P/N53802-031T Rev. A
1
CUTTING PRO
FC3100-60
SERVICE MANUAL
asd
Irvine, California U.S.A.
-1-
CONTENTS
1. INTRODUCTION
1.1
2. BASIC OPERATION
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
4. MECHANISMS
4.1
-2-
4.3
4.4
4.5
4.6
4.2.9
Replacing the X Motor and X Motor Pulley .... 4-26
4.2.10 Replacing the Y Motor and Y Motor Pulley .... 4-28
4.2.11 Replacing the X Drive Pulley ... 4-30
4.2.12 Replacing the Y Drive Pulley ... 4-30
4.2.13 Replacing the Y Tension Pulley .... 4-31
4.2.14 Replacing the Y Flexible Printed-Circuit Cable ... 4-32
4.2.15 Replacing the Front and Rear Paper Size sensor .. 4-35
4.2.16 Replacing the LCD Panel .. 4-36
4.2.17 Replacing the Control Panel Sheet ... 4-37
4.2.18 Replacing the Main Board (PCB:PR216001) .. 4-38
4.2.19 Replacing the Power Unit (PS089A) 4-39
4.2.20 Replacing the ROM Chips .... 4-40
4.2.21 Tightening the Drive Rollers . 4-41
Removing the Mechanisms .. 4-42
4.3.1
Components Not to be Removed ... 4-42
4.3.2
Replacing the Vacuum Fan .4-42
The Film Stocker .. 4-43
4.4.1
Overview ... 4-43
4.4.2
Assembling the Accuload TM Film Stocker .. 4-43
4.4.3
Loading Sheet Film ... 4-46
The Stand and Media Basket Option 4-49
4.5.1
Overview ... 4-49
4.5.2
Assembling the Stand 4-49
4.5.3
Mounting the Plotter on the Stand .4-52
4.5.4
Assembling the Media Basket 4-54
The Pounce Tool Option .. 4-57
4.6.1
Replacing the Pouncing Pin .. 4-57
4.6.2
Replacing the Mat .. 4-59
5. ELECTRICAL ADJUSTMENTS
5.1
5.2
Location of the Main Board, Test Pins, Trimmers, DIP Switch, and ROM Chips .. 5-1
Power Unit (PS089A) .. 5-2
5.2.1
Checking Operation .. 5-2
5.2.2
The Protective Circuit .. 5-2
5.3 Switching the Power Units Supply Voltage .. 5-3
5.4 Setting the DIP Switches .. 5-4
5.5 Clearing the Non-Volatile RAM .. 5-5
5.6 Default Trimmer Setting .. 5-6
5.7 Adjusting the Motor Offset .. 5-7
5.8 Adjusting the Pen Offset .. 5-8
5.9 Adjusting the Pen Servo ... 5-9
5.10 Adjusting the Pen Force ... 5-11
5.11 Overall Adjusting ..5-12
5.12 Adjusting the Distance Accuracy . 5-14
5.13 Factory Preset Settings ..5-16
5.14 Testing the Sensors ... 5-18
5.15 Testing the Control Panel Keys 5-19
5.16 Printing the Test Patterns . 5-20
5.17 Test Modes for Production Inspection .. 5-22
5.18 Interpreting the Mechanical Check Pattern ..5-24
5.19 Setting the DIP Switch from the LCD ..5-27
-3-
..
..
..
..
6-1
6-1
6-2
6-3
7. TROUBLESHOOTING
7.1
Mainframe .8-1
Y Drive Section 8-3
X Drive Section 8-5
Push Roller Arm and Y Rail Section ... 8-7
Pen Block and Y Slider Section .. 8-9
Chassis Section . 8-12
Film Stocker Section .... 8-14
Carton Box and Accessory .. 8-16
Users Manual, Operation Manual, and Other Documentation 8-16
Stand and Media Basket Option 8-17
Pouncing Tool Option 8-19
-4-
1. INTRODUCTION
1.1 Notes on Installation and Use
1.1.1 Notes on Installation
Avoid use or storage of the plotter in places subject to direct sunlight or the direct draft from airconditioning systems.
Prior to cutting, ensure that no obstacles are placed in the vicinity of the pen carriage or loaded
medium. Impeded movement of the pen carriage or loaded medium may prevent accurate cutting.
To prevent malfunctions of the plotter's sensors, position the plotter at least one meter away from
fluorescent lamps, electric lamps, and any other sources of indoor illumination.
1-1
To avoid scratching the cutting mat, ensure that the cutter pen's blade is not excessively extended.
While the plotter is operating, do not touch the moving parts of the plotter.
