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GRAPHTEC FCX4000 SERIES User manual

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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 DISASSEMBLYAND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 ELECTRICALADJUSTMENTS ......................................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
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 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
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)
/