shown below:

Users can test whether the state of keys, input and output ports and the rotation
direction of motor are correct. After completing the installation for the first time, users
must enter the interface for switch jog to determine whether the rotation direction of
motor and the director of encoder signal are correct. If the rotation direction of motor is
incorrect, users need to modify the “servo direction” parameters in “mechanical
parameters”, and then conduct open-loop jog to determine whether the direction of
encoder signal is correct. If it is prompted that the direction of encoder is incorrect,
users need to modify the “encoder direction” parameters in “mechanical parameters”.
The input and output ports of the interface are defined as below:
Input Definition Outpu Definition
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port t port
IN1 Follow to cutting height OUT1 Signal for following to place
IN2 Move to aligning coordinate OUT2 Reserved
IN3 Lift-up signal OUT3 Alarm output signal
IN4 Stopping signal OUT4 Punching signal
IN5 Negative limit OUT5 Servo clearing alarm (servo
signal)
IN6 Positive limit OUT6 Servo enabled (servo signal)
IN7 Servo alarm (servo signal) OUT7 Zero speed clamp (servo signal)

7 Interface of Advanced Settings

On the main interface, press <F4> to enter the interface of <advanced settings>, as
shown below:

7.1 Product Information

Press <1> to enter the interface of <product information>, as shown below:

Users can view the following on this interface:

Information Description
Such as V409. “Plane” represents being used for plane cutting.
Version
“Three-dimensions” represents being used for 3D mechanical cutting.
ID number Such as 201111180100
Expiration The remaining time for BCS100, such as 30 days or unlimited.
When the service time of BCS100 expires, alarm information (service time
expires) will be displayed on the main interface, and key functions cannot be
implemented, such as following. Users can press [F1] to register and enter <registration
interface>, and then continue to use the height controller after inputting the correct
registration code.
 BCS100 Independent Capacitance Height Controller 22

7.2 Alarm Information

Press <2> to enter the interface of <alarm information>, as shown below:

In this interface, the previous alarm events are displayed in a list. The system can
record as many as 9 alarm events. Users can clear the alarm list after pressing <F1>.
When various operations are implemented, alarms may occur are as shown below:
Alarm name Description
Z+/Z- limit
If Z+ or Z- limit signal is enabled, this alarm occurs.
enabled
Out of Z range Exceed the set Z-axis travel during movement.
Follower hit The follower contacts the board surface or the controller is not
board normally connected to amplifier.
Servo alarm Servo is not normally connected, or a run-time error occurs.
After following to specified place, the following error exceeds the
Follow
set alarm value. Please refer to the related sections of common
deviation large
problems for specific reasons.
Encoder move
Encoder readings change when the system is at rest.
abnormally
Encoder no
Encoder readings do not change when the system is in movement.
response
Z- limit continue The height controller cannot be far away from the upper limit for a
enable long time after going back to the origin.
Expiration of The set service time expires, users need to extend the service time
time through registration.
Network alarm Network communications fail.
Capacity too Please check the spray, sensor, amplifier and connection. If there is
small no problem, do capacitance calibration.
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7.3 Restart
Users can press <3> to restart BCS controller. This operation is equal to that the
system is powered down and then powered on. Users can first insert USB disk to BCS
when they want to upgrade the firmware, and complete the upgrade with restart
function, which can avoid the trouble to power down and then power on the system.

7.4 System Settings

Users can press <4> for system settings, and then enter the interface of <system
settings> after inputting the password of 61259023.

Parameter Description
Application 0: plane cutting applications. 1: 3D cutting application.
Language 0: Chinese version. 1: English version.
User
Special customization function
configuration
0: Parameters are not encrypted. 1: Parameters are encrypted.
Parameter
Users need to enter the password if they want to modify the
protect
parameters. Password: 11111111

7.5 Config file

Press <5> to enter config file interface, is as shown below:

The function of configuration file includes:

 Copy parameter of specify machine to all same type machines.
 Make boot logo of BCS100.
 Back up BCS100’s parameter.
Make notice of:
 Use a USB disk with FAT/FAT32 format.
 The configuration file’s format is xxx.CFG. When import file from USB disk,
make sure there is only one .CFG file at the root directory of the disk.
 BCS100 Independent Capacitance Height Controller 24

 The file export to USB disk named EXPORT.CFG. If there is a file

EXPORT.CFG in the USB disk before exporting. This file will be covered.

