GRAPHTEC FCX4000 SERIES User manual

CUTTING MACHINE

SERVICE MANUAL

FCX4000

FCX4000-UM-251-02-9370

FCX4000-UM-251-9370 i

HISTORY OF REVISIONS

No. Date issued Description of revision Page Edition

118.1.16 First Printing All 01

218.3.09 The parts number for X Belt 50 was corrected. 5 -1,10 - 3 02

318.3.09 The parts number for X Belt 60 was corrected. 5 -1,10 - 3 02

418.3.09 The parts number for Y Belt 50 was corrected. 5-1 02

518.3.09 The parts number for Y Belt 60 was corrected. 5-1 02

618.3.09

The parts number for X Flexible Cable FFC403104 was corrected.

5-1,10-7,10-10 02

718.3.09

The parts number for X Flexible Cable, FFC403102 was corrected.

5-1,10-7,10-10 02

818.3.09 "a10,1.Axxxxxxxxx” was corrected to "a10,1,Axxxxxxxxx”. 8-37 02

FCX4000-UM-251-9370 ii

CONTENTS

1 INTRODUCTION .............................................................1-1

1.1 ModelNamesandBasicSpecications .........................................................1-1

1.2 StandardAccessories ......................................................................................1-1

1.3 MainSpecications ..........................................................................................1-2

1.4 ExternalDimensions ........................................................................................1-3

2 DescriptionofParts ......................................................2-1

2.1 PlotterNomenclature .......................................................................................2-1

2.2 CutterPlunger ...................................................................................................2-2

3. BasicOperation .............................................................3-1

3.1 HowtoUsetheControlPanel .........................................................................3-1

3.2 MenuTree ..........................................................................................................3-5

3.3 ReplacingtheCutterBlade ............................................................................3-12

3.4 AdjustingtheBladeLength ...........................................................................3-13

3.5 AttachingaTool ..............................................................................................3-14

3.6 AbouttheInitialSetupScreen .......................................................................3-15

3.7 SelectingToolCondition ................................................................................3-16

3.7.1 Selectingthetoolconditionnumber ................................................................................................... 3-17

3.7.2 SettingtheToolCondition .................................................................................................................... 3-18

3.8 RunningCuttingTests ...................................................................................3-21

3.8.1 CuttingTest ............................................................................................................................................ 3-21

3.8.2 ConrmtheResultsoftheCuttingTest .............................................................................................. 3-23

4 DailyMaintenance .........................................................4-1

4.1 DailyMaintenance ............................................................................................4-1

4.2 StoringthePlotter ............................................................................................4-1

4.3 CleaningtheCutterPen ...................................................................................4-1

5 RECOMMENDEDPARTSLIST......................................5-1

6 LISTOFTOOLS .............................................................6-1

6.1 Tools ..................................................................................................................6-1

FCX4000-UM-251-9370 iii

7 DISASSEMBLYANDASSEMBLY .................................7-1

7.1 OuterPart ..........................................................................................................7-1

7.1.1 RightFrontCornerCover ....................................................................................................................... 7-1

7.1.2 RightRearCornerCover ........................................................................................................................ 7-1

7.1.3 LeftFrontCornerCover .......................................................................................................................... 7-2

7.1.4 LeftRearCornerCover ........................................................................................................................... 7-2

7.1.5 RightTopCover ....................................................................................................................................... 7-3

7.1.6 LeftTopCover .......................................................................................................................................... 7-3

7.1.7 RightSideCover ...................................................................................................................................... 7-4

7.1.8 LeftSideCover ........................................................................................................................................ 7-4

7.1.9 FrontTopCover ....................................................................................................................................... 7-5

7.1.10 RearTopCover ........................................................................................................................................ 7-6

7.1.11 XFlexibleCableCover ............................................................................................................................ 7-7

7.1.12 RearBottomCover .................................................................................................................................. 7-8

7.1.13 YBarCover ............................................................................................................................................ 7-10

7.1.14 PenBlockCover .................................................................................................................................... 7-10

7.1.15 FrontYBarEndCover ...........................................................................................................................7-11

