How to Replace Controller for Thunder Bolt
Detailed steps:
1. How to save the parameters of the old controller
a. Exporting factory parameter
Ensure that the machine communicates successfully | Edit>Machine Settings |
Click Read | Click Save to file |
Finally, the exported factory parameter file is placed on the desktop and named and documented. Like this. |
b. Exporting Scan Offset Parameters
Ensure that the machine communicates successfully | Edit>Device Settings |
Click Read | Click Export and save file to desktop |
|
2. Finding the Controller first
Bolt Electrical Panel Location | Bolt Controller Location |
3. Remove and Install
Tools Needed:
Phillips Head Screwdriver (Red one from tool box)
Start by powering off the machine and unplugging it from the wall power. Then remove all the connectors as well as the USB and Ethernet connections from the controller.
Controller | Controller with Plugs removed |
Unplug all connectors shown in the diagram. Note: Please take care to remember the corresponding positions of all the cables insertions. You can take a picture of it before you pull it out. |
Mark the Controller Before Removing | Remove these 4 Screws to Remove the Controller |
Then put stickers on the damaged controllers to distinguish the good ones, like this. |
Reinstall the controller in reverse and prepare for power up by not plugging the X and Y driver connections and the CN5 Connector.
Controller Placed Back into Machine | X and Y Driver and Tube CN5 Connections unplugged |
The RED LEDs should be oriented at the top. Plugging in the power, HMI, and signal line connectors to the controller before securing it to the machine will help ensure the controller is mounted correctly. | After replacing the controller with a new one, disconnect the X and Y drives and the Tube CN5 connection. |
4. Configuration After Replacement:
a. For the initial powerup, you must wait for the controller to time out. Since the X and Y axes cannot move, the homing sequence will run until the timeout is reached
After clicking on the prompt to allow the laser head to the origin position, the following screen will remain displayed for approximately 60 seconds. After 60 seconds, the machine will initialize the remaining functions and allow you to use the screen.b. Check the language and set it to the desired language.
If your interface shows Chinese interface, you can refer to this article to change your language system.
How do i change the language of Thunder Bolt HMI if it is Chinese
5. Reconnect to the Machine
If you're using Ethernet, you'll need to re-assign the IP address to the machine unless you are using the default IP of 192.168.1.100. And USB connections should connect directly to the machine without any additional configuration.
6. Update the Firmware
Touch Panel's controller and HMI firmware upgrade method
If you cannot find the firmware version, please contact us by Ticket!7. Restoring Machine Settings
First, we need to check for a backup of the machine settings file. Locating a backup will simplify and expedite the recovery process, so it's worthwhile to take the time to search your computer for the file.
a. How to find your factory parameters
ⅰ. The first step has been completed, saving the parameters of the old controller.
Please find the parameter file of the old controller that has just been saved in advance 【STEP 1】.
ⅱ. Manual search
Search your computer for .lbset files and find the one that corresponds to your Machine. If you have multiple machines, you may have multiple files. If you are unsure of the file that you have, email it to our with your machine type and we can review and confirm.
ⅲ. Lightburn Automatic Backups
These automatic backups are stored near the location of your Lightburn 'Preferences' configuration file.
In Lightburn, Select File, Open Prefs Folder* | Once in the Prefs folder, Select Backup\Machine Settings |
|
b. How to find your Scan Offset parameter
ⅰ. The first step has been completed, saving the Scan offset parameter.
Please locate the Scan Offset parameter file you just pre-saved.
ⅱ. Find the Scan Offset parameter via gold card.
You can find the gold card in your key bag | Take out the gold card |
|
ⅲ. Find the Scan Offset parameter via U disk.
You can find the U disk in your key bag | Take out the U disk |
Insert the U disk into the computer | Please find a screen shot of the Scan Offset parameter setting |
c. Write Machine Settings
ⅰ. Importing factory parameters
Step 1: Edit>Machine Settings | Step 2: Click Load From File |
Step 3: Write | Step 4: Click OK |
|
ⅱ. Importing Scan Offset Parameters
You can refer to this article on how to import Scan Offset parameters.
If you are not able to find the machine settings files, then complete the following Manual Configuration.8. Manual Configuration
Please see the above warning, these steps are only needed if you do not have a copy of your specific machine settings.
a. Load Base Machine Settings
Use the Lightburn Machine Settings window to upload a basic settings file for your machine to the controller.Machine
Machine | Download Link |
Bolt |
Once you have written the machine settings you can power off the machine, plug in the connectors for the X and Y Drivers and then power up the machine.
b. IO Checkout
Need to use the Diagnostics screen to check out the IO to verify that the IO responds. When you press the switch, the corresponding IO point should light up on the screen. To access the diagnostics screen, Press your MENU button and then select the Diagnostics screen option.
See the below table for the Points to Check:
IO Point Common Name | Older Screen Diagnosis Name | Newer Touch Screen Diagnosis Name | Description/Link |
X Axis Endstop | XLimit- | X-Left Limit | Back Left Homing Switch for X Axis |
Y Axis Endstop | YLimit- | Y-rear Limit | Back Left Homing Switch for Y Axis |
Z Axis Upper Endstop | ZLimit- | Z-Upper Limit | Autofocus on Novas, Limit Switch on Bolt\Odin |
Z Axis Lower Endstop | Zlimit+ | Z-Bottom Limit | Z Lower Endstop, down near crumb tray |
Doors OK | IF | Lid Protection | Machine Protected Work pause error. |
Autofocus (Bolt\Odin) | N/A | Auto Focus | Touch Post Sensor in the Laser Head |
Air Pressure | N/A | Blow Protection | For Machines that have a Sensor that stops them from running. |
c. X, Y and Z Direction Checks
You will need to verify that when you press a direction arrow on the screen, that the laser moves the selected axis in the correct direction and that the machine can home itself ok. You will need to adjust the machine settings for each Axis as directed in the below steps. But first we need to get familiar with where to find those settings.