8 Oscilloscope
Oscilloscope function is one of the unique functions of BCS100. Users can enter
the interface of <capacitance oscilloscope> after pressing <5> on the main interface.
The principle of the oscilloscope is to display capacitance value C in real time. It also
displays the maximum value (MAX), minimum value (MIN), difference between the
MAX and MIN (DIF) and average value (AVE) of the measured capacitance. As shown
below:

Please observe the changes of capacitance while keeping the cutting head and
board stationary. The greater DIF value, the greater the interference, or the more
unstable the capacitance is.
Users can determine the interference size in reference with the values below:
DIF value Interference size
0~10 None
10~20 Very little
20~30 Little
30~50 Average
50 以上 Large

9 Edge Cutting Function

As shown below:
foll
ower

Cut board into 2 pieces

Edge cutting function is widely used for board corner cutting, board cutting and
oddment cutting. This function supports the cutting head to cut in the board from the
external, and cut out from the edge of the board. This function is effective only when
CypCut software is used.
 BCS100 Independent Capacitance Height
25
Controller

Before cutting, the cutting head needs to follow to the position near the cut-in
point of board, and the position is set as the “through cut height” . The edge cutting
function needs to be enabled in CypCut software.
In the practical operation, users need to first lower the cutting head to the edge
finding height, and then conduct cutting movement. The system will immediately
enable the functions for following when it detects that the distance between the
follower and the board is smaller than “incoming edge sensitivity” parameter. The
system will immediately move up to the edge finding height when the follower cuts out
of the edge of the board and the following deviation of follower is greater than “cut out
check” parameter and last more than “cut out delay”.
When using this function, users need to note the following:
Please be sure to set “through cut height” before conducting cutting for the first
time.
Ensure that the distance between every two cut-in points is within 5mm at Z-axis,
so as to avoid the case that some cut-in points cannot sense the incoming edge, while
others sense the incoming edge too early.
During the operation, if the follower moves in advance, users need to reduce the
“cut in check” parameter. If the follower lags or does not move, users need to increase
the “cut in check” parameter.
When the board slope is large and the cutting speed is high, users need to
appropriately increase the “cut out check” parameter.
When enabling edge cutting function, following error alarm will not take effect.
When the conditions are met for cut out, users need to lift the follower to the edge
finding height and continue cutting.
 BCS100 Independent Capacitance Height Controller 26

Chapter 3 Description of Accessories

1 Introduction to Accessories
Capacitance control system is composed of BCS100 controller, preamplifier, laser
cutting head and cable, as shown below:

1.1 List of Standard Accessories

 BCS100 master controller x1
 Preamplifier x1
 Laser cutting head (short focal length, with ceramic part and nozzle) x1
 Thermostable cable (140mm, the length can be customized) x1
 Sensor signal cable (20m, the length can be customized) x1
 DB15 plug (pin) x1
 DB15 plug (jack) x1
 Manual x1

1.2 Wearing Parts

 Laser nozzle
 Ceramic part
 Thermostable cable
 BCS100 Independent Capacitance Height
27
Controller

1.3 Options
 Thermostable cable with customized length (50 to 300 mm)
 Sensor signal cable with customized length (5 to 100m)
 CypCut laser cutting software (be able to greatly improve the performances
of BCS100 for fiber laser cutting)
 Industrial grade wire (communicate with CypCut laser cutting software, 3 to
30m )
 Laser nozzle of different models (Han’s, Unity, Farley and Precitec, etc.)

2 Preamplifier
The preamplifier with unique design can sample and amplify the capacitance
signal of cutting head and then converted it into digital signal for remote transmission.
There is no parasitic capacitance basically when the transmission cable is 100m long,
and thus the signal is not attenuated with strong stability. The appearance of
preamplifier is as shown below.

