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The replacement method for Ray5 20W and Ray5 40W is similar. This example uses the Ray5 40W.

1. First, disconnect the cables connected to the motors, limit switches, and laser module. Then use an M5 hex wrench to loosen the screws securing the control box and remove the control box.

2. Use an M2 hex wrench to loosen the screws on the back panel of the control box and open the control box.

3. Disconnect the combo cable from the mainboard.

4. Insert the new cable into the corresponding ports. The combo cable is labeled for easy identification.

5. Close the control box, tighten the back panel screws with an M2 hex wrench, reinstall the control box onto the machine, and reconnect the cables for the motors, limit switches, and laser module.

Replacement complete.

1. Use an M5 hex wrench to loosen the screws securing the control box and remove the control box.

2. Use an M2 hex wrench to loosen the screws on the back panel of the control box and open the control box.

3. Disconnect or unscrew the cables on the mainboard.

4. Use an M2.5 hex wrench to loosen the screws on the motion sensor and flame sensor (for Ray5 40W, only the flame sensor needs to be replaced). Remove the old sensor and replace it with the new one. Use the M2.5 hex wrench to secure the screws, then reconnect the original cables.

5. Close the control box, tighten the back panel screws with an M2 hex wrench, and reinstall the control box onto the machine.

Replacement complete.

Step 1: Basic inspection (SD card and slot)
Card type: The motherboard supports MicroSD cards (TF cards). Make sure the card fits securely in the slot.
Physical contact and cleaning:
Gold finger oxidation: Remove the SD card and gently wipe the metal contacts (“gold fingers”) with a cotton swab dipped in a small amount of anhydrous alcohol. Wait until it’s completely dry before reinserting.
Slot condition: Check the SD card slot on the engraver’s mainboard for physical damage, dust, or debris. You can use an air blower to clean it carefully.
Poor contact: When inserting the SD card, ensure it is fully inserted and that you hear or feel a slight “click” indicating it’s locked in place.

Step 2: File and engraving settings inspection
If the SD card is recognized but files cannot be read or “access is denied”:

File name and format:
File name: Use simple English letters or numbers. Avoid Chinese characters, special symbols (like @#$%^&), or long filenames.
File format: Make sure the file format is supported by the engraver’s mainboard — it should be .nc, .gc, or .gcode. Check that your laser software (e.g., LightBurn) exports the correct format when saving to the SD card.

File path:
Do not place files in nested folders. It’s best to store G-code files directly in the root directory of the SD card, as the firmware may not support reading from subfolders.
Encrypted files: Encrypted files cannot be loaded.

G-code content:
Sometimes a file may be corrupted or contain special commands that the engraver’s firmware cannot recognize.
Troubleshooting: Try using a very simple, newly generated G-code file for testing, such as one that only engraves a square. If the simple file is recognized, the original file may be the issue.

Step 1—Identify the Type of Noise

Different sounds usually point to different root causes. Listen carefully:

High-pitched whining/electrical buzzing: Often occurs when the motor is idle or at low speed. Usually related to driver current settings or microstepping configuration.

Vibration/resonance (hum): The motor produces a loud buzzing while running and the whole machine may vibrate. Often caused by mechanical resistance, incorrect current, or acceleration/speed settings.

Regular “clicking” or “clunk” sounds: rhythmic impacts or skipping. Usually mechanical jamming, physical collisions, or severe missed steps.

Irregular grinding / rubbing noises: Could be bearing failure or foreign objects inside.

Step 2—Mechanical Inspection (first priority)

Most noise problems come from mechanical issues.

Clean & lubricate (first task)

Power off. Manually push the laser head (X axis) and the gantry (Y axis) to feel for uneven resistance. Any sticking suggests dirty guide rails or shafts.

Clean: use swabs and anhydrous alcohol to thoroughly clean all rails and shafts.

Lubricate: after cleaning, apply a dedicated linear-rail lubricant or white lithium grease.

Timing belt check

Tension: A loose belt causes vibration and missed steps; a too-tight belt increases motor load, heat, and noise. Press the belt mid-span—it should have moderate give (typically 5–10 mm deflection). It should not be taut like a guitar string nor floppy.

Condition & routing: Make sure the belt is seated on pulleys and shows no edge wear or cracking.

