Renishaw NC4+Blue Laser Tool Alignment Instrument Installation, Calibration, and Maintenance Practical Guide

#Renishaw NC4+Blue Laser Tool Alignment Instrument Installation, Calibration, and Maintenance Practical Guide

&Gt; * * Document Version * *: V1.0
&Gt; * * Applicable systems * *: FANUC/MITSUBISHI MELDAS and compatible CNC systems
&Gt; * * Applicable products * *: Renishaw NC4+Blue series non-contact laser tool setter
&Reference Manual: NC4+Blue Installation Guide (Renishaw), NC4+Blue Data Sheet, NCTS Programming Manual H-2000-6656-19-B, NCi-6 Interface Installation Guide H-6516-8500
&GT; * * Compilation Unit * *: Technical Department of Ningbo Jiangce Technology Co., Ltd
&Gt; * * Release Date * *: July 13, 2026

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catalogue

1. [Overview and Security Statement] (# 1- Overview and Security Statement)
2. [NC4+Blue Hardware Explanation and Selection] (# 2-nc4-blue Hardware Explanation and Selection)
3. [NCi-6 Interface Unit and Working Mode] (# 3-nci-6 Interface Unit and Working Mode)
4. [Air System and Installation Preparation] (# 4- Air System and Installation Preparation)
5. [Mechanical Installation and Wiring] (# 5- Mechanical Installation and Wiring)
6. [Laser Beam Alignment (O9860)] (# 6- Laser Beam Alignment o9860)
7. [System Calibration Process (O9861)] (# 7- System Calibration Process O9861)
8. [Macro Programming Reference] (# 8-Macro Programming Reference)
9. [Daily Maintenance and Care] (# 9- Daily Maintenance and Care)
10. [Common Troubleshooting and Diagnosis] (# 10- Common Troubleshooting and Diagnosis)
11. [Precision Best Practices] (# 11- Precision Best Practices)
12. [Conclusion and Reference Documents] (# 12- Conclusion and Reference Documents)

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## 1. Overview and Safety Statement

###1.1 What is NC4+Blue

The Renishaw NC4+Blue series non-contact laser tool setter is a high-precision, high-speed non-contact tool setter and tool breakage detection system designed specifically for vertical machining centers, horizontal machining centers, composite five axis machine tools, and large gantry machining centers. Unlike traditional contact type tool presetters (such as TS27R, RTS, OTS) that rely on mechanical triggering for measurement, NC4+Blue adopts the principle of laser beam passing detection – when a rotating tool passes through the laser beam, the system detects the moment when the beam is cut, thereby accurately determining the geometric dimensions and position of the tool.

The core technology upgrade of NC4+Blue lies in the use of * * 405 nm blue laser * * (compared to the previous generation NC4’s 670 nm red laser), which has significantly better penetration and anti-interference ability in cutting fluid mist and metal chip environments. The short wavelength characteristic of blue laser makes it scatter less and the signal more stable when encountering droplets and dust. All NC4+Blue products comply with the Class 2 laser product standard (IEC 60825-1:2014), with a maximum output power of less than 1 mW, and are safe for operators under normal usage conditions.

###1.2 Applicable Scenarios

The NC4+Blue series covers the full spectrum of requirements from micro precision machining to large-scale mold processing:

-F100-10 (beam Ø 5 μ m): Suitable for extreme precision scenarios such as micro drills (Ø 0.05 mm or less), micro milling cutters, and clock parts processing
-F100 (beam Ø 15 μ m): Suitable for detecting small cutting tools such as precision molds and medical devices
-F115 * (beam Ø 30 μ m): a standard vertical machining center with universal configuration, balancing fine and universal machining
-F145 * (beam Ø 50 μ m): Optimal choice for horizontal machining centers and universal milling
-F230 (beam Ø 100 μ m): Large vertical/horizontal additive, suitable for medium and above diameter cutting tools
This guide is based on Renishaw’s official technical manual (NC4+Blue installation guide and NCTS programming manual H-2000-6656-19-B), combined with the technical team’s years of on-site debugging experience, aiming to provide complete installation, calibration, maintenance, and troubleshooting references for equipment installation and debugging engineers and on-site maintenance personnel.