7.1.16 RearYBarEndCover ............................................................................................................................7-11

7.1.17 FrontBottomCover ............................................................................................................................... 7-12

7.1.18 TrayAssembly ....................................................................................................................................... 7-13

7.2 X-AxisDrivePart .............................................................................................7-15

7.2.1 XMotor ................................................................................................................................................... 7-15

7.2.2 XMotorBelt ........................................................................................................................................... 7-17

7.2.3 FrontXBelt ............................................................................................................................................ 7-20

7.2.4 RearXBelt ............................................................................................................................................. 7-23

7.2.5 XHomeSensorBoard ........................................................................................................................... 7-26

7.2.6 XFlexibleCable ..................................................................................................................................... 7-27

7.3 Y-AxisDrivePart .............................................................................................7-31

7.3.1 YMotor ................................................................................................................................................... 7-31

7.3.2 PenBlockAssembly ............................................................................................................................. 7-33

7.3.3 YMotorBelt ............................................................................................................................................ 7-34

7.3.4 YHomeSensorBoard ........................................................................................................................... 7-36

7.3.5 YRelayBoard ........................................................................................................................................ 7-37

7.3.6 PenBoard ............................................................................................................................................... 7-38

7.3.7 RegistrationSensorBoards ................................................................................................................. 7-39

7.3.8 YFlexibleCable ..................................................................................................................................... 7-40

7.3.9 YBelt ....................................................................................................................................................... 7-41

FCX4000-UM-251-9370 iv

7.4 BelttensionAdjustment.................................................................................7-43

7.4.1 AdjustingtheXMotorBeltTension ..................................................................................................... 7-43

7.4.2 AdjustingtheYMotorBeltTension ..................................................................................................... 7-44

7.4.3 AdjustingtheFrontXBeltTension ...................................................................................................... 7-45

7.4.4 AdjustingtheRearXBeltTension ....................................................................................................... 7-48

7.4.5 AdjustingtheYBeltTension ................................................................................................................ 7-51

7.5.1 MainBoard ............................................................................................................................................. 7-53

7.6.1 PowerSupplyBoard ............................................................................................................................. 7-54

7.6.2 Fan .......................................................................................................................................................... 7-55

7.6.3 HighVoltageBoard ................................................................................................................................ 7-56

7.6.4 ElectrostaticRelayBoard ..................................................................................................................... 7-56

7.6.5 MotorPowerRelayBoard ..................................................................................................................... 7-57

7.7 ControlPanel ..................................................................................................7-58

7.7.1 ControlPanelBoard .............................................................................................................................. 7-58

7.7.2 LCD ......................................................................................................................................................... 7-61

7.7.3 ControlPanelkeys ................................................................................................................................ 7-61

7.7.4 ElectrostaticAdhesionSwitch ............................................................................................................. 7-62

7.8 ElectrostaticAdhesionPanel ........................................................................7-64

7.8.1 ReplacingtheElectrostaticAdhesionPanel ....................................................................................... 7-64

8 ELECTRICALADJUSTMENTS ......................................8-1

8.1 ListofItemsRequiringReadjustment ............................................................8-1

8.2 FlowchartoftheAdjustmentSequence .........................................................8-2

8.2.1 Themainboardwasreplaced(Normalprocedure) .............................................................................. 8-2

8.2.2 Themainboardwasreplaced

(IftheadjustmentvaluescouldnotcopyfromtheSUB-NVRAM.) ......................8-3

8.2.3 Thepenblockwasreplaced ................................................................................................................... 8-4

8.2.4 TheXhomesensorwasreplaced .......................................................................................................... 8-4

8.2.5 TheYhomesensorwasreplaced .......................................................................................................... 8-4

8.2.6 Theregistrationmarksensorwasreplaced ......................................................................................... 8-4

8.2.7 TheXorYmotorwasreplaced .............................................................................................................. 8-5

8.2.8 TheXorYbeltwasreplaced .................................................................................................................. 8-5