In order to change the Direction Polarity or Invert the Keypad Direction, you will need to access the Vendor Settings in the Machine Settings.
How To Access the Machine Settings Vendor Section | Each Axis (X,Y and Z) will have their own section |
Reading and writing:
Use Read to upload the Current Values | Use Write to Download your Changes |
|
How to change the configuration and what to do if so:
This is a multi-step process starting with these test for the X and Y axes. First test is to get the direction right for the controller. The second test is to get the direction right for the keypad. Both tests must be performed and in order.
ⅰ. X/Y Test and Adjust 1:
First, with the machine powered off, move the Laser Head to the middle of the bed. This will allow it to move in all four directions without immediately running into a wall.
Then power up observe how the machine starts up and attempts to home. The X axis should go to the left and the Y axis to the back of the machine. If either axis goes the wrong direction, Esc Button to cancel or Estop the homing sequence. Power off then machine and unplug the X and Y axis Driver connectors.
Power the machine and adjust the machine setting as follows if the machine does not home properly:
IF | Axis "Direction Polarity" is | Then Change and Write |
X Axis Went to the Right | ||
X Axis Went to the Right | ||
Y Axis Went to the Front | ||
Y Axis Went to the Front |
Then power off, re-run the test. If the machine homes properly, go to this next step. Otherwise adjust until it homes properly.
ⅱ. X/Y Test and Adjust 2:
Now that the machine can home properly, we know the motor direction is correct for the controller. Now we need to check the keypad direction arrows work right.
Power up the machine, let it home. Then try to use the right and down arrows to move the laser head.
IF | Axis "Invert Keypad Direction" | Then Change and Write |
I press the Left or Right arrow button, and the X axis moves in the incorrect direction | ||
I press the Left or Right arrow button, and the X axis moves in the incorrect direction | ||
I press the Front or Back arrow button, and the Y axis moves in the incorrect direction | ||
I press the Front or Back arrow button, and the Y axis moves in the incorrect direction |
After you Write the changes, test again with the Direction Arrow buttons. Confirm that the direction the head moves is proper and then go to the next step.
d. Auxiliary Function Check Out - Auto Focus
To test the autofocus, you need to have already checked that the AF Sensor or Zlimit- depending on the machine, is working in the IO.
On your Nova Series machines, it would be best to remove the laser head to limit the crash potential.
ⅰ. Z test and Adjust 1:
1. Be alert and ready to E-stop the machine if a crash is imminent.
2. Place material on the bed in the proper position for an autofocus
3. Initiate the auto focus from the controller screen on the machine.
If the bed lowers and clears the AF eyes\Touch Post and then continues to go towards the bottom with no sign of stopping, E-stop the machine or abort the homing process.
IF | Z Axis "Direction Polarity" is | Then change and Write |
Z Axis Went Down towards bottom abnormally | ||
Z Axis Went Down towards bottom abnormally |
ⅱ. Z test and Adjust 2:
Now that the motion direction is correct, we need to check if the Up and Down Arrows work correctly.
IF | Axis "Invert Keypad Direction" | Then change and write |
I press the Down or Up arrow button, and the Z axis moves in the incorrect direction | ||
I press the Down or Up arrow button, and the X axis moves in the incorrect direction |
If the system autofocuses properly and moves up and down properly, then proceed to the next step.
e. Calibration - X, Y and Z axis
You will nee to check that each axis move the correct distance when commanded so that your cuts come out to the correct size. Please see this article for further instructions.
f. Calibration - Auto Focus
For the Bolt and Odin series that use touch posts, you will have an offset that you need to dial in for your auto focus. You can use this article to dial it in.
Still need help?
For specific technical questions or help requests, please open a Ticket with picture or video, so our Support team can assist you ASAP.
For the information provided in the ticket, please refer to this link：
Help Tech Support Troubleshoot Faster
End.
Related Articles
Thunder Bolt Series User's Manual
Please see attached: ENDThunder Bolt Troubleshooting guide for having an Alarm Messege on the Screen
Preface: Below is a list of warning messages that may appear on the screen of your Thunder Bolt Machine. These messages are important for diagnosing potential issues and ensuring the proper operation of the machine. You can refer to the following to ...Optional lenses for Thunder Bolt
Preface： This article covers the difference between the Four Lens options for the Bolt series machines. Intro Video: Appearance of the four lenses: Engraving Test:The same picture was engraved with all four lens with the same power speed with the ...How to Replace USB Expansion Board for Thunder Bolt
Preface: Switch off the machine and unplug it from the wall before starting replacement. Detailed steps： 1. Finding the USB Expansion Board First Bolt Interface Board Location Bolt USB Expansion Board Location It is located on the right side of the ...The Circuit Diagram of the Thunder Bolt
Here's the circuit drawing for the Thunder bolt. Please check attached file. End.