###1.2 Safety precautions and disclaimer

The numerical control system parameters and macro program calls (O9860/O9861/O9862, etc.) involved in this article are all based on Renishaw standard non-contact tool alignment macro program logic. Due to differences in PLC ladder diagram control logic, secondary development variable addresses, and coordinate system settings among machine tool manufacturers (Mazak, Demage, Makino, Haas, and domestic brands), * * before the first machine debugging or running any calibration macro program, please strictly follow the following precautions:**

1. Switch the machine to “Dry Run” mode and limit the fast moving channel magnification (G00) to below 5%.
2. Pay close attention to the relative movement direction between the tool and the NC4+Blue body, and do not leave the Single Block and emergency stop button with your hands.
3. * * Laser Safety * *: NC4+Blue is a Class 2 laser product (405 nm,<1 mW). Do not look directly at the laser beam, ensure that the beam is not reflected by the reflective surface inside the machining center (such as the machined surface of the workpiece or the mirror blade) to the eyes. Renishaw permanently affixes laser warning labels (as required by BS EN 60825-1:2014) on both sides of the Tx transmitter, along with an adhesive warning label. It is recommended to affix it in a prominent position outside the machine tool.
Before performing any wiring or maintenance operations on the NCi-6 interface unit, be sure to cut off the power supply.
Before cleaning the optical lens, the power must be cut off and the air pressure must be adjusted to zero.

The technical information provided is for industry experience exchange only, and we do not assume any legal or economic responsibility for physical collisions or workpiece scrapping caused by directly copying code or parameters.

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## 2. NC4+Blue Hardware Detailed Explanation and Selection

###2.1 Complete Model Parameter Comparison Table

The model system of the NC4+Blue series is named after the "F+value", which corresponds to the beam projection spacing (B-size, Tx and Rx spacing) in millimeters. The B-size of each model is shown in the following table:

|Model | Beam diameter | Beam spacing B | Repetitive positioning accuracy (2 σ) | Minimum detectable tool | Applicable model reference|
|:—-|:——–|:———-|:—————–|:————-|:———–|
|F100-10 | Ø 5 μ m (197 μ in) | 140.0 mm | ± 0.10 μ m (4 μ in) | Ø 5 μ m | Micro machining center|
|F100 | Ø 15 μ m (591 μ in) | 140.0 mm | ± 0.10 μ m (4 μ in) | Ø 15 μ m | Precision machining center|
|F115 | Ø 30 μ m (1181 μ in) | 155.0 mm | ± 0.50 μ m (20 μ in) | Ø 30 μ m | Standard vertical machining center|
|F145 | Ø 50 μ m (1968 μ in) | 185.0 mm | ± 0.50 μ m (20 μ in) | Ø 50 μ m | Standard vertical/horizontal machining center|
|F230 | Ø 100 μ m (3937 μ in) | 270.0 mm | ± 0.75 μ m (30 μ in) | Ø 100 μ m | Large vertical/horizontal machining center|
|F300 | Ø 200 μ m (7874 μ in) | 340.0 mm | ± 0.75 μ m (30 μ in) | Ø 200 μ m | Longmen Machining Center|

**Repetitive accuracy explanation * *: The accuracy values in the table are ± values, marked with a 2 σ statistical standard. This is the nominal value of Renishaw under standard testing conditions (standard core rod, standard feed rate, standard temperature conditions). In actual machine tools, due to the influence of mechanical accuracy and environmental factors, the comprehensive tool accuracy is usually lower than the nominal value.

###2.2 Detailed explanation of hardware composition

The NC4+Blue body consists of the following core components:

**Transmitter Head (Tx) * *:
-Blue semiconductor laser (wavelength 405 nm, maximum output power10 μ m → Mechanical fine-tuning needs to be repeated
-Return value far exceeds (e.g. hundreds of μ m) → Check if the adjustment board is installed roughly parallel and if the Tx/Rx head is loose

O9860 only provides deviation indication and does not automatically compensate. After discovering the deviation, it is necessary to mechanically adjust the position and angle of the NC4+Blue body on the adjustment plate, and then re run O9860 for verification.

###6.5 Specialized Alignment Tools

Renishaw recommends using the Ball nosed cylinder type calibration tool for optimal alignment. This tool has known precise geometric dimensions and can provide clear and repeatable signal triggers in the beam.

Renishaw provides step-by-step alignment operation guidance documents, please refer to the technical support page on the official website for details.
-Wiring Configuration Guide
-Air pressure setting video guidance
-Alignment operation video guidance
-Daily Maintenance Guide
-Troubleshooting Manual

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## 7. System calibration process (O9861)

###7.1 Physical Principles of Calibration

The system calibration of NC4+Blue essentially establishes a benchmark mapping relationship: that is, when a standard core rod with a known diameter passes through a beam, the “dark bright” or “bright dark” edge position detected by the system should correspond to the actual geometric center position of the core rod and the known diameter. Through calibration, the system converts these positional information into usable tool diameter and length measurements.