8.3 ExplanationoftheValuesoftheMainBoard .................................................8-6

8.4 SettingtheDIPSwitches ..................................................................................8-7

8.5 UpdatingtheSystemFirmware .......................................................................8-8

8.6 ClearingtheNV-RAM ......................................................................................8-10

8.7 SelectingDisplayLanguage&LengthUnit .................................................8-12

8.8 CopyingtheAdjustmentvalueformtheSUB-NVRAM ................................8-13

8.9 AdjustingtheHomePosition .........................................................................8-15

FCX4000-UM-251-9370 v

8.10 AdjustingthePenForce ................................................................................8-18

8.11 AdjustingtheDistanceandthePerpendicularityAccuracy .......................8-22

8.12 AdjustingtheToolInterval .............................................................................8-27

8.13 AdjustingtheRegistrationMarkSensorSensitivity ...................................8-31

8.14 AdjustingtheOffsetofRegistrationMarkSensor ......................................8-33

8.15 BackuptotheSUB-NVRAM ..........................................................................8-37

8.16 TestingtheControlPanelKeysandHomeSensors ...................................8-39

8.17 AboutStartUpMode ......................................................................................8-40

9 TROUBLESHOOTING ....................................................9-1

9.1 Thepowerisnotturnedon. .............................................................................9-1

9.2 Whenitdoesnotworkrightly .........................................................................9-2

9.3 TheCuttingResultisNotGood ......................................................................9-6

9.4 ErrorMessagesinGP-GLCommandMode ...................................................9-8

9.5 ErrorMessagesinHP-GLCommandMode ...................................................9-9

9.6 ARMSErrorMessages ...................................................................................9-11

9.7 Hardwareerrors ..............................................................................................9-15

9.8 OperationalError ............................................................................................9-19

9.9 CautionMessage ............................................................................................9-20

9.10 SelfDiagnosticTest ........................................................................................9-21

10.PARTSLISTS ...............................................................10-1

10.1 MainOuter .......................................................................................................10-1

10.2 MainFrame ......................................................................................................10-2

10.3 XDriveSection ...............................................................................................10-3

10.4 MainBox&PowerBox ...................................................................................10-4

10.5 ControlPanel ..................................................................................................10-5

10.6 YBarOuter ......................................................................................................10-6

10.7 YBarPart ........................................................................................................10-7

10.8 PenBlock ........................................................................................................10-9

10.9 WiringHarness .............................................................................................10-10

10.10 OptionStandfortheFCX4000-60 ................................................................10-10

10.11 StandardAccessories ..................................................................................10-11

FCX4000-UM-251-9370 vi

11 BLOCKDIAGRAMS ..................................................... 11-1

12 TargetelectricalcomponentforWEEEinstruction .12-1

FCX4000-UM-251-9370 1-1

1 INTRODUCTION

CAUTION

DOUBLE POLE/NEUTRAL FUSING

1.1 Model Names and Basic Specications

Model Media hold down method Cutting area Mountable media width

FCX4000-50ES Electrostatic adhesion 660 (X) x 488 (Y) mm 536 mm

FCX4000-60ES 976 (X) x 660 (Y) mm 708 mm

1.2 Standard Accessories

Item Q’ty Item Q’ty

Power cable 1 pc. USB cable 1 pc.

DVD

• Various software

• User’s Manual (pdf)

1 pc. TO ENSURE SAFE AND CORRECT

USE SETUP MANUAL

Cutter Blade Manual

1 set

Cutter plunger (PHP33-CB15N-HS) 1 pc. Cutter blades: CB15U-1 1 pc.

Oil-based ballpoint pen Plunger

(PHP33-BALL)

1 set Oil-based ballpoint pen (KF700-BK [1P]) 1 pc.

Cutter blade adjustment magnier (PM-

CT-001)

1 pc.

• Other guide for the accessory may be attached.