Coupler check

A loose coupler (between the motor shaft and lead screw/pulley) will make a sharp “clack” when reversing.

With power off, check that the coupler set screws are tightened.

Bearings / linear blocks

If, after cleaning and lubrication, manual movement still feels gritty or sticks, linear bearings or the motor’s bearings may be damaged.

To confirm, remove the carriage or motor and spin components individually. This is more advanced—seek professional help if unsure.

Step 3—Electrical & Driver Inspection

If mechanical parts are OK, inspect motor-driver interaction.

Driver current settings (one of the most common causes)

If driver current is too low, the motor lacks torque → buzzing and missed steps.

If the current is too high, the motor overheats and noise increases; there is a risk of damage.

Adjust driver current to the motor’s specifications.

Motor cables

Poor contacts or internal breaks can cause phase loss or incorrect phase sequencing → violent vibration and noise.

Reseat all motor connectors and inspect cables for damage.

Step 4—Software & Motion Parameter Tuning

Software parameters control how the motor moves.

Acceleration and max speed set too high

If acceleration or max speed exceeds the mechanical capability, the motor will struggle to follow commands → violent vibration and loud noise.

In your laser control software (LaserGRBL, LightBurn, etc.), dramatically reduce the axis acceleration and max speed to test. This is a highly effective debugging step. Start with a low acceleration (for example, try a low provisional value) and slowly increase until you find a stable setting.

Motor direction / signal interference (less common)

Strong electromagnetic interference can disrupt control signals.

Keep motor power cables separated from control or limit-switch signal cables. Use shielded motor cables if needed.

Step 1: Basic Inspection and Cleaning

Check for Physical Obstructions

Visual Check: Carefully inspect the entire movement path of both the X and Y axes for any debris or objects blocking movement (such as engraving residue, loose screws, or tools).

Manual Push Test: With the machine powered off, gently push the laser head (X-axis) and the gantry (Y-axis) by hand. They should move smoothly.

If one axis is jammed or hard to move, it’s likely a mechanical issue.

Check the Timing Belts

Ensure the belts are not too loose or too tight. 

A loose belt may cause skipped steps or misalignment.

An overtightened belt increases motor load and may prevent movement.

Also inspect for cracks, fraying, or missing teeth.

Clean and Lubricate Rails and Carriages

Cleaning: Use cotton swabs and anhydrous alcohol to clean the round shafts or linear rails, removing any dust, oil, or debris.

Lubrication: Apply linear-rail lubricant or white lithium grease after cleaning.

⚠️ Do not use WD-40 or other penetrating oils — they’re too thin, evaporate quickly, and attract dust.

Step 2: Cable and Connection Inspection

Motor Cable Check

Confirm that the X- and Y-axis stepper motor cables are firmly plugged in at both the motor and mainboard ends.

Re-seat (unplug and replug) the connectors.

Inspect the cables for bends, cuts, or pinching, especially near moving parts.

Mainboard Connector Check

Ensure that the X-axis and Y-axis motor connectors are plugged into the correct sockets on the control board and are not loose.

Step 3: Electrical Component Diagnostics

If mechanical parts and cables look fine, test the electrical components using the cross-swap method.

Cross-Swap Test (Key Diagnostic Step)

Laser engravers typically use identical stepper motors and drivers for the X and Y axes.

Swap Motor Cables:

Unplug the X-axis motor cable and connect it to the Y-axis motor.

Try to move the X-axis in software.

If the Y-axis motor now moves, the X-axis motor is fine, and the issue is in the driver or cable.

If it still doesn’t move, the X-axis motor may be faulty.

Check Motor Resistance (Advanced):

Use a multimeter to measure coil resistance.

The two coil pairs should show similar resistance values. 

Infinite (open) or zero (short) resistance indicates a burned or damaged motor.

Check the stepper driver (if a separate module):

If swapping motors transfers the problem from X to Y, the driver is defective.

If the issue stays on the same axis, the driver is fine—the fault may be in the mainboard or motor.

Observe driver LEDs—a dead or unlit indicator means no power or internal fault.

Check the Mainboard:

1.  If both the motor and driver are confirmed good but the axis still won’t move, the mainboard output for that axis may be damaged.