Calibration also records temperature compensation benchmark data. Due to the thermal expansion and contraction of the machine tool and NC4 body with temperature changes, the calibration system needs to know the relative position between the beam and the tool at a known temperature in order to compensate for temperature changes.

###7.2 Preparation before Calibration

1. * * Insert the Calibration Bar into the spindle**
-The core rod must be a high-precision cylinder with a known diameter (recommended to be made of hard alloy or ceramic material)
-The surface of the core rod must be clean, without any bumps or residual cutting fluid
-Suggest using a core rod with a diameter similar to that of daily machining tools

2. * * Confirm that the mechanical alignment has been completed and verified by O9860**
-Run the O9860 beam straightening macro and confirm that the deviation is within the tolerance range
-If O9860 displays out of tolerance, mechanical fine-tuning must be completed before calibration

3. * * Confirm that the machine tool is thermally stable**
-Start up and run for at least 15-30 minutes to achieve thermal equilibrium between the spindle bearings and guide rails
-In seasons with large temperature differences (such as winter mornings), longer preheating time may be required

4. * * Confirm that the gas source and power supply are normal**
-The barrier gas pressure is set correctly
-The status LED is blue
-Clear and visible beam of light

###7.3 O9861 System Calibration Macro

The O9861 macro program is the core support for the accuracy of the entire NC4+Blue system. The calibration process is divided into three sub stages, and after each sub stage is completed, the system automatically saves the corresponding benchmark data.

G65 P9861 B1. (System calibration, including temperature compensation tracking)

**Parameter Description * *:

|Parameter | Meaning | Default Value | Description|
|:—-|:—-|:——|:—–|
|Bb. | Calibration mode selection | 1 | B1.=Standard calibration with temperature compensation tracking|

**Detailed process of sub stage standardization * *:

First sub stage – * * Diameter Calibration * *:

The core rod rotates at a set speed (e.g. S3000) and moves from the initial safe position towards the beam direction at a standard feed rate. When the core rod first enters the beam, the system records the edge position of “bright → dark” or “dark → bright”. Then the core rod continues to pass through the beam, and the system records the position of the edge on the other side. Subtract the known diameter of the core rod from the difference between the two edge positions to obtain the reference offset of the system, which is stored in the macro program variable.

**Key points of the project:
-Before calibration, confirm that the surface of the core rod is free of bumps, oil stains, and residual cutting fluid
-The nominal diameter of the core rod must be known and traceable (it is recommended to use a calibrated standard core rod)
-The calibrated feed rate must be consistent with the daily measured feed rate (2.0 μ m/rev principle)

Second sub stage – * * Position/Height Calibration * *:

After completing the diameter calibration, the system automatically performs position calibration in the Z direction. The position of the core rod tip in the beam is recorded as the reference zero point for measuring the blade length.

Third sub stage – * * Temperature Compensation Baseline * *:

The system reads the current temperature sensor value of the machine tool and records it as the compensation baseline. In the subsequent daily measurement cycle (such as O9862), the system will read the current temperature in real time and compare it with the reference line, automatically calculating and compensating for the beam position drift caused by thermal expansion and contraction.

**The engineering significance of temperature compensation: From cold start in the morning to hot equilibrium in the afternoon, the relative position between the spindle and the worktable of a machining center may change by 10-30 μ m (depending on the size of the machine tool and temperature rise). If there is no temperature compensation, this thermal drift will result in inconsistent measurement results for the same knife in the morning and afternoon. The temperature compensation baseline established by O9861 is designed to address this issue.

###7.4 Verification after Calibration

After calibration is completed, run a confirmation measurement using the same core rod (using O9862 for tool length and diameter measurement) to verify:

If the deviation exceeds the above range, perform systematic troubleshooting:
1. Whether the core rod is clean – wipe the surface of the core rod with non-woven fabric dipped in anhydrous ethanol and retest
2. Check if the core rod is bumped – visually inspect the cylindrical surface of the core rod at high magnification
3. Mechanical alignment for drift – rerun O9860 to check
4. Check if the barrier gas pressure is correct – check the pressure gauge reading
5. Whether the optical lens is contaminated – visually inspect the Tx/Rx MicroHole area

###7.5 Dynamic strategy for calibrating frequency

It is not recommended to use fixed calibration intervals. The following dynamic strategies are more in line with actual production needs:

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## 8. Macro Programming Reference