Appearance of amplifier
36
44

Φ3.5×4
39 31

Installation of amplifier
 BCS100 Independent Capacitance Height Controller 28

3 Cutting Head
Laser cutting head is composed of mechanical part of the cutting head, ceramic
part, clamping nut and laser nozzle. This system provides several different types of
laser cutting head for the users to choose. The cutting heads are mechanically
connected to the lift shaft of laser cutting machine through M30*0.75 thread, as shown
below:

Short Type
Normal Type

3D Type
Ceramic part is a wearing part, so it can be replaced after damage. It is required to
align the two positioning columns on the sensor body when installing the ceramic part;
otherwise, it cannot be properly installed and thus the sensor will fail. When locking the
ceramic part, users should be sure to lock if firmly with locking nut. If locking nut is not
tightened, the operating parameters of the sensor will be directly affected.
As a sensitive element of the sensor, laser nozzle is connected to the sensor body
through threads. It is required to tighten the cutting nozzles, or there will be gap
between sensor gaps when blowing. Because nozzle is a kind of wearing parts, it is
required to timely remove the bonding slag after a period of time and promptly replace
the seriously burned nozzle.
Users should note the following when using the sensor:
(1) Dry and pure auxiliary gas should be used for cutting. When the gas contains
water, oil and other impurities, the working gap will mutate, and the sensor may fails.
(2) The sensor should be cleaned after being stained. It is required to clean the
sensor with dry and clean cotton cloth, and avoid washing the cutting head and ceramic
part using liquid. It is required to correctly connect and assemble the sensor after
cleaning.
(3) Users can replaced nozzle, ceramic part and cable at any time. Nozzles can be
replaced by those of other shapes and models, but it is required to conduct a capacitance
calibration for the follower.
The installation dimensions of three kinds of cutting heads are as shown below.
 BCS100 Independent Capacitance Height
29
Controller

3.1 Short Focal Length Type

3.2 Common Type

 BCS100 Independent Capacitance Height Controller 30

3.3 3D Cutting Type

Notes: In addition to the standard cutting heads above, we can also accept the
design and manufacturing of cutting heads with special structures and non-standard
sizes. The standard cutting head provides a gas connector with a pore diameter of 6MM.
The connector can play a role in blowing off the slag and protecting the nozzle in the
cutting process after connecting it to a gas pipe.
 BCS100 Independent Capacitance Height
31
Controller

Chapter 4 Installation Instructions

1 Wiring Instructions

1.1 Interface Layout

The detailed interface layout of BCS100 wiring terminal is as shown below:

Dorsal view

USB

15 14 13 12 11 10 9 9 10 11 12 13 14 15
24V 0V FG

8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8

Sensor Input and output Servo Net Power

1.2 Power Interface Instructions

24V 0V FG

To machine main
metal part

The machine casing is the negative electrode of the measured capacitor. In order to
ensure the steady operation of measured circuit, it is required to reliably connect “FG
pin” of power interface to the machine casing (i.e., have good conduction with machine
casing), and preamplifier casing also must have good conduction with machine casing.
The specific indicator is that D.C. impedance is always less than 10 ohms, or the actual
following effect may be poor.
 BCS100 Independent Capacitance Height Controller 32

1.3 Servo connection and setting

8 7 6 5 4 3 2 1

15 14 13 12 11 10 9

15-pin female servo control interface

Pin Signal name Pin Signal name
1 DA (with an analog 9 AGND (Analog ground)
output of -10~10V)
2 0S (Zero speed clamp) 10 0V (Power ground)
3 A+ (Encoder A+) 11 (Encoder A-)
4 B+ (Encoder B+) 12 (Encoder B-)
5 Z+ (Encoder Z+) 13 Z- (Encoder Z-)
6 SON (Servo on) 14 ALM (Alarm signal)
7 CLR (Clear alarm) 15 0V (Power ground)
8 24V (Power output)
Wiring diagram of Panasonic servo
BCS100 servo interface Panasonic MINAS-A servo 50 pin interface

Pin No. shielded wire No. PIN

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+
0S 2 26 ZEROSPD
SON 6 29 SRV-ON
CLR 7 31 A-CLR
0V 10 36 ALM-
ALM 14 37 ALM+
0V 15 41 COM-