When manually moving the pen carriage to load the medium, be sure to move the pen carriage slowly.
1-2
1-3
Compatible film
Standard interfaces
Buffer memory
Resident command sets
LCD panel
Compatible paper for pouncing
Power supply
Power consumption
Operating environment
Recommended environment
External dimensions
Weight
16-bit
Grit-rolling cutting plotter
Digital servo
50 m x 580 mm
10 m x 580 mm *1
50 to 635 mm (2 to 25 inches)
80 cm/s
21-step range (1 to 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 80
cm/s)
31-step range (5 to 300 g)
about 5 mm square (varies with the film and character font)
0.005 mm
GP-GL: 0.1/0.05/0.025/0.01 mm (selected by menu)
HP-GLTM emulation mode: 0.025 mm *2
Within 0.1 mm/2 m (excluding expansion or contraction caused by
changes in the operating environment)
1
Cutter blades: Super-steel, ceramic, and sapphire blades
Plotter pens: water and oil based, fiber-tip, water based ball-point,
ceramic, refillable ink, and disposable ink pens
Pouncing pen: 1.2 mm diameter pin
Mono-vinyl chloride film, fluorescent film, and film for illuminated
displays (highly-reflective film excluded), up to 0.25 mm thick
Sandblast rubber up to 1 mm thick *3
RS-232C serial, Centronics compatible parallel (automatic interface
selection)
1 M byte
GP-GL and HP-GLTM emulation (selected by menu)
20 characters x 2 lines; in six languages
Regular paper from 0.06 to 0.13 mm thick
100 to 120 VAC; 50/60 Hz
220 to 240 VAC; 50 Hz
120 VA max.
Temperature: +10C to +35C
Humidity: 35% to 75% RH (non-condensing)
Temperature: +16C to +32C
Humidity: 35% to 70% RH (non-condensing)
approx. 860 (W) x 622 (D) x 310 (H) mm
approx. 22 kg
1-4
1.3.2 Options
Item
Stand
Pouncing tool set
Model no.
ST1001
PPA31-TP12
Contents
With basket
Pouncing plunger
Pouncing pin
Pouncing mats
1
1
5
1-5
1-6
2. BASIC OPERATION
2.1 Control Panel
Indicator Lamps
The POWER lamp remains lit (green) while the plotter is on.
The PROMPT lamp lights (red) when the plotter receives data that will
cause the pen carriage to move outside the effective cutting area or
receives the "Prompt Light" command (T) from the computer.
SELECT Keys
Depending on the menu being displayed, these keys are used to:
Load a group of cutting conditions retained in the plotter's memory;
Shift the cursor when setting a numeric value far a function;
Select the desired sub-menu.
POSITION Keys
All four keys are used to move the pen carriage when setting a function
that requires the specification of a coordinate position.
The [ ] and [ ] keys are used to raise or lower the displayed numeric
setting of a function.
The [] and [] keys are used to select the pen type when setting a
group of cutting conditions.
PAUSE Key
Press the [ PAUSE ] key to select PAUSE mode (its green lamp lights) and
temporarily suspend a cutting or plotting operation. Press it again to cancel
PAUSE mode (the lamp goes off).
Select PAUSE mode to set functions at the control panel (see Section 2.2,
"Selecting a Function Menu") or to store data from the computer in the
plotter's receive buffer.
ENTER Key
After setting a function at the display panel, press the [ ENTER ] key to
register your setting.
To reset the plotter, concurrently press the [ ENTER ] and [ ORIGIN ] keys.
2-1
ORIGIN Key
Used to move the origin point.
To reset the plotter, concurrently press the [ ENTER ] and [ ORIGIN ] keys.
COPY Key
Used to repeat the cutting operation defined by the data in the plotter's
receive buffer.
CONDITION Key
Used to set the four groups of cutting conditions retained in the plotter's
internal memory or to select one group as the current cutting conditions.
NEXT Key
To set a function at the control panel, press the [ PAUSE ] key to select
PAUSE mode and then consecutively press the [ NEXT ] key until the
desired menu appears (see Section 2.2, "Selecting a Function Menu").
2-2
Function selection
Sub-menus
Function Description
_ [2] Film _________ [1] ORIGIN POINT Setting the Origin in HP-GLTM Mode
_ [2] OVERCUT
For information on setting the COPY function and other special functions, see USERS
MANUAL Section 4.11 "Using the COPY Function", and USERS MANUAL Section 5.18
"Using the Special Function".
2-3
Language selected
Japanese
German
English
French
Spanish
Italian
[ NEXT ]
[ NEXT ]
[4]
[4]
[4]
2-4
To select DUMP mode, press the [ 2 ] key to shift the blinking cursor next to ON.