###8.1 List of Macro Programs O9860~O9868

Non contact knife alignment (NCTS) uses independent O9860~O9868 macro series, which is completely different from the O9850~O9854 macro series of contact knife alignment. The following is an overview of the functions of each macro:

|Macro Number | Function Classification | Detailed Functions | Typical Calls|
|:—-|:——–|:——–|:——–|
|O9860 | Installation/Maintenance | Laser Beam Alignment and Verification | G65 P9860 B1|
|O9861 | Calibration | System Calibration+Temperature Compensation Tracking | G65 P9861 B1|
|O9862 | Measurement | Tool length and/or diameter setting | G65 P9862 A3. B1. H0.01 S5000 Y10|
|O9863 | Tool breakage detection | Cutting tool (end mill) breakage detection | G65 P9863 A1. Q5. S5000|
|O9865 | Measurement | Tool radius and linear contour detection | G65 P9865 A1|
|O9866 | Tool breakage detection | Solid tool (drill/tap) breakage detection | G65 P9866 A1|
|O9867 | Measurement | Arc radius measurement (ball end knife/rounded corner knife) | G65 P9867 A1|
|O9868 | Measurement | Eccentric Tool Measurement | G65 P9868 A1|

###8.2 Detailed explanation of commonly used macro parameters

The following parameters apply to all O986x series macros (some parameters are not applicable in specific macros):

|Parameter | Variable Type | Meaning | Typical Value Range|
|:—-|:——–|:—-|:———-|
|Aa. | Integer selection | Measurement mode selection (1=tool length, 2=diameter, 3=tool length+diameter, etc.) | 1~8|
|Bb. | Integer selection | Calibration/straightening mode selection | 1|
|Hh. | Real number tolerance | Tool detection tolerance (mm): Exceeding this value triggers an alarm or mark | 0.005~0.500|
|Jj. | Real distance | Overtravel increment (mm): Extra search distance beyond expected position | 1.0~5.0|
|Mm. | Real number tolerance | Position tolerance (mm): allowable deviation of the tool from the expected position | 0.01~1.0|
|Qq. | Real distance | Safety increment (mm): Safety approximation distance before measurement | 2.0~10.0|
|Ss. | Integer speed | Spindle speed (rpm): Laser tool alignment must rotate the tool | 1000~15000|
|Tt. | Real distance | Backward distance (mm): After measurement is completed, the main axis backward distance | 1.0~5.0|
|W. | Switch selection | Over travel judgment selection | 0/1|
|Yy. | Real number feed | Measurement feed rate (mm/min): The speed of the tool passing through the beam | Calculated at 2.0 μ m/rev|

###8.3 Feed rate calculation and correction

**Core principle: Laser cutting is a dynamic measurement, and the feed rate directly affects the measurement accuracy.

Renishaw recommends a standard feed rate of * * 2.0 μ m/rev * * (feed per revolution). The actual feed rate is calculated based on the spindle speed:

Y (mm/min) = 2.0 (μm/rev) × S (rpm) / 1000

**Common feed rate lookup table * *:

|Spindle speed (rpm) | Recommended feed rate (mm/min)|
|:————–|:——————|
| 1000 | 2.0 |
| 2000 | 4.0 |
| 3000 | 6.0 |
| 5000 | 10.0 |
| 8000 | 16.0 |
| 10000 | 20.0 |
| 15000 | 30.0 |

**Important: If the feed rate during calibration is inconsistent with the feed rate during daily measurement, it will result in systematic measurement deviation. Be sure to maintain consistent feed rates for calibration and measurement.

###8.4 Complete Programming Example

**Example 1: Standard tool alignment process (simultaneous measurement of tool length and diameter)**

O1000 (main program startup)
T02 M06 (replace with No.2 knife)
G90 G00 X150. Y100. Z100. (Position to safe position)
S5000 M03 (spindle rotates forward at 5000 rpm)
M65 (activate NC4 air curtain protection/blowing)
G65 P9862 A3. B1. H0.02 J2.0 Q5.0 S5000 T3.0 Y10.0
(A3.=simultaneous measurement of blade length and diameter)
(B1.=Standard Mode)
(H0.02=tolerance ± 0.02 mm)
(J2.0=Over travel 2.0 mm)
(Q5.0=safety distance of 5.0 mm)
(S5000=spindle speed 5000 rpm)
(T3.0=measured back by 3.0 mm)
(Y10.0=feed rate of 10 mm/min)
M66 (Close NC4 air curtain/blow air)
G90 G00 Z100. (Return to safe position)
M30

###8.5 Common Macro Programming Errors and Prevention

The following macro programming errors that repeatedly occur during on-site debugging are worth paying special attention to:

**Error 1: Forgetting to activate the air curtain protection before laser alignment**

(Example of Error)
T01 M06
G90 G00 X100. Y100. Z50.
S5000 M03
G65 P9862 A3. B1. H0.02 S5000 Y10.0
(Failure to activate air curtain protection – measurement may be affected by cutting fluid interference)