Wiring diagram of Yaskawa servo

 BCS100 Independent Capacitance Height
33
Controller

BCS100 servo interface Yaskawa Σ-V servo 50 pin interface

Pin No. shielded wire No. Pin

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

0S 2 41 /P-CON
SON 6 40 /S-ON
CLR 7 44 /ALM-RST
0V 10 32 ALM-
ALM 14 31 ALM+
0V 15 1 SG

Wiring diagram of Delta servo

BCS100 servo interface Delta ASD-A servo 50 pin interface

Pin No. shielded wire No. Pin

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 OZ
Z- 13 24 /OZ

24V 8 11 COM+
0S 2 10 DI2
SON 6 9 DI1 SON
CLR 7 33 DI5 ARST
0V 10 45 COM-
ALM 14 28 DO5+ ALRM
0V 15 27 DO5-

Wiring diagram of Teco servo

 BCS100 Independent Capacitance Height Controller 34

BCS100 servo interface Teco JSDEP servo 50 pin interface

Pin No. shielded wire No. Pin

DA 1 12 SIC
AGND 9 13 AG

A+ 3 21 PA
A- 11 9 /PA
B+ 4 22 PB
B- 12 10 /PB
Z+ 5 23 PZ
Z- 13 13 /PZ

24V 8 17 DICOM
0S 2 15 DI-4
SON 6 9 DI-1
CLR 7 x x
0V 10 24 IG
ALM 14 19 DO-2
0V 15 x x

Wiring diagram of Mitsubishi MR-J30A servo

BCS100 servo interface Mitsubishi MR-J30A servo

shielded wire
Pin No. No. Pin
DA 1 2 VC
AGND 9 28 LG

A+ 3 4 LA
A- 11 5 LAR
B+ 4 6 LB
B- 12 7 LBR
Z+ 5 8 LZ
Z- 13 9 LZR

24V 8 20 DICOM
0S 2 17 ST1
SON 6 15 SON
CLR 7 19 RES
0V 10 46 DOCOM
ALM 14 48 ALM
0V 15 42 EMG
 BCS100 Independent Capacitance Height
35
Controller

Other pins of MR-J30A:

Pin Logic
ST2 NO Connection
SP1 NO Connection
SP2 NO Connection
SP3 NO Connection
EMG DOCOM

Corresponding to the wiring modes above, the servo parameters are set as follows:
Panasonic A5 series:
Parameter Recommended Description
No. value
Pr001 1 Control mode: It must be set speed mode.
Pr002 3 Real-time automatic adjustment: The
recommended setting is vertical axis mode.
Pr003 17 Servo rigidity, the recommended range is
from Grade 14 to Grade 20.
Pr302 500 Input the gain of speed command.
Pr315 1 Enable zero speed clamp function.
Yaskawa Σ-V series:
Parameter Recommended Description
No. value
Pn000 00A0 Speed control with zero-position fixation
function.
Pn00B - Set to 0010 when using single-phase power.

Pn212 2500 Number of pulses output by the encoder per

revolution. The pulse parameter of
corresponding BCS100 per revolution is
10,000.
Pn300 6.00 The speed gain of corresponding height
controller is 500 r/v/min.
Pn501 10000 Zero fixed value.
Pn50A 8100 Forward rotation is enabled.
Pn50B 6548 Reverse rotation is enabled.
Delta ASD-A series:
Parameter Recommended Description
No. value
P1-01 002 Control mode: It must be set to speed control
mode.
P1-38 2000 Set zero speed clamp value to the maximum.
P1-40 5000 The speed gain of corresponding height
 BCS100 Independent Capacitance Height Controller 36

controller is 500 r/v/min.

P2-10 101 Set DI1 to SON, normally opened.
P2-11 105 Set DI2 to CLAMP, normally opened.
P2-12 114 Set speed command to external analog
control.
P2-13 115 Set speed command to external analog
control.
P2-14 102 Set DI5 to ARST, normally opened.
P2-22 007 Set DO5 to ALRM, normal close.
Deco JSDEP series:
Parameter Recommended Description
No. value
Cn001 1 Control mode: It must be set to speed control
mode.
Cn002.2 1 Automatic gain. (Note: It is the parameter of
the second figure of Cn002 )
Cn005 2500 Number of pulses output by the encoder per
revolution. The number of pulses of
corresponding BCS100 per revolution is
10,000
Cn026 4 Rigidity. Level 4 is the default.