If you decide not to select DUMP mode, press the [ 4 ] key to shift the blinking cursor to OFF.
[ ENTER ]
: Press the [ ENTER ] key.
If DUMP mode has been selected, CHAR DUMP MODE appears on the display to indicate that the plotter
has entered DUMP mode.
Transmit the data from the computer. As the data is received, the character data is printed as ASCII
codes and the non-character (control) data is plotted as two-digit hexadecimal values (e.g., Line Feed =
0A, Carriage Return = 0D, ETX = 03).
When all of the data has been printed, turn off the plotter to cancel DUMP mode.
2-5
[ NEXT ]
[ NEXT ]
[ NEXT ]
[4]
[4]
[3]
To select the SELF TEST mode, press the [ 2 ] key (YES) to initiate printing of the self test pattern.
To return to the OPTION 1/2 selection menu, press the [ 4 ] key.
When you have finished printing the self test pattern, turn off the plotter to cancel SELF TEST mode.
Note : The self test pattern is repeatedly printed until the plotter is turned off. To discontinue printing,
even if a pattern is not completely printed, simply turn off the plotter.
2-6
[ NEXT ]
[ NEXT ]
[ NEXT ]
[4]
[4]
As soon as the [ 2 ] key (CONDITION) is pressed, the message below appears and the plotter begins
printing a list of the currently set cutting conditions.
When all of the conditions have been printed, the READY message reappears.
2-7
2-8
2-9
2 - 10
2 - 11
For the specifications of your plotter's serial interface, see Section 2.11,"RS- 232C Serial
Interface."
Procedure
[ PAUSE ]
[ NEXT ]
[ NEXT ]
[1]
[2]
The menu below appears, so select the group of RS-232C interface conditions to be changed.
2 - 12
Press the numeric key next to the condition you wish to change. The selected condition blinks to indicate
that you can change its setting, so press the [ ] or [ ] key until the desired value appears.
To set the rate of data transfer, press the [ 1 ] key. Next, consecutively press the [ ] or [ ] key to cycle
through the available speeds in the sequence below.
300 600 1200 2400 4800 9600
|_________________________________________|
To set the number of bits per character, press the [ 2 ] key. Next, press the [ ] or [ ] key to select 7 or
8 bits.
78
|_________|
To set the parity mode, press the [ 3 ] key. Next, press the [ ] or [ ] key to cycle through the available
choices.
N(No parity check) E(Even parity) O(Odd parity)
|_________________________________________________|
To set the handshaking mode, press the [ 4 ] key. Next, consecutively press the [ ] or [ ] key to cycle
through the available handshaking modes.
H(Hardwire) X(X on/X off) E(Enq/Ack)
|__________________________________________|
E(Enq/Ack) only appears when HP-GLTM command mode has been selected.
[ ENTER ]
[ PAUSE ]
: When the displayed settings are all correct, press the [ ENTER ] key to register your
settings.
: Press the [ PAUSE ] key to cancel PAUSE mode.
Note : Your settings are retained in the internal memory even while the plotter is turned off.
2 - 13
[ NEXT ]
[ NEXT ]
[1]
[4]
To select GP-GL command mode, press the [ 2 ] key to shift the blinking cursor to the left.
To select HP-GL command mode, press the [ 4 ] key to shift the blinking cursor to the right.
[ ENTER ]
[ PAUSE ]
Note : Your COMMAND setting is retained in the plotter's internal memory even while the plotter is
turned off.
2 - 14
[ NEXT ]
[ NEXT ]
[1]
[1]
To select the programmable resolution, consecutively press the [ ] or [ ] key to cycle through the
available sizes in the sequence below.
0.010 0.025 0.050 0.100
|_______________________________|
[ ENTER ]
[ PAUSE ]
Note : Your STEP SIZE setting is retained in the plotter's internal memory even while the plotter is
turned off.
2 - 15
DATA, BUSY
Negative logic
2 - 16
Compatible Connectors
Plotter end: FCN685JO36-L/Y (FUJITSU)
Cable end: 57-30360 (DDK)
Pin Assignment of the Parallel Connector
The pin assignment of the Centronics-compatible parallel interface connector is described below.
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Signal Name
STROBE
DB 0
DB 1
DB 2
DB 3
DB 4
DB 5
DB 6
DB 7
ACK
BUSY
GND
SLCT
Not used
Not used
GND
Not used
+5V
Pin No.
