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  • Digital Cutters

  • Zund Cutting Tables

    • Error 0000- No Error Source

      • Internal software error- contact Helicon for serivce help  

    • Error 0001- Last Error Pending

      Your last problem was not completely solved.

      • T- or Z-axis ( RzP) blocked

      - Fix the cause of the previously reported error

      - In the T- override example switch of plotter and check for a blocked T-axis

      • Faulty encoder or motorcircuit

      - Check T-axis with another head if avaiable or use testfunction 52

    • Error 0002- Exception Vector

      Call Helicon for service help.

      • In most cases a full installation has to be made

      - If this message comes up with an index 6 it could be because a new MC- software is installed 

    • Error 0101- Serial Interface (Parity Check)

      Parity settings on PC and plotter are different, noise on the data cable.

      • Check RS232 settings on PC and plotter 

      • Check if the noise sources near the data cable connect PC and plotter to the same mains outlet 

    • Error 0102- Serial Interface (Frame)

      There is different data formats on PC and plotter, different baudrates.

      • Check RS232- settings on PC and plotter

      This message can be disabled with SCI-diagnostic set to level 1 or 2, expect there is another serial error at the same time.

    • Error 0103- Serial Interface (Buffer Overflow)

      • Plotter input buffer overflows, transmission stop was ignored

      - The message 103-2 indicates an output buffer overflow

      - Overflow happens when the cutter tries to send data while the receiving unit is not ready

      • Data Cable is not suitable or defect

      - Overflow could happen from a broken data cable

      - Check data cable

      • PC and protocol settings are different

      - Check protocol settings on PC and plotter 

       

    • Error 0104- Serial Interface (Noise Detect)

      Noise on the serial link 

      • Check if there is noise sources near the data cable

      - Connect PC and plotter to the same mains outlet

      This message is disabled with SCI- diagnostic set to level 1 or 2, expect there is another serial error at the same time. 

    • Error 0105- Serial Interface (Overrun)

      • Microprocessor input buffer overrun

      Call Helicon for service help. 

       

       

    • Error 0106- Replot not available

      • Replot function selected while plotter is still receiving data on the serial input

      - Clear error message, then select replot after first job is finished 

    • Error 0201- Curve Generator (Sr smaller zero)

      • Unknown cause

      Call Helicon for service help 

    • Error 0202- Curve Generator (SF bigger accel)

      • Unknown cause

      Call Helicon for service help 

    • Error 0203-0206- Curve Generator (...Step too large)

      • An invalid machine state was recognized

      Call Helicon for service help 

    • Error 0301- AC Fault X- Override

      The X-axis has been blocked or pushed out of its setting position

      •  Reinitialize plotter, when not possible then switch off plotter and check X-axis

      - Testfunction 52

      • Message 301-10: Wil appear when the motor current of the X-axis exceeds 6.5A although the axis is not moving

      - This high current can be caused by a very high friction or the possibilty of the beam to move into a bumper

      The home switch could be dirty or loose, check that as well. 

       

    • Error 0302- AC Fault Y- Override

      The Y- axis has been blocked or pushed out of its setting position

      • Reinit plotter, when not possible then switch off plotter and check Y-axis

      - Testfunction 52

      • Message 302-10: Wil appear when the motor current of the Y-axis exceeds 2.0A although the axis is not moving

      - This high current can be caused by a very high friction or the possibilty of the carrier to move into a bumper

    • Error 0303- AC Fault T- Override

      The T-axis has been blocked or turned out its setting position.

      • Reinit plotter, when not possible then switch off plotter and check T-axis 

      -Testfunction 52

      • Possible second error: 0001

    • Error 0304- AC Fault Z-Override

      The Z-axis has been blocked or pushed out of its setting position. 

      • Reinit plotter, when not possible then switch off plotter and check Z-axis 

      -Testfunction 52

      • Possible second error: 0001

       

    • Error 0305- AC Fault (No MCIRQ Response)

      • AC not running or too busy

      Call Helicon for service help 

    • Error 0306- AC Fault (No curve available)

      • MC not running or too busy

      Call Helicon for Service help 

    • Error 0307- AC Fault (Check AC)

      • Error in the AC part of the system detected

      • MC software version is older than the one on the AC system 

      - Check for messages with <ENT>

      Call Helicon for service help if there are no further messages 

    • Error 0308- AC Fault (Emergency Stop)

      • Emergency stop on laser inerface detected

      - Check stop buttons and possibly the emergency stop circuit connected to the laser interface