(Correct example)
T01 M06
G90 G00 X100. Y100. Z50.
S5000 M03
M65 (opening NC4 air curtain/blowing – must be performed before the measurement cycle)
G65 P9862 A3. B1. H0.02 S5000 Y10.0

**Error 2: The measured feed rate does not match the calibrated feed rate**

This is the most covert and common source of systemic bias. If Y10.0 (corresponding to S5000) is used for calibration, but Y20.0 is changed to Y20.0 in daily measurements to meet the deadline, there will be a fixed directional deviation in each measurement. The reason is that the response time of the laser signal processing circuit has already been calibrated at a constant feed rate. After the feed rate changes, the timing of signal edge interpretation is different from the calibration.

Preventive rules:
-Calibrated feed rate=measured feed rate (strictly equal)
-Every time the feed rate is modified, it must be recalibrated
-Recommended value: 2.0 μ m/rev

**Error 3: Forgetting to set tool rotation when using O9862 (S command)**

Laser tool alignment is a dynamic measurement, and the tool must rotate. If the S command is forgotten to be issued (or the spindle has not reached the set speed), the measurement results will be unreliable. The laser tool setter detects the contour of the envelope surface of the rotating tool, rather than the unilateral position of the stationary tool. When there is no rotation, the tool only has one surface facing the laser beam and cannot obtain complete diameter information.

**Error 4: Measuring directly after changing the tool without first locating it in a safe position**

After changing the tool, the spindle may be located at any position, and directly calling the tool setting macro may cause the tool to directly collide with the NC4 body. It is necessary to first perform G00 positioning to the safe coordinates (ensuring that the tool is above the beam and away from the Tx/Rx head), and then call the measurement macro. This is the first step in programming security and cannot be omitted.

**Error 5: The H tolerance parameter is set too strictly, resulting in frequent false alarms**

The H parameter defines the tool tolerance judgment value. If set to H0.005 (± 5 μ m), and the tool change repeatability of the machine itself is in the range of 5-10 μ m, then an alarm will be triggered for each tool change (even if the tool itself is fine). The H value should be set according to the actual processing requirements, and it is usually recommended to use H0.01~H0.02 (± 10~20 μ m) as the starting value, and then adjust it according to the actual process capability.

**Example 2: Tool breakage detection (insert milling cutter)**

O2000
T02 M06
S5000 M03
M65
G65 P9863 A1. Q5.0 S5000 Y10.0 (Renishaw standard knife breakage detection macro, if a knife breakage is detected, the system alarm will be directly triggered internally in the macro to stop the machine, without the need for external variable judgment)
M66
M30

**Example 3: First calibration after installation * *:

O3000
G90 G00 X150. Y100. Z100.
S3000 M03
M65
G65 P9860 B1. (Running beam straightening verification)
If the deviation returned by O9860 exceeds the tolerance, it needs to be mechanically aligned again
G65 P9861 B1. (Perform system calibration)
M66
G90 G00 Z100.
M30

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## 9. Daily maintenance and upkeep

###9.1 Maintenance Plan Summary Table

NC4+Blue is designed as a permanent fixed equipment for machine tools, with low maintenance requirements under normal working conditions. However, a systematic maintenance plan is still the foundation for ensuring long-term stable accuracy

###9.2 Detailed operation of optical lens cleaning

** ⚠️ Warning * *:
-Before cleaning the optical lens, the power supply of the NCi-6 interface unit must be cut off
-Adjust the barrier pressure to 0 MPa
-The dustproof panel can only be disassembled by trained personnel using specialized tools during maintenance
-Before disassembling the Tx head panel, power must be turned off to avoid exposure to laser radiation
-After the PassiveSeal of the internal optical cavity is exposed, the interior of the panel becomes the Class 3R laser radiation area