FCX4000-UM-251-9370 1-2

1 INTRODUCTION

1.3 Main Specications

FCX4000-50ES FCX4000-60ES

Conguration Flatbed

Drive system Digital servo

Media hold-down method Electrostatic adhesion

Effective cutting area 660 x 488 mm 976 x 660 mm

Mountable media (Y-axis) 536 mm 708 mm

Maximum cutting speed 75 cm/sec (Omnidirection)

Max. acceleration 9.8 m/s2 (Omnidirection)

Speciable speeds

1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75cm/s 23 steps

Max. force Max. 5.88N (600gf)

Settable force 48 steps

Min. character size About 10 mm2 alphanumeric characters (depending on the materials and font)

Mechanical resolution 0.005 mm

Programmable resolution GP-GL mode: 0.1/0.05/0.025/0.01 mm, HP-GLTM mode: 0.025 mm

Distance accuracy

Distance moved within ±0.2% or less or within ±0.1 mm or less, whichever is larger (Plotter mode)

Perpendicularity 0.3 mm/430 mm or less (Plotter mode) 0.4 mm/610 mm or less (Plotter mode)

Repeatability

0.1 mm or less: Expansion and contraction of the media are excluded (plotter/cutting mode)

Interfaces USB2.0 (full speed) , RS-232C, Ethernet 10BASE-T / 100BASE-TX

Buffer memory 2 MB

Command sets GP-GL and HP-GLTM emulation

Number of cutters/pens 2

Tool type

Cutter Plunger, Water based ber-tip pen, Oil-based ballpoint pen, Creasing tool

Compatible media

• Marking film (PVC/fluorescence/reflection)

• Thickness less than 0.5 mm paper *2

• Thickness less than 0.8 mm compressed foam sheet *3

• Thickness less than 1 mm sandblasting rubber *3

• F, G flute

• Clear package sheet

• High-intensity reflective film *4

Ofine output function USB memory - 64 files

Bar code data management function

Yes

LCD display Graphic type (240 × 128 dot)

Power supply 100 to 240V AC 50/60Hz

Operating environment 10 to 35˚C, 35 to 75% RH (non-condensing)

Guaranteed precision operating

environment

16 to +32˚C, 35% to 70% RH (non-condensing)

External dimensions

(W x D x H)

1089 mm × 897 mm × 204 mm

(Including media stocker)

1405 mm × 1069 mm × 204 mm

1405 mm × 1069 mm × 895 mm (with optional stand)

Weight (Approx.) 29 kg 37 kg

53 kg

(with optional stand)

*1 : HP-GL is a registered trademark of the US Hewlett Packard Company.

*2 : Please use cutter blade CB15U or CB15U-K30.

*3 : Use cutter blade CB15U-K30.

*4 : Use Cutter blade CB15UA.

*5 : It depends on our specified paper and conditions.

*6 : The accuracy read with the pattern prepared for this plotter, using the attached pen and coated (glossy) paper.

FCX4000-UM-251-9370 1-3

1 INTRODUCTION

1.4 External Dimensions

FCX4000-50ES

1089

897

204

Unit: mm

Dimensional accuracy: ±5mm

FCX4000-60ES

1405

1069204

Unit: mm

Dimensional accuracy: ±5mm

FCX4000-UM-251-9370 1-4

1 INTRODUCTION

FCX4000-60ES with Stand

1405 895

1096204

Unit: mm

Dimensional accuracy: ±5mm

FCX4000-UM-251-9370 2-1

2 Description of Parts

2.1 Plotter Nomenclature

The names of the plotter parts are as follows.

(10) Network interface

connector

(8) USB interface connector

(9) RS-232C interface connector

(11) USB memory

dedicated port

(1) Control panel

(5) CHART HOLD key

(6) Tool carriage

(4) Writing panel

(7) Y bar

(3) AC line inlet

(2) Power switch

(1) Control panel .......................................... Used to access various cutting plotter functions.

(2) Power switch ..........................................Used to turn the cutting plotter on and off.

(3) AC line inlet ............................................Inlet where the power cable is connected.

(4) Writing panel ..........................................Cutting/Plotting/Creasing work is performed on the panel.

(5) CHART HOLD key.................................. Lamp lights up when the [CHART HOLD] key is pressed, you

can see that the electrostatic adsorption is functioning. Lamp

is turned off by pressing again, the electrostatic adsorption is

released.

(6) Tool carriage ........................................... Part to drive the cutter/pen.

