Replacing the DSP Controller

Replacing the DSP Controller

Preface: This guide will walk you through the physical replacement of the controller. Be sure to read it completely and understand that the machine will not react like normal until the controller is configured correctly. If you attempt to use features like autofocus, air assist, to run a job etc, the result may be unexpected and damage may occur.


Physical Replacement:

Power off the machine and unplug it from the wall before you begin work.

Locate the DSP Controller:

The DSP will be inside the electrical cabinet, on the right side of your Thunder Laser.  For the Mars series machines, use the NOVA information as a basis.

Bolt Electrical Panel Location
Bolt DSP Controller Location



Nova Electrical Panel Location
Nova DSP Controller Location



Odin Electrical Panel Location
Odin DSP Controller Location




How To Remove and then Reinstall:

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 green and white connectors as well as the USB and Ethernet connections from the controller.

Controller
Controller with Plugs removed



Mark the Controller Before Removing
Remove these 4 Screws to Remove the Controller



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 to the right or Top. If you go ahead and plug in the Power and HMI connectors to the controller before you screw it to the machine, it will help make sure you mounted the controller correctly.



Configuration After Replacement:


Step 1: Initial Power Up:

For the initial powerup, you will have to wait until the controller times out or cancel the homing by pressing the ESC button or Cancel button. Since the X and Y axes cannot move, the homing sequence will run until it is timed out or canceled.
Older Screen
Newer Screen

While the system is Resetting, press the ESC a few times to abort.
After you click the prompt to allow the Machine To Home, this will appear for about 60 seconds

After 60 seconds, the machine will initialize the rest of the functions and allow you to utilize the screen

Check the Language and set back to the desired language. If it is already in your preferred language, then carry on.
If your Screen Looks like this, Click the image for the guide
If your Screen looks like this, Click the image for the guide



Step3: Reconnect to the Machine

      If you were connecting with Ethernet, you need to re-assign the IP to the machine if you are not using the default 192.168.1.100 IP for the machine. USB connections should connect right back to the machine without any additional configuration.

Step 3: Flash the Firmware

All DSP's are sent with Nova\Odin firmware that is compatible with the V8.4 and older TL Timers. If you have a Bolt series machine, you will need to flash the firmware.

Please see this guide and contact us for the firmware:


Step 4: Restoring Machine Settings:


First we need to check for a backup of the machine settings file. Locating a backup will make the recovery process much easier and faster. It is worth taking the time to search your computer for the file.

How to find your Machine Settings backups:

            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 support with your machine type and we can review and confirm. Use the built in search functions for Windows and Mac.

Lightburn Automatic Backups

These automatic backups are stored near where Lightburn stores your presences configuration file.
In Lightburn, Select File, Open Prefs Folder*
Once in the Prefs folder, Select Backup\Machine Settings


*Depending on your vintage of Lightburn, the link to the Prefs folder might be right under the FILE listing or in a sub-menu 

Inside the Machine Settings backup folder, there will be folders for each controller you have connected to with Lightburn. They will not have names like "Nova" or "Odin" etc. Inside each folder is a backup file that may be usable. 

Write Machine Settings (If available)

      If you were able to locate a backup copy of your machine settings you can download them to the controller and skip the full configuration steps below Otherwise you will have to complete the Manual Configuration shown further down in the next section of this article and skip the steps shown here

Here is how to write the Machine Settings File to the controller.

Step 1: Edit>Machine Settings
Step 2: Click Load From File


Navigate to where your machines settings file is and select it.

Step 3: Write
Step 4: Click OK

This will write the loaded settings to the machine


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. Allow the machine to home and then begin Lasering again.


Manual Configuration

You only need to perform these steps if you were unable to transfer your machine settings. If you were able to transfer your machine settings then you should have everything you need to run assuming you had good machine settings.

Please see the above warning, these steps are only needed if you do not have a copy of your specific machine settings.

Step 1: Load Base Machine Settings:

Use the Lightburn Machine settings window to send a basic settings file for your machine to the controller.

Machine
Download Link
Nova 24
Nova 24 Base Settings
Nova 35
Nova 35 Base Settings
Nova 51
Nova 51 Base Settings
Nova 63
Nova 63 Base Settings
Bolt
Bolt Base Settings
Odin 22
Odin 22 Base Settings
Odin 32
Odin 32 Base Settings
*If your machine is not in the table, then you will need to use the file on the controller and complete the configuration with it

Step 2: IO Checkout

Need to use the Diagnosis 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.

Older Screen Diagnosis View
Newer Touch Screen Diagnosis View




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
Chiller Water Alarm
Water Prot
Water Cooling
Signal from chiller, plugs into the back of the machine
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.


Air Assist Protection

Depending on your machine model, you may be able to skip this step.

How To Enable
Sample Air Sensor
If you have a Machine with an Air Pressure sensor, you will need to enable its. This guide will walk you through enabling the protection. Currently this does require RDworks which is a free software.


Step 3: 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.

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.

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.

Step 4: 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.

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


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.


Step 5: 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. 

Step 6: 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.


Other Considerations:

If you purchased a 3rd party controller and have dual air:

Air Assist Control
Wire Swap
This is mostly applicable to machines built in 2020 and beyond or if you have sourced a controller from a 3rd party vendor like Ebay, Amazon, or CloudrayLaser.com etc.
The wiring for the Air Assist Changed in 2020 and coincided with a firmware change by Thunder Laser. In order to get the dual air assist to function for High and Low, you may need to swap the brown wire from Out1 to Wind on the Ruida DSP CN1 connector.

To test, first do a small project where you engrave a bit of text onto a circle. Set the Engrave layer to Low Air and the Line layer to High Air. Send the job to the machine and test that the air will toggle to High on the cut. If it does not, power off the machine and perform the wire swap shown below and retest