**Required tools and materials * *:

**Step by step cleaning operation * *:

1. * * Cut off power * *: Disconnect the power supply of the NCi-6 interface unit (can be disconnected from the NCi-6 or NC4+Blue connector)
2. * * Cut off the gas source * *: Rotate the barrier gas pressure regulating valve to 0 MPa
3. * * Check the trachea * *: If the trachea is damaged, replace it in this step
4. * * Disassemble the dust panel * *: Use a needle wrench to rotate counterclockwise to unscrew the dust panel of the Tx or Rx head
5. * * Check and remove debris * *: Visually inspect the large particle debris in the panel installation area and blow it off with a dust removal cylinder. Be careful not to let debris fall into the interior of the casing
6. * * Push PassiveSeal * *: Insert the cleaning tool into the housing and rotate it 70-80 degrees to detach PassiveSeal from the optical glass surface
7. * * Blow air cleaning * *: Briefly ventilate for about 1 minute, using airflow to remove loose pollutants
8. Spray cleaning solvent: Spray precision cleaning solvent onto the lens through the center hole of the cleaning tool
9. Wipe the lens: Use a cleaning cotton swab to gently wipe the surface of the lens with a quarter turn motion
10. * * Caution * *: Do not press the lens or PassiveSeal hard, as the optical surface is extremely precise
11. * * Blow off solvent residue * *: Spray the inside of the shell with a dust removal gas cylinder to remove all solvent traces
12. * * Clean the dustproof panel * *: Clean the MicroHole panel with cleaning solvent and dry compressed air
13. * * Reinstall the panel * *: Remove the cleaning tool, reinstall the dust panel, and tighten it with a needle wrench to * * 2.0 Nm**
14. * * Repeat on the other side * *: Perform the same cleaning on the other head (Tx or Rx)

**Restoration inspection after cleaning * *:

1. Reconnect and power on the NCi-6 interface unit
2. Restore the barrier gas supply and set the correct air pressure
3. Turn SW1-2 (NC setup) on NCi-6 to On, wait for about 5 seconds, and then turn it back off – this triggers automatic gain adjustment
4. Pass an object through the beam of light and verify that the status LED changes normally by pressing “blue → red → blue”

###9.3 Replacement of membrane dryer

The life indicator of a membrane dryer is the color of the Dew Point Indicator:

**Replacement steps * * refer to Section 4.3 for details, key points:
-The dryer is installed on the pneumatic triple component
-Replace with Renishaw exclusive service package
-After replacement, the barrier gas pressure needs to be reset

###9.4 Replacement of blowing nozzle

When the blowing nozzle is damaged due to collision or long-term use, it needs to be replaced:

1. Cut off the power supply of NCi-6 interface unit
2. Lower both the barrier gas and blowing pressure regulating valves to 0 MPa
3. Use a nozzle wrench (nozzle key, included in the replacement kit) to unscrew the old nozzle counterclockwise
4. Install a new nozzle assembly (including gasket) and tighten it to * * 2.0 Nm**
5. Restore power and gas supply
6. Set the blowing pressure (typical value 0.3~0.6 MPa)

If the nozzle is damaged and continues to be used, the direction of the blowing airflow may be incorrect, which may cause the cutting fluid on the tool to be unable to be effectively blown away, affecting the measurement accuracy.

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## 10. Common troubleshooting and diagnosis

###10.1 Complete Troubleshooting Table

When conducting on-site inspections, engineers should read the table in the following order: first confirm the fault phenomenon → search for possible causes (in descending order of probability) → perform corresponding operations. If the operation is invalid, investigate the next cause down the table.