    • Error 0309- AC Fault (Check Powersource)

      • Defective fuse

      - Display further messages with <ENT> and check according fuses

      • Supply out of tolerance

    • Error 0310- AC Fault (Check ADC-VReference)

      • Current measurement observation (max. +- 4 ADC counts) or zero offset (max. +- 10 ADC counts) is too large

      - If this is the only reported error, replace the amplifier board, if not try to repair other failures first

      You will most likely need to call Helicon for Service help 

    • Error 0312- AC Fault (Check Axis)

      • Failure while checking the axes after the power up of the plotter

      - Check for more messages with <ENT>

      Call Helicon for service help if there are no further messages

    • Error 0313- AC Fault (Overrun in ACParser)

      • AC not running or too busy

      Call Helicon for service help 

    • Error 0314- AC Fault (Unknown Command)

      • Incompatible AC and MC software versions

      -Check software versions 

    • Error 0315- AC Fault (Orderirqspike)

      • Noise on DPR- IRQ

      -If this error comes more than once, exchange the master board

      Call Helicon for service help

    • Error 0316- NO IRQ- Response

      • MC not running or too busy

      -If this error comes more than once exchange the master board

      Call Helicon for service help 

    • Error 0317- AC Zeromark X (Permanent Light)

      • X-axis zeromark sensor defect

      • Defect on C-board, or interruption between C-board and masterboard

      See zeromarks chapter for more information

    • Error 0318- AC Zeromark Y (Permanent Light)

      • Y-axis zeromark- sensor defect

      • Defect on X-board, or interruption between X-board and masterboard

      See zeromarks chapter for more information

    • Error 0319- AC Fault ( Zeromark X wrong)

      Common causes

      The zero mark sensor is broke.

      The beam can be out of square so it hits stop bumper before it gets to the sensor.

      Sensor came loose.

      Sensor is dirty

      Sensor can be bad.

      To check the sensor you will need to remove the right hand side cover. The sensor is a small black C shape device that is located on a bracket just below the control panel.

      Inspec the sensor for damage.

      If no damage then next on the beam you will see a black flat plate with a slot in it, pull beam forward and see if the slot will reach the sensor before hitting the beam stops. If it doesnt reach then your beam is out of square. ( see beam squareing section )

      If not broke and beam is not out of square try cleaning the sensor with q-tip and cleaning solution.

      If none of the above are the problem then sensor is bad and needs to be replaced.

      Replacment zero mark sensor is part number 3110050

    • Error 0320- AC Fault (Zeromark Y wrong)

      Common causes

      The zero mark sensor is broke.

      Sensor came loose.

      Sensor is dirty

      Sensor can be bad.

      To check the sensor it is a small black C shape device that is located on the front of the beam about 12 inches to the left from the right hand side of table.

      Inspec the sensor for damage.

      If not broke cleaning the sensor with q-tip and cleaning solution.

      If none of the above are the problem then sensor is bad and needs to be replaced.

      Replacment zero mark sensor is part number 3110051

    • Error 0321- AC Fault ( DPR Check)

      • Dualported RAM error detected (AC part of the system)

      -If this error comes more than once, exchange the master board

      Call Helicon for serive help 

    • Error 0322- AC Fault (MC Version too low)

      • THe MC (MasterController) software version is incompatible to the currently used AC (AxisController) software version

      - Turn off plotter and use compatible versions 

    • Error 0323- AC Fault (Check EPROM in AC)

      • Defect in a AC- EPROM (wrong checksum)

       - Exchnage AC-software

    • Error 0324- AC Fault (Status in DPR fault)

      • Wrong Status (AC-side of the dualported RAM)

      - If this error occurs more than once, exchange the master board

      Call Helicon for service help

    • Error 0325- AC Fault ( Pos. Gliding Disc)

      • RzP potentiometer measuring system defective (gliding disk)

      • Measurment out of range (adjustment)

      • Noise

      - Check the adjustment 

      Error can be forced by pushing gliding disk to the upper limit 

      WARNING! Touch Rzp carefully when plotter is switched on. The Z-axis is very powerful!

    • Error 0326- AC Fault (Timeout Z-axis)

      • Z- axis blocked or potentiometer meaursing system disadjusted 

      (electrically the T-axis is used to drive the RzP Z-axis)

      - Switch off plotter and check Z-axis (moving by hand)

      - Check the adjustment 

      WARNING! Touch Rzp carefully when plotter is switched on. The Z-axis is very powerful!