(7) Y bar ....................................................... Holds the tool carriage; moves left/right.

(8) USB interface connector ........................Used to connect the plotter to the computer with a USB interface

cable.

(9) RS-232C interface connector ................. Used to connect the plotter to the computer with a RS-232C

interface cable.

(10) Network (LAN) interface connector ........ The connector used when connecting this plotter with the

network (LAN)interface cable.

(11) USB memory dedicated port .................. The port that is used only for the USB memory.

FCX4000-UM-251-9370 2-2

2 Description of Parts

2.2 Cutter Plunger

This chapter describes the structures and types of the cutter plungers (cutter pens).

Cutter Plunger Nomenclature

There is two different plungers to suit the diameter of the cutter blade to be mounted (the φ1.5 mm cutter

plunger is provided as a standard accessory (PHP33-CB15N-HS)).

Cutter blade Plunger

Plunger-cap Blade-length adjustment knob

(Blue: For φ0.9 mm-diameter blades)

(Red: For φ1.5 mm-diameter blades)

PHP35-CB09-HS/PHP35-CB15-HSPHP33-CB09N-HS/PHP33-CB15N-HS

Cutter blade Plunger

Blade-length adjustment knobPlunger-cap

(Blue: For φ0.9 mm-diameter blades)

(Red: For φ1.5 mm-diameter blades)

Structure of Cutter Plunger

PHP35-CB09-HS/

PHP35-CB15-HS

Cutter blade

φ0.9 mm / φ1.5 mm

Plunger

Chuck

Blade-length adjustment knob

(Blue) / (Red)

Plunger-cap

Hole

PHP33-CB09N-HS/

PHP33-CB15N-HS

Cutter blade

φ0.9 mm / φ1.5 mm

Plunger

Plunger-cap

(Blue) / (Red)

Blade-length adjustment knob

Hole

FCX4000-UM-251-9370 2-3

2 Description of Parts

FCX4000-UM-251-9730 3-1

3. OPERATIONS

3. Basic Operation

3.1 How to Use the Control Panel

This section explains the function of lamps and keys on the control panel.

[ENTER] key

[SLOW] key[1, 2, 3, 4] key POSION

(, , , )

key

Screen (LCD) [COND./TEST] key

[ESC] key

[COPY] key

[ORIGIN] key

ORIGIN lampUSER 1/2 lamp

[PAUSE/MENU]

lamp

[PAUSE/MENU] key[USER1/2] key

Indicator Lamp

USER 1/2 lamp ..........................User lamp that has been selected lights.

PAUSE/MENU lamp ..................Lights at the time of the menu mode.

ORIGIN lamp .............................When the origin point has been saved, the lamp lights.

Control key

USER 1/2...................................Switches the user selection.

PAUSE/MENU ...........................Switches to the MENU mode.

It will go into MENU mode if the key is pressed once, and MENU mode will

be turned off when the key is pressed again.

Various functions are set in the MENU mode.

When the PAUSE/MENU key is pressed during the operation, the cutting/

plotting operation stops.

ORIGIN ......................................Sets the current position as an origin point.

On the READY screen, pressing the [ENTER] and [ORIGIN] keys at the

same time will allow you to reset the plotter.

COPY ........................................Copy of data in the buffer memory is output.

ESC ...........................................Cancels the setting change and then returns to the previous screen in the

setting screen. Returns to the previous screen in the menu screen.

ENTER ......................................Saves the settings, and then returns to the setting screen in various functions

and condition setting screen of the menu screen.

On the READY screen, pressing the [ENTER] and [ORIGIN] keys at the

same time will allow you to reset the machine.

COND/TEST ..............................Displays the screen to set the tool conditions.

Use this when checking tool conditions to activate a cutting test.

FCX4000-UM-251-9730 3-2

3. OPERATIONS

SLOW ........................................When pressing the POSITION key at the same time, the tool carriage moves

slowly.

When the “SLOW” icon is displayed on the screen, it works as a menu key.

When the [SLOW] key is pressed in the READY screen, the current cutting/

plotting area and the position of tool carriage are displayed.

1, 2, 3, 4.....................................Selects the menu number displayed in the screen.