|Fault phenomenon | Possible causes (sorted by probability) | Troubleshooting and solutions|
|:——–|:——————–|:————-|
|* * Tx/Rx LEDs are not lit * * | ① Wiring error | Check the line color function correspondence one by one according to the wiring table in Section 5.2|
|| ② NCi-6 power supply abnormality | Measure the input terminal voltage of NCi-6 power supply, which should be within the range of 11~30 Vdc|
|| ③ Fuse blown | After cutting off the power, check if there is a short circuit between the terminals, eliminate it, and then turn on the power again (the fuse can be reset and automatically restored)|
|④ Cable damage | Check if there is any outer skin damage or internal wire breakage on the 12.5m cable|
|* * Power supply but no laser emission * * | ① Barrier gas not connected (PassiveSeal activated) | Check if the main valve of the gas source and the pressure regulating valve of the pneumatic triple piece are open|
|② Insufficient barrier gas pressure | Gradually increase the pressure and observe when the laser beam is clearly emitted|
|③ Tracheal bending or damage | Check the bending points and damaged areas section by section along the diameter of the gas pipeline|
|④ Dust proof panel MicroHole blockage | Remove the panel and clean the MicroHole after power failure|
|* * Poor repeatability/abnormal readings * * | ① Cutting fluid/chips on the tool | Extend blowing time or increase blowing pressure; High speed rotation to shake off cutting fluid|
|| ② High feed rate | Check if the measured feed rate is set at 2.0 μ m/rev|
|③ Electromagnetic interference | Check if the NC4 cable routing is far away from the power line and servo drive|
|The machine tool is not thermally stable. Preheat for 15-30 minutes before retesting|
|⑤ Incorrect barrier gas pressure | Reset according to section 4.2|
|| ⑥ Calibration failure/offset | Re execute O9861 calibration|
|| ⑦ Inconsistent measurement and calibration feed rate | Ensure that the calibration and daily use feed rates are the same|
|| ⑧ Poor mechanical repeatability of machine tools | Perform machine tool health checks (guide rail clearance, screw back clearance)|
|| ⑨ Loose installation bracket/adjustment plate | Check and re tighten to the specified torque|
|The voltage exceeds 1.0~7.0 V in the setting mode | ① Poor power regulation | Confirm that the NCi-6 power supply voltage is stable|
|| ② Optical lens contamination | Follow the cleaning process in Section 9.2|
|③ Incorrect barrier air pressure | Reset air pressure|
|Deviation between Tx/Rx heads | Follow section 10.4 to realign Tx/Rx|
|Improper connection of multimeter | Check the connection between multimeter probe and CN1-1/CN1-2|
|The LED is violet in color (setting mode Off) | ① System voltage drops (lens contamination/low air pressure/alignment deviation) | Clean the lens → check air pressure → check alignment → eliminate all three one by one|
|| ② MicroHole or lens dirt | Perform cleaning process|
|③ Install the incorrect model of dustproof panel | Confirm that the panel model matches the NC4 model (refer to the attached data sheet H-2000-2223)|
|* * LED flashing blue/violet (1 Hz) * * | ① System voltage high | Re execute Tx/Rx alignment|
|In Tool Set 2/Latch mode, the tool rotates in the beam, which is a normal phenomenon – the gap between the tool teeth allows the laser to pass through, and the system is not triggered|
|* * LED red light is always on * * | ① No air supply | Check the air circuit|
|| ② Damage to trachea | Check if the trachea is damaged or bent|
|Serious offset between Tx/Rx heads | Perform Tx/Rx realignment|
|④ The laser beam is obstructed by foreign objects | Remove the obstruction|
|| ⑤ Severe lens contamination or MicroHole blockage | Follow the cleaning process|
|| ⑥ Wiring Error | Check all cable connections according to the wiring table|
|⑦ Air source does not meet the standard (Class 1.4.2) | Confirm the quality of the air source and install Renishaw special triple fittings if necessary|
|| ⑧ Non Renishaw air filter was used | Confirm that the filter meets Class 1.4.2 standard|
|| ⑨ Automatic drain valve damaged | Replace filter/dryer/pressure regulating valve assembly|
|Fill the trachea with cutting fluid or oil | Blow off or replace the trachea|
|The NC4 setting tool cannot be turned on. The contact spring contacts are dirty/damaged. Clean the spring contacts at the bottom of the setting tool|
|| ② NC4+Blue top fouling | Clean the NC4 top shell to ensure electrical contact|
|③ Battery installation reversed or depleted | Check battery polarity and replace with a new battery|
|④ Use non-standard batteries | Only compatible with: Saft LS 14250/Tadiran SL-750/Xeno XL-050F|
|* * Setting tool reading abnormal * * | ① Low battery level | Replace with a new battery|
|| ② Not in setting mode | NCi-6 SW1-2 must be in the On position|

###10.2 Multi meter diagnostic method

The use of a digital multimeter is an accurate method for determining the health status of the NC4+Blue system:

**Connection method * *:
1. Set the multimeter to DC voltage mode (DCV, 20V range)
2. Connect the red probe to CN1-1 (analog output 1) of NCi-6
3. Connect the black probe to CN1-2 of NCi-6 (analog output 2)
4. Turn the SW1-2 (NC setup) switch of NCi-6 to On

**Normal reading diagnosis * *:

**Normal mode SW1-2=Off * *:
|Reading range | Status description|
|:———|:——–|
|4.7 V~5.4 V | Normal – The system is operating at its optimal state|
|>5.4 V | Voltage high, maintenance required|
|± 5 ° C | Measurable systematic deviation generated | Precision machining can only continue after recalibration|

**Best Practice * *:
-Wait for 15-30 minutes after turning on the machine to reach thermal stability before performing precision tool alignment
-The calibration period should be shortened to half of the regular period during the season change (spring and autumn)
-Using the temperature compensation tracking function of O9861- after calibration, the system automatically records the temperature reference and implements compensation

###11.3 Installation location and cable routing

**In terms of mechanical installation:
-NC4+Blue should not be installed in positions directly impacted by chips
-Adequate space should be left around the body for daily inspection and cleaning
-Gas pipes and cables must be fixed with pipe clamps to prevent machine tool movement from applying tension to the NC4 body
-The bending radius of the trachea shall not be less than the specified minimum bending value (air tube ≥ 25-30 mm)

**In terms of electrical wiring * *:
-NC4 shielded cables must not be wired in parallel with power cables (motor power lines, frequency converter output lines)
-Must maintain a minimum spacing of 100 mm or more
-All shielded wires (green) must be connected to the “star point grounding” of the machine tool
-The NCi-6 interface unit is installed inside the control cabinet and is located away from transformers and servo drives

###11.4 Feed rate consistency

**This is the most common systematic mistake for beginners: calibrating O9861 with a feed rate of 10 mm/min, but measuring O9862 daily with a feed rate of 20 mm/min. When the two are inconsistent, a systematic deviation in a fixed direction will occur, and the deviation will increase with the difference in feed rate.