    • Error 0327- AC Init- Fault Z- Pen (Try to remove tool)

      • Z-axis blocked by the toolholder

      - Switch off plotter and remove tool holder

      - Reinsert toolholder after the initializaton process

    • Error 0328- AC Fault (Out of range: -5V)

      • -5V out of tolerance, caused either by a out of tolerance +5V or by a defect on the amplifier board

      - Check +5V (refer to "Powersupply M-line")

      - If +5V is OK, replace the amplifier board 

      Problems with the +5v can cause further effects. It is recommended to solve the +5V problems first.

    • Error 0329- AC Fault ( Out of range +12V)

      • +12V supply out of tolerance or defective fuse

      - Check fuse F11 on the amplifierboard, check +12V

      The message can be surpressed with AC DIP-Switch 1 "on"

      Please contact us if you are using this feature. 

    • Error 0330- AC Fault (Out of range +24V)

      • +24V supply out of tolerance or defective fuse 

      - Check fuse F12 on the amplifierboard, check +24V 

      This message can be surpressed with a AC DIP- switch 1 "on"

      Please contact us if you are using this service.

    • Error 0331- AC Fault (Out of range +53V)

      • +53V supply out of tolerance or defective use 

      - Check fuses F8, F9, F1 and F13 on the amplifierboar, check the +53V

      This message canbe surpressed with AC DIP- switch 1 "on"

      Please contact us if you are using this service. 

    • Error 0345- AC Fault RzP-Init blocked

      • RzP initialzing speed too low

      - Check for a blocked dust absorber or Z-axis 

      If this message comes after power on, the meausring system connected to the dust absorber has an error 

      If this messages comes after RzP-initialzing command, a possible cause is that the dust absorber doesn't move or moves too slow downward 

       

  • Kongsberg Cutting Tables

    • Fuse Location

    • Error 3006- Servo-lag X1-Axes

      This issue is rarely the fuse, but check the fuse first (see fuse location document)

      • Connections on the motor came loose - check the two power wires and the encoder cable

      • Most common cause - bad brushes in the X1 motor (Helicon part #2002)

      • Following common cause - bad motor (Helicon part #2001)

      The X1 motor is located on the non-work station side (left side). 

       

    • Error 3056- Servo-lag X2-Axes

      This is issue is rarely the fuse, but check the fuse first (see fuse location document)

      • Connections on motor came loose- check the two power wires and the encoder cable.

      • Most common cause - bad brushes in the X2 motor (Helicon part #2002)

      • Following common cause - bad motor (Helicon part #2001)

      The X2 motor is located on the work station side (right side). 

    • Error 3007- Servo-lag Y-Axes

      This issue is rarely the fuse, but check the fuse first (see fuse location document)

      • Connections on the motor came loose- check the two power wires and the encoder cable 

      • Most common cause - bad brushes in the Y motor (Helicon part #2002)

      • Following common cause - bad motor (Helicon part  #2001)

      The Y motor is located behind the tool head by the saftey light.

    • Error 3057- No Movement Y Axes

      This issue is rarely the fuse, but check the fuse first (see fuse location document)

      • Check output to Z motor 

      • Check encoder feed back 

    • Error 3078- Servo-lag on X1 on"SCU"

      This issue is rarely the fuse, but check the fuse first (see fuse location document) 

      X1 axis has not reached the expected position 

      • Check output to X1 motor 

      • Check encoder feedback (check encoder cable)

    • Error 3039- Tool Holder to low or Material to thick

      Try to remove insert tool that is not currently in use.

       One of the other tools may hit the matieral when the active tool is lowered

      -Remove tool that is so long it will hit the material even when not used 

    • Error 3101- Tool Returned Illegal Identification Code

      Tool head identification values are outside legal ranges.

      • Check inputs in Technical Manual 

    • Error 1003- Block not finished

      • Operator has tried to make a manual operation while the machine is in "Run" mode

    • Error 1004- Safety Switch

      • Photocell safety has been activated
    • Error 1005- No input file selected

      • Operator has pressed start but no input file has been opened 

    • Error 1010- Outside Table Limit

      One or more axis has been programmed outside the sw limits.