Usually requires mainboard replacement.

Step 4: Software and System Check

Emergency Stop & Limit Switches

Ensure the emergency stop button is released and not stuck.

Check all limit switches:

If a limit switch is falsely triggered, the system locks that direction.

Inspect for bent arms, stuck levers, or broken wires.

Check wiring for loose or shorted connections.

In software (LaserGRBL or LightBurn), open the “Status” panel—if a limit shows “triggered,” it must be fixed before movement is allowed.

Reset the Control System

Power off the machine completely.

Wait for about one minute, then restart.

Temporary firmware errors (in GRBL, for example) can sometimes cause axis lockups that clear after rebooting.

How to Troubleshoot When the Machine Fails to Work Properly After Powering On

Phase 1: Basic Inspection

This stage addresses the most common and easily overlooked issues.

1. Power and Physical Connection Check

Main Power and Emergency Stop Switch:

Confirm: Is the wall socket powered? Is the machine’s power cable securely plugged in?

Check: Is the machine’s own power switch turned on?

Most Important Step: Has the emergency stop button been pressed? If yes, rotate it clockwise to release it.

Internal Cables:

Check: Open the control box and inspect the power and data cables of the mainboard, laser power supply, and stepper motor drivers. Look for loose connections, disconnections, or burn marks.

2. Software and Communication Check

Software Connection Status:

Confirm: Has your laser engraving software (such as LightBurn or LaserGRBL) successfully connected to the control board? The software interface usually displays a connection indicator.

Port and Driver:

In Device Manager, check whether the COM port corresponding to the control board appears normally and has no warning icons (driver issues).

Try reconnecting the USB cable or using a different USB port.

Configuration and Settings:

Confirm: Did you select the correct device model and COM port in the software?

Check: Are engraving parameters (such as laser power and speed) set correctly? (Laser power should not be 0.)

Manual Control Test:
In the software’s Manual Control or Laser Control panel, try:

Clicking X+, X-, Y+, Y- to check if the machine can move and whether the directions are correct.

Clicking “Fire” or “Test” to see if the laser emits light.

⚠️ Note: Do not place materials during the test. Ensure proper focus to avoid fire hazards.

Conclusion from this step:

If movement works but no laser output → Problem likely in the laser module.

If neither movement nor laser output → Problem likely in the mainboard, power supply, or communication.

If movement and laser output are normal → Problem likely in the engraving file or software settings.

3. Basic Mechanical Condition Check

With the power off, gently push the laser head along the X-axis and Y-axis by hand.

Check if there is excessive resistance or if anything is stuck.

Inspect timing belts for proper tension — not too loose or too tight.

Phase 2: In-Depth Hardware Troubleshooting

If all basic checks are normal, proceed to inspect specific hardware modules.

1. Motion System Troubleshooting (Axis Not Moving or Moving Abnormally)

Limit Switches:

Check: When powered on, does the machine move immediately in one direction and hit the limit switch?

This may indicate the limit switch wiring is shorted (always triggered) or motor direction is incorrectly set.

Multimeter Test:

With power off, use a multimeter in continuity mode to test the limit switch.

It should show open circuit when untriggered and connected when pressed.

3. Control Core Troubleshooting (Mainboard)

Mainboard Power Supply:

Verify that the mainboard’s supply voltage (usually 12V or 24V) is stable and normal.

Firmware Status:

Try reflashing or updating the control board firmware (follow the manufacturer’s instructions carefully).

Physical Damage:

Carefully inspect the mainboard for signs of capacitor bulging or burnt components.

Summary: Quick Diagnosis by Symptoms

No Response at All (fan not spinning, lights off) → Power cable, main switch, emergency stop, or internal fuse.

Software Connection Failed → USB cable, COM port, driver, or software settings.

Connected but Motors Don’t Move → Mainboard power supply, motor enable signal, or firmware.

Motors Move but No Laser Output → Laser power supply, PWM control signal, or laser diode.

Moves Erratically Upon Startup → Limit switch wiring error or motor direction misconfiguration.

Stops Mid-Job → USB interference, motor overheating protection, overly complex graphics file, or poor cooling.

1) Manually moving the laser position during engraving causes limit triggering.