**Rule * *:
-Calibrated feed rate=daily measured feed rate (strictly equal)
-Recommended calculation based on 2.0 μ m/rev
-After each modification of the measurement feed rate, it must be recalibrated

###11.5 Preparation before tool measurement

Laser tool alignment is * * dynamic measurement * *, which means that compared to contact tool alignment, it has several unique requirements:

1. The tool must rotate (S command is valid): NC4+Blue needs to be measured while the tool is rotating. This is because the cutting edge of the tool repeatedly passes through the beam during rotation, and the system detects the contour of the tool’s rotating envelope surface. The detection of broken tools also relies on this principle – a rotating complete tool produces a stable signal pattern, while a broken tool produces an abnormal pattern.

2. The tool surface must be clean: When cutting fluid or chips adhere to the tool surface, additional scattering or obstruction may occur when the laser passes through, resulting in measurement results that are larger than the actual tool size. Suggested method:
-Use the Air Blast blowing system to spray the tool before measurement
-For stubborn attachments, high-speed rotation (8000~10000 rpm) can be used to shake off the cutting fluid

3. Special treatment of small cutting tools: For small cutting tools with a diameter less than Ø 0.5 mm, the blowing pressure should be appropriately reduced (from 0.6 MPa to 0.3~0.4 MPa) to prevent high-speed airflow from bending and deforming the slender cutting tools, causing measurement errors.

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## 12. Conclusion and Reference Documents

###12.1 Review of Core Points

The installation, calibration, and maintenance of NC4+Blue non-contact laser tool setter can be summarized into three key dimensions:

**Installation dimension * * – Correct installation is the cornerstone of accuracy:
-The quality of the gas source must meet BS ISO 8573-1 Class 1.4.2 (Pneumatic triple components with membrane dryer and precision filter are essential and not optional)
-Adjustment board installation verticality ≤ 1.0 mm/board total length
-Shielded cable wiring should be kept away from interference sources, and all shielding layers should be grounded at single ended star points

**Calibration Dimension * * – Continuous calibration ensures accuracy:
-Beam straightening O9860: spindle axis direction ≤ 10 μ m/100 mm
-System calibration O9861: Establish a benchmark using a standard core rod, including temperature compensation tracking
-The calibration frequency is dynamically adjusted according to the requirements of machining accuracy and changes in environmental temperature

**Maintenance dimension * * – Regular maintenance is a stable prerequisite:
-The quality of the gas source directly determines the lifespan of the optical lens
-The color of the status LED is the most intuitive diagnostic tool
-Special tools and procedures are required for cleaning optical lenses

As a key equipment for high-precision tool alignment in CNC machining centers, the potential of NC4+Blue can only be fully realized with proper installation and systematic maintenance. I hope this guide can provide on-site engineers with practical reference for the entire process from installation to maintenance.

###12.2 Reference Documents

*The technical data in this article are all quoted from the official Renishaw technical manual mentioned above. If you have any questions, please refer to the original manual*

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&Gt; * * Document Version * *: V1.0
&Gt; * * Applicable products * *: Renishaw NC4+Blue non-contact laser tool setter
&Gt; * * Applicable systems * *: FANUC/MITSUBISHI MELDAS and compatible CNC systems
>
&The Renishaw and related product names referenced in this document are registered trademarks of Renishaw plc. All macro program parameters are based on Renishaw’s official NCTS programming manual*

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**Related Reading**

-Is the signal of the Bolong Blum laser tool setter unstable? Diagnosis and Solutions（ https://jcetech.cn/blum-laser-signal-instability/ ）Troubleshooting of laser tool setter signal faults
-[Renishaw probe and tool setter selection guide]（ https://jcetech.cn/renishaw-probe-selection-guide/ ）Renishaw’s full range selection reference
-[Renishaw Inspection Plus Macro Programming Guide]（ https://jcetech.cn/renishaw-inspection-plus-fanuc/ ）- Fanuc System Inspection Plus Programming Explanation

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