      • Check reference point

      - If persistent check ruler positions 

  • i-Cut software

    • There's a blue screen on the i-Cut camera window

      The blue screen is a result from loss of video feed

      • Check coax cable connections on back of PC and camera

      • Break in coax cable - use a multimeter and tone out the coax cable

      • No power to camera - check that camera light is on

      • Check if the Epix Card in PC has came loose in the socket or if it is bad 

    • Error -1 when using the i-Cut camera system

      Possible solutions:

      • Epix Card driver error - restart PC

      • The driver might have been corrupted by software - update and reinstall driver

      • The Epix Card is bad - go to the device manager and check that the Epix Card is displayed as an imaging device

  • HP Flatbed Printers

    • 1) Why is Ink dripping from my print heads?

      This occurs most frequently on the FB950s.

      • Most common cause: Air getting into the ink reservoir

      -The vacuum that holds the ink inside the reservoir is compromised by an air leak

      The reason it is more common on the FB950 is the type of reservoir is uses and the amount of caps and thermistors. If any of the fittings on the reservoir are loose air is getting in.

      Usually, it is just a matter of removing the carriage cover and checking all the fittings on all the ports on the reservoir. Normally you can find one that is loose, which would be the cause of the problem.

    • 2) Why is Ink dripping from my print heads?

      • Second most common cause: Ink has been drawn up the vacuum tubes blocking the vacuum

      -This can happen from an ink overfill or again due to an air leak somewhere on the reservoir

      - It can also happen if the thermistor which tells the printer that the reservoir is full is not working

      The printer will continue to try and fill the reservoir until the rises to the point that it is being drawn up the vacuum tubes

      In this case you need to go into tools and service printer and carriage tests or ink tests. You should find thermistors. Open that menu and it will tell you if it thinks the reservoir is full or it will say "air." If it says "air" it thinks the reservoir is empty, then your thermistor is bad.

    • 3) Why is Ink dripping from my print heads?

      • Reservoirs on FB950s can actually come apart at the seams

      -If you look closely you can see the gap, normally at the top of the reservoir

      -Replace the reservoir

      • Air leaks can also develop if the print head is not tightened onto the reservoir securely

      -At each end of the print head on the bottom of the carriage is a socket head cap screw (it will be the one more in the center and not the one off to one side)

      -Raise the carriage and use an Allen wrench to try and tighten it more on each end of the print head

      These are the most common reasons this happens and the most common fixes for this problem. If you have tried all of these steps with no change then it could be a bad “O” ring on one of the thermistors, or even the print head itself. For these service issues a technician should be called in.

    • Why have I lost all of one color?

      • The cause of this is from an air leak

      -It's most likely very slight and commonly one of the “O” rings on one of the thermistors

      Check all the things listed above. Check the thermistor information in “tools." (This is explained in question '2) Why is ink dripping from my printer heads?')

      The printer may think the print head is full and not attempt to fill it. If it says “air” then the thermistor is working.

      • Another cause could be an ink pump is not working

      -Try doing an ink fill on that color and listen for the ink pump to come on

      The ink pump is the first pump to activate on an ink fill. The loud pump sound which follows is the air pressure pump. If you do not hear the low murmur of the ink pump right away once the process begins, your ink pump is not working.

    • Carriage Motion Failure

      This can be caused by a multitude of problems:

      Motor, encoder strip, encoder reader, drive belt on the carriage motor, or the belt tensioner on the service end of the rail

      • Any time the carriage does not read the encoder strip properly it will stop and give a carriage motion failure

      -Clean the encoder strip first and see if it goes away

      • Look behind the carriage with a flash light to see if there is a buildup on the encoder reader

      -Clean the encoder reader

      • Check the drive belt on the user end of the rail to see if it is worn or loose

      In Tools then Diagnostics, you will find carriage motion tests. Once you have cleaned the encoder strip run the various tests that it prompts you to run. If during the slow motion test it keeps stopping in the same spot you need a new encoder strip.

    • My FB950 doesn’t want to boot up, I have to try several times and it is very slow- why?

      • Unplug the video net cable coming from the computer and try again

      If this is becoming a regular problem with your FB950 and it continues to wait to connect to the computer before booting, the most likely cause is that if it can't find the computer and in many cases it will not boot. 

    • Banding

      • Common cause: Missing nozzles

      -Run a prime bar or nozzle check

      • Common cause: Media feed calibration needs to be redone

      • Common cause: Missing nozzles do a purge

      - If they do not come back, try cleaning the print head with a lint free cloth and head flush by hand.

      - If they are still missing, run jet mapping to map out and the printer will replace the missing nozzles with working ones. 

      If you know someone with an ultrasonic head cleaner you can get them cleaned and most of the time the clogged nozzles will open up. You will need a technician to remove them and re-install them once they are cleaned.