2) When you click Stop during engraving, this error will be reported, which is normal.

3) When engraving an image or vector filling at the current position, if the overscan function is turned on, the soft limit may be triggered, and the engraving may not be possible. You need to change the coordinates to absolute coordinates. If you do not change the coordinate system, then reduce the pattern and put it in the middle, or turn off the overscan function.

4) The machine continuously detects the signal of the limit switch, resulting in a zeroing abnormality. The solution is to confirm that the XY axis does not hit the limit switch after the XY axis completes zeroing.

Core Principle
The rotation direction of a motor is determined by two factors:

Motor wiring sequence—the physical wiring determines the motor’s default rotation direction.

Direction control signal—the mainboard sends a signal through software or firmware to tell the driver whether to rotate forward or backward.
To correct a reversed motor, you simply need to make the control signal match the wiring.

Step 1: Check and adjust software settings (the quickest method)

Open your control software (such as LightBurn).
Go to Device Settings or Machine Settings (usually found under Edit > Device Settings or Machine > Machine Settings).
Look for settings related to “Axis Mapping” or “Motor Direction.”
You will see options for the X and Y axes, usually with checkboxes like “Invert X Axis,” “Invert Y Axis,” or “Reverse Direction.”
Check the box for the axis that is rotating in the wrong direction.
Click “OK” to save the settings.
Use the software’s jog control function to test whether the direction is now correct.
If your software doesn’t offer this graphical option, or if it doesn’t work, continue to the next step.

Step 2: Adjust firmware parameters (the fundamental solution)

The mainboard of your laser engraver (such as GRBL, Smoothieware, or Marlin) stores configuration parameters internally. You can modify the motor direction directly by sending specific G-code commands.
Required tool: any software that can send G-code to the engraver, such as LaserGRBL or LightBurn. Normally, this is done through the “Console” or “Terminal” window in your laser software.
Connect your engraver to the computer and open LightBurn.
Go to Edit → Machine Settings → Output Settings → Select the X Direction pin invert ($3) (or Y Direction pin invert ($3)) to adjust motor direction. → Write → OK. 

The default parameter value is “false” (normal direction). If set to “true,” the axis direction is inverted.
To modify direction parameters:
If you need to reverse the X-axis, set the X Direction pin invert ($3) to “true,” then write the change.
If you need to reverse the Y-axis, set the Y Direction pin invert ($3) to “true,” then write the change.

Important: Since your motor is currently reversed, you need to apply the opposite of its current setting.
The simplest method: regardless of the current value, toggle it to the opposite until the motor moves in the correct direction. For example, if the X-axis is reversed, select “true.” Switching back and forth will always yield the correct direction.
Test: use the jog control to confirm the correct direction. If correct, the problem is resolved.

Step 3: Physical adjustment

If the above software methods don’t work, you can reverse the motor direction by changing the wiring order—a hardware-level solution.
Power off: Make sure the laser engraver is completely powered off.
Locate the motor wire: find the wire connected to the motor that rotates in the wrong direction.
Adjust the wiring sequence: swap any one pair of the motor’s four wires (e.g., swap A+ and A− or B+ and B−). This will reverse the rotation direction physically. Then power on and test again.

The flame sensor can be easily triggered. When the flame sensor is triggered, the LightBurn

The console will display an alarm 3. This may be due to ignition during use, strong light exposure, settings

issues, short circuits, or damage. Please refer to the following settings for inspection:

Avoid open flames during the engraving process. If an open flame occurs, please reduce the laser

power.

Place the engraving machine in a normal indoor environment, avoiding direct exposure to strong

lights such as flashlights or sunlight.

Adjust the flame trigger threshold. First, run the LightBurn or LaserGrbl software, connect the

engraving machine to the PC via USB, and enter $42=1300 in the control command panel and press

Enter to lower the trigger threshold. If it still triggers, you can continue to reduce the $42 threshold

and send it.