Sn216 4000 Speed gain. The speed gain of corresponding

BCS100 is 400.
Mitsubishi MR-J30A series:
Parameter Recommended Description
No. value
PA01 2 Control mode: It must be set to speed control
mode.
PA15 10000 Number of pulses output by the encoder per
revolution. The number of pulses of
corresponding BCS100 per revolution is 10,000
PC12 5000 Speed gain. The speed gain of corresponding
BCS100 is 500 r/v/min
PC17 0

In addition, it is required to set the servo type of “mechanical parameters” of

BCS100. Please refer to Section 2.5.5 for specific settings.
 BCS100 Independent Capacitance Height
37
Controller

1.4 Description of Input and Output Interface

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

15-pin male input and output interface

Pin Signal definition Pin Signal definition
1 24V (Power output) 9 DA1 (0~10V analog quantity)
2 DA2 (0~10V analog quantity) 10 AGND (Analog ground)
3 OUT1 (Cutting in place) 11 OUT2 (Reserved)
4 OUT3 (Alarm) 12 OUT4 (Punching in place)
5 IN1 (Cutting tracking) 13 IN2 (Move to aligning
coordinate)
6 IN3 (Quick lift up) 14 IN4 (Stop)
7 IN5 (Upper limit) 15 IN6 (Lower limit)
8 0V (Power ground)
Notes:
1. Output ports (OUT1~OUT4) are all open drain output, and they are connected
with the power ground for outputting.
2. Input ports (IN1~IN6) are all active low level input, and the input is enabled
when the input ports are connected with the power ground.
3. 2-channel analog output of height controller is 0 to 10V, and it can be used for
controlling the pressure of auxiliary gas and the power of air conditioner and laser.
4. When the cutting head punches to place, OUT4 will output a desired signal with
a width of 200ms. When the cutting lead follows to the cutting height, OUT1 will
output continuous desired signal.

1.5 Description of Sensor Interface

1:Connect with pin 1 of the cable

1 4
2:Connect with pin 2 of the cable
3:Connect with pin 3 of the cable
2 3
4:Connect with shield of the cable

4-pin signal transmission cable of sensor can be manufactured with 3-pin shielded
cable and 2 4-pin air plugs. It is required to connect Pin, 1, 2 and 3 together, and connect
Pin 4 to shielding layer during the manufacturing process.

2 Debugging Steps
After the installation, users need to debug the controller as follows:
Set servo parameters. See “servo parameters” in Chapter V for details.
 BCS100 Independent Capacitance Height Controller 38

After powering on and completing the initialization, enter the parameter interface
and set “mechanical parameters”.
Go back to <main interface> to check whether the travel switch is enabled. If it is
an optoelectronic switch, the interface will display “upper limit is enabled” when
blocking the upper limit with shade; it will display “lower limit is enabled” when
blocking the lower limit.
Enter <test interface> to conduct open-loop jog, and check whether the rotation
direction of motor is right. If the direction is wrong, please change the servo direction
parameters. And then conduct open-loop jog again, please change the encoder direction
parameters if the encoder signal is inverse (mechanical parameters).
Enter <calibration interface>, and conduct “servo calibration” to eliminate the
zero shift of servo.
Return to the origin manually, and turn on the power-on reset function on the
interface of <reset parameters>.
Enter <calibration interface> and do “capacitance calibration” for the follower.
Modify other parameters as required after completing the steps above.
 BCS100 Independent Capacitance Height
39
Controller

3 Installation Size
Front view
236
224

BCS100 V2.0

F1 1 2 3

CONTROL
F2

HEIGHT
BCS100 电容随动控制器 4 5 6

>>>>>>>>>>>>>>>>>----------- F3 7 8 9

F4 . 0
144
156

跟随关 跟随快 跟随高 停止 确定

SHUT FAST +0.1 STOP ENT
变速
跟随开 SHF
跟随慢 跟随低 回原点 取消
FOLL
SLOW -0.1 ORG ESC
OW

Φ4.5×4
218

34 8

Top view

Left view
137
 BCS100 Independent Capacitance Height Controller 40

Chapter 5 Alarm process and FAQ

1 System alarm analysis

1.1 Z+/Z- limit enable

When system checked Z+/Z- limit input is enabled, the alarm happens. The
reason includes:
 Z+/Z- sensor detect something.
 Z+/Z- sensor is broken. Or it is used for long time, there is oil contamination
and powder on the surface.
 The parameter of “Limit logic” can be set to normal open or normal close
 The wiring is not correct.