POSITION ( , , , ) key ........Adjusts various settings, selects numerical value changes, moves the cursor,

and changes the positions in the menu screen.

Reading the Screen (LCD)

Information reecting the status will be displayed in the screen of the control panel.

Name of the button and corresponding function are displayed on the screen when a function is allocated to

the button on the control panel. Button name will be displayed in reverse when the button is enabled.

Ready Screen

(READY)

Menu Screen

(PAUSE/MENU)

Condition Screen

(COND/TEST)

Display of setting condition

Corresponding button name of control panel

(Valid button is displayed in reverse)

User number

Tool condition currently using

Command : HP-GL

: 0.1

0.05 50 µm

0.25

0.01

:

25 µm

:

10 µm

:

: 0.1mm

: GP-GL Command

GP-GL : HP-GL Command

(No Display) Command Auto

Step size

Rotate/Mrror : R90 : Rotate (rotate 90°)

: Mir : Mirror

R90 Mir : Mirror & Rotate

Priority : MANUL : Manual priority

PROGRA : Pogram priority

Sort : Sort ON : Display when sort is on

FCX4000-UM-251-9730 3-3

3. OPERATIONS

Default Screen (READY Screen)

The condition number (Cut Condition) that has been set is displayed.

In this READY status, you can set the cutting and communication conditions by pressing [PAUSE/MENU] or

[COND/TEST] key.

When it is in the draft mode, the (D) is displayed after the READY.

Screen to set the corresponding conditions is displayed when the [PAUSE/MENU] key or [COND/TEST] key

is pressed.

Menu Screen Condition Screen

[PAUSE/MENU]

It will return to default screen

when [PAUSE/MENU] key is

pressed while displaying MENU

screen.

[COND/TEST]

It will return to default screen

when [COND/TEST] key is

pressed while displaying

CONDITION screen.

Page number is displayed in the upper right corner of the screen if there are many settings or selection that

will need multiple pages to display.

Press the POSITION ( , , , ) key to move to different page.

[3] key

POSITION ( , )

Page number

Example of moving page and operation button

FCX4000-UM-251-9730 3-4

3. OPERATIONS

Icon of the corresponding operation button is displayed in the screen to change the setting values.

Increase or decrease the setting

value using POSITION ( ) key.

Select the change unit by [FAST]

key.

Select the setting by number keys (1,

2, 3, 4) or POSITION ( , , , )

keys.

Example of screen to change the settings value

Contents of Operation from Menu Screen

Menu screen

Contents of the operation and settings that is displayed in MENU screen with [PAUSE/MENU] key is as

following:

[1] (TOOL) : Sets the setting for the operation of the tool.

[2] (ARMS) : Sets the settings and operation to position the tool and media, such as automatic

scanning of the registration marks by the ARMS.

[3] (AREA) : Sets the settings for area, magnication, rotate, mirror, etc., of the cutting.

[ ] (I/F) : Sets the settings of the condition for the interfacing with the control computer.

[ ] (ADV) : Sets the settings of the conditions for the basic operation of the plotter, such as display

language, unit of the measurements.

[ ] (TEST) : Performs the operation necessary for maintenance, such as self diagnostic test or

printout of the condition settings list.

[ ] (MEM.) : Performs the operation necessary for the output such as off-line output.

[PAUSE/MENU] : It will close the MENU screen and return to default screen.

[SLOW] : Displays the position key screen. When media is set, the tool position can be moved.

See the “Menu Tree” for list of the descriptions about each settings.

FCX4000-UM-251-9730 3-5

3. OPERATIONS

3.2 Menu Tree

Default screen

CONDITION

setting screen (1/4)

CONDITION

setting screen (2/4)

CONDITION

setting screen (3/4)

[COND/TEST]

[ENTER]

[COPY]

[1]

[2]

[3]

[4]

[1]

[2]

[3]

[4]

[1]

[2]

[3]

[4]

Continued CONDITION

setting screen (4/4)

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GRAPHTEC FCX4000 SERIES User manual

GRAPHTEC FCX4000 SERIES User manual

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