If the flame sensor is triggered at the start of engraving, it may be due to a short circuit between the

sensor’s metal pins and the metal casing. Please manually adjust the position of the flame sensor

behind the control box to prevent contact between the metal pins and the casing (the flame sensor is

a black cylindrical probe located at the back of the RAY5 control box); if ineffective, you can send the

command $38=0 in the LightBurn or LaserGrbl console to disable the flame sensor function (to

30. Enable it again; send the command $38=1.

 The motion sensor may be triggered due to machine movement during use, settings issues, or

sensor damage. Please refer to the following settings for inspection:

Check that the engraving machine is placed on a stable surface to avoid movement during operation.

Adjust the motion sensor trigger threshold. First, run the LightBurn or LaserGrbl software, connect

the engraving machine to the PC via USB, and enter and send the commands $40=200 and $41=40 in

the control command panel to lower the sensor trigger threshold.

If the motion sensor is continuously triggered at the start of engraving, it may be due to the sensor.

damage. You can send the command $39=0 in the LightBurn or LaserGrbl console to disable the

motion sensor function (to enable it again, send the command $39=1)

I. Software and Connection Issues (Most Common)

1. Data Transmission Interruption (USB/Cable Issues)
Cause:
This is one of the most common causes. Poor-quality USB cables, loose connections, overly long cables, or interference can cause brief interruptions in data transmission, leading the machine to stop.

Troubleshooting:

Reconnect both ends of the USB cable (computer and engraver).

Try using a high-quality, shielded, and as short as possible USB cable.

Keep the USB cable away from power cords and motor cables to avoid interference.

If using a network connection, check for network stability.

2. Computer or Software Issues
Cause:
Insufficient computer performance, system freezing, unresponsive software, or conflicts with other programs.

Troubleshooting:

Restart the software and computer — this is often the simplest and most effective fix.

Check the computer’s power management settings: ensure the system is not in “Power Saver” mode to prevent USB ports or hard drives from sleeping.

Lower the data output speed: in your laser engraving software (e.g., LightBurn), look for the “Output Frequency (kHz)” or similar setting. If it’s too high (above 20 kHz), reduce it to improve stability.

Open Task Manager while running the job to check whether CPU or memory usage is maxed out.

3. File or Design Issues
Cause:
The design file is overly complex, contains too many small line segments or points, or the G-code file is corrupted.

Troubleshooting:

Optimize the design: use “Combine,” “Simplify Path,” or similar tools in vector software to reduce unnecessary nodes.

Check for stray points: zoom in on your design to locate and delete tiny, irrelevant points or lines that may cause empty movements.

Regenerate the G-code: save the file as a new version or re-export it from the software.

II. Electrical and Hardware Issues

1. Power Supply Problems
Cause:
Unstable power supply to the laser engraver or computer.

Troubleshooting:

Check that all power plugs are firmly inserted.

Confirm that the voltage selector switch on the engraver is set correctly (110V/220V).

Avoid sharing a power circuit with other high-power appliances (e.g., air conditioners) that can cause sudden voltage drops.

2. Overheat Protection
Cause:
The laser module, stepper motor driver, or mainboard overheats, triggering an automatic safety shutdown.

Troubleshooting:

Check whether all cooling fans (laser, mainboard, and motor drivers) are running properly.

Ensure good ventilation in the workspace and avoid high ambient temperatures.

3. Motor Stall or Step Loss
Cause:
If machine movement is obstructed or the load is too heavy, the motor cannot reach its commanded position, and the controller triggers an emergency stop.

Troubleshooting:

Check that guide rails and belts are properly tensioned—not too tight or too loose.

Clean rails of dust and debris and apply suitable lubrication.

Check for any foreign objects blocking the laser head or gantry movement.

Reduce the motor “acceleration” setting in the software to allow smoother start/stop motion.

4. Limit Switch False Trigger
Cause:
The machine accidentally triggers a limit switch during operation, which causes an emergency stop and reset.

Troubleshooting:

Check whether the limit switch lever is loose.

Inspect cables for damage that could cause short circuits or false signals.

Move the laser head manually—if you hear a “click” before reaching the end, the limit switch may be triggering too early.

III. Control Board and Firmware Issues

1. Control Board Malfunction
Cause:
The components on the control board may be aged, damaged, or affected by static electricity.

Troubleshooting:

Observe the indicator lights on the control board when the machine stops—abnormal blinking or power loss may indicate a fault.

Restart the control board by turning the machine off and back on.

If possible, try refreshing or updating the firmware.