1.2 Out of Z range

When Z moves large then range, which is a parameter of system, the alarm will
be throw out. If it is wrong alarmed, take attention in the range parameter, if the
system returned origin, and if the encoder feedback is correct.

1.3 Z- limit continue enable

When system is returning origin, it moves back when z- sensor is enabled, but
can’t quit the z- sensor enable area, the alarm happens. Take attention if the sensor is
broken.

1.4 Servo alarm

When system checked NO. 14 input ALM is enabled, which reflect the servo
alarm status, the alarm is shown on the screen. The reason of servo alarm includes:
 The servo alarms.
 The “Servo Type” parameter is not correctly set.
 Wiring is not correct.
 Electrical system disturbs the wire.

1.5 Encoder moves abnormally

When system keeps in stop status, the encoder feedback value changed, there
will be this alarm. The reason lead to the alarm includes:
 The axis vibrates by outside force.
 Wiring wrong, the zero speed signal does no effect.
 Servo rigidity is very low.
 The encoder wire is disturbed. The shield is needed, and should be connect to
the ground. Add some wire magnet ring is better.
 BCS100 Independent Capacitance Height
41
Controller

1.6 Encoder no response

The system try to move, send out speed command as voltage, but the encoder
feedback value does not change at all. The alarm happens. The reason includes:
 Wring error.
 Servo type is wrong. Servo must have speed control mode.
 Servo parameter is not correctly set. It should be switched to speed control
mode.

1.7 Encoder deviation large

When the difference between destination position and feedback position is too
large, the alarm happens. It reflects the servo can’t follow the speed command
correctly. The reason includes:
 Encoder feedback direction is wrong. The relative parameter should be
modified.
 Wiring error or disturb make the encoder feedback wrong.
 The mechanic is stuck, the really position can’t follow the destination
position.

1.8 Capacity is 0
When system can’t check the capacity of the spray, the capacity value is shown
as 0 on the screen. The following situation may cause the alarm:
 The spray touched the board below.
 There is water in cutting head.
 The local capacity of the cutting head is large, which is out of the check
range of the preamplifier.
 The preamplifier is broken.
 Connection is not fixed.
 In the internal of cutting head, the positive of capacity (spray) is short circle
with the negative of capacity (the shell of machine).

1.9 Local capacity small

When local capacity changes less, the alarm happens. The reason includes:
 Connection or some part is changed or moved. You can do calibration again.
 Laser shoots on the spray, the temperature gets very high is short time. Man’s
hands can’t stay on the pray.
 Blow leads to the change of distance of positive pole (spray) and negative
pole (shell of the machine).
 Connection is not fixed.
 The parameter of calibration range is low can also lead the alarm. In 2D
mode 15mm is recommended. And 10mm is recommended in 3D mode.
 One of the reason is the cutting fire and electronic affects the capacity sensor
when the board material is stainless steel.
If there is plastic film on the surface of steel, remove the film first. Check if
the machine is connect to the ground well. The following height should be
 BCS100 Independent Capacitance Height Controller 42

large than 0.5 mm. Improve the blowing pressure.

1.10 Follow deviation large

When system check the H height (the distance between spray and board) changes
large in short time in follow state, the alarm happens. The relative parameter is
interpreted in Chapter 2.5.5. The alarm reason includes:
 Cut out of the board. There is nothing to follow below.
 Board is vibrating heavily.

1.11 Sample capacity large

When sampled capacity is larger than the largest capacity in calibration, the
alarm happens. The reason includes:
 The spray touched the board below.
 There is water in cutting head.
 Connection is not fixed.
In the internal of cutting head, the positive of capacity (spray) is short circle with
the negative of capacity (the shell of machine).

1.12 Expiration of time

There is no more time permitted to use this system.

2 FAQ

2.1 Obvious vibration and mechanical shock in the following movement

 Amplifier casing or controller FG pin are poorly connected to the machine
casing.
Machine casing is the negative electrode of the measured capacitor. When the
conductivity of amplifier casing and machine casing is poor, the AC impedance
between the positive and negative electrodes of the capacitor is large. Thus, the load of
measured circuit varies, which may lead to larger measurement error. If good
mechanical connection cannot be achieved, users can add a wide wire(copper material
is better) between amplifier metal casings to reduce AC impedance. The AC impedance
of single-point connection is greater than that of good mechanical connection. It is
required to make the AC impedance less than 10 ohms.
 Too large servo rigidity
Mechanical shock and obvious vibration may be caused during the movement due
to too large servo rigidity. For example, it is recommended that the servo rigidity of
Panasonic MINAS A5 series should not be above Level 19.
 Too large following speed level
Vibration may be caused during the movement due to too large following speed
level. Level 3 to 7 are recommended.
 Poor follower calibration
When the data stability and smoothness of capacitance and position stored in
BCS100 is poor, vibration will be caused during the following movement. Please do
 BCS100 Independent Capacitance Height
43
Controller

follower capacitance calibration again, until the stability and smoothness becomes
excellent or good.
 If there is a large interference at the field, users can appropriately reduce the
parameter of “servo gain coefficient”.

2.2 The follower always hits the board during in following movement
 Too small calibration range or too large Z-axis speed
The smaller the calibration range, the smaller the deceleration distance of
following movement. If Z-axis speed is too large and it is not reduced to 0 when the
follower flows to place, overshoot will be unavoidable. The greater the Z-axis speed is,
the greater the overshoot is. When Z-axis speed is greater than 100mm/s, it is
recommended to set the calibration range to be 15mm. When Z-axis speed is greater
than 250mm/s, it is recommended to set the calibration range to be 20 to 25mm.
 Too small servo rigidity
Servo response may lag behind the control signals of controllers due to too small
servo rigidity, and thus the follower will hit the board. For example, it is recommended
that the rigidity of Panasonic MINAS A5 series should not be below Level 13.
 Capacitance calibration
The follower will hit the board when there is a large deviation between the
capacitance stored in BCS100 and actual measured capacitance. For example, the
nozzle temperature increases a lot or the connection is not stable. Users need to first
find the reason, and then calibrate capacitance again after solving the problem.
 No preheating
Please preheat the amplifier for 2 to 5 minutes, and then operate BCS100
controller after the sampling capacitance in the amplifier becomes stable.
 The locking nut of ceramic part is not connected tightly.
The locking nut of ceramic part is not connected tightly, which may lead to
instable detecting capacitance.

2.3 The following height is different from the actual height

No preheating
Please preheat the preamplifier for 2 to 5 minutes, and then operate BCS100
controller. The sampling capacitance in the preamplifier may changes with the changes
in temperature. Please preheat the amplifier for 2 to 5 minutes, and then operate
BCS100 controller after the sampling capacitance in the amplifier becomes stable.
Calibration problem
The phenomenon above often appears if the follower capacitance is not calibrated
again after replacing the nozzle.
Nozzle temperature increases abnormally (above 100oC) because the laser scatter
to the nozzle or the blowing is abnormal, and thus the capacitance of cutting head
changes.
The follower does not hit the board in intelligent calibration, and the actual
following height is higher than the setting height.
Please do calibration after closing the intelligent check option.
 BCS100 Independent Capacitance Height Controller 44

2.4 The follower cannot move up to the correct height

If the follower cannot move up or the lift-up height is incorrect, users need to first
observe and determine whether Z-axis coordinates are normal. If Z-axis coordinates get
less obviously, it is required to first return to the origin, press repeatedly “FOLLOW”
and “SHUT”, and then obverse whether Z-axis coordinates are consistent with each
other after following to the board. If Z-axis coordinates continue to decrease, there may
be a problem in the position feedback of the system. The reason may be that: servo
motor or ball screw and coupling slide against each other, resulting in coordinate offset.

2.5 It shows that: “Validation error, failed ARM upgrading” when

upgrading the controller
Upgrade file may be infected by computer virus.

2.6 Follower moves up without contacting the board when calibrating the
capacitance
Please check the follow material is set to “metal” or “nonmetal”