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
2 - 17
Signal Name
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
Not used
ERROR
GND
Not used
GND
GND
Electrical Characteristics
RD,SD
(Negative logic)
+ 5 V to + 12 V
- 5 V to - 12 V
+ 5 V to + 8 V
- 5 V to - 8 V
RS,CS,DR,ER
(Positive logic)
Logical "0" "ON"
Logical "1" "OFF"
Logical "0" "ON"
Logical "1" "OFF"
Compatible Connectors
Plotter end :
Cable end :
DB-25S
(ISO 2.6mm nut (M2.6 x 0.45) or ANSI #4-40 nut should be used as the locking nut.)
DB-25P
(ISO 2.6mm screw (M2.6 x 0.45) or ANSI #4-40 screw should be used as the locking.)
2 - 18
Diameter and
blade offset value
Diameter
0.9 mm
Blade offset
0.45
Plunger part
number
PHP32-CB09
CB15U
(super-steel)
Diameter
1.5 mm
Blade offset
0.75
PHP32-CB15
CB15U-K30
(super-steel)
Diameter
1.5 mm
Blade offset
0.75
PHP32-CB15
CB15-10C
(ceramic)
Diameter
1.5 mm
Blade offset
0.50
PHP31-CB15
CB15-05S
(sapphire)
Diameter
1.5 mm
Blade offset
0.25
PHP31-CB15
3-1
3-2
Color
classification
Blue
Red
PHP31-CB15
Red
Compatible blade
types
CB09UA
CB15U
CB15U-K30
CB15-10C
CB15-05S
Blade material
Super-steel
Super-steel
Super-steel
Ceramic
Sapphire
18 2
28 2
28 2
18 2
92
3-3
3-4
If the film thickness cannot be accurately determined, adjust the blade length by gradually increasing it
until only traces of the blade appear on the backing sheet when a cutting test is executed. For more
information about the cutting test, see USERS MANUAL Section 4.7, "Running a Cutting Test ".
3-5
(1) Loosen the screw securing the pen holder. While pressing the pen holder upward, push the cutter pen
all the way into the holder until it contacts the pen stopper.
(2) When the pen has been properly mounted, tighten the screw.
3-6
Adjust the blade length according to the thickness of the medium (see
Section 3.4, "Adjusting the Blade Length").
Cutting force
Cutting speed
Cutting quality
Cutter offset
Set this condition according to the type of cutter blade you are using (see
USERS MANUAL Section 4.5, "Setting the Cutter Pen Conditions").
To ensure optimum cutting results, be sure to set the above parameters in conformance with the guidelines
provided in the tables below.
Cutting Conditions by Medium
Cutting medium
Outdoor film
Indoor film
Transparent film, translucent film
Reflective film
Fluorescent film
Thickness
(mm)
0.05 to 0.08
0.08 to 0.1
0.08 to 0.1
0.08 to 0.1
0.20 to 0.25
0.5 to 1.0
Blade type
FORCE
SPEED
QUALITY
CB09UA
CB09UA
CB09UA
CB09UA
CB09UA,
CB15U
CB15U-K30
10 to 14
14 to 17
14 to 20
14 to 20
20 to 24
over 30
over 30
over 30
over 30
10 to 20
3 to 4
3 to 4
3 to 4
3 to 4
2 to 3
17 to 24
5 to 15
*1 Before cutting sandblast rubber, make sure that Condition 4 has been selected, and that THICK
MODE has been enabled.
Cutter Offset by Blade Type
Ceramic
Sapphire
Other
CB09UA
CB15-10U
CB15U
CB15U-SP
CB15U-K30
CB15U-K30-SP
CB15-10C
CB15-05S
Blade type
09U
15-10U
15U
15U
15U-K30
15U-K30
15-10C
15-05S
OTHER
Panel display
CUTTER OFFSET
Default
Setting range
0
5
0
5
0
5
0
5
0
5
0
5
0
5
0
5
1
1 to 45
When using a blade type that is not listed in the table above or when a cutting operation using a thick or
otherwise difficult to cut medium produces unsatisfactory results, set the blade type to OTHER and then
alternately adjust the CUTTER OFFSET value and run a cutting test until the desired results are achieved.
3-7
3-8
4. MECHANISMS
4.1 Removing the Outer Casing
4.1.1 Removing the Left and Right Side Covers
(1) Remove the left and right side covers as shown in Figs.4-1 and 4-2.
Four M4 x L6 bind-head screws (black) each
Fig. 4-1
Fig. 4-2
(2) To attach a side cover, reverse the above procedure.
4-1
Fig. 4-3
Fig. 4-4
(2) As shown in Figs.4-5 and 4-6, push the guide inward and upward to release it and then pull it off
toward you.
Fig. 4-5
Fig, 4-6
(3) To attach the front or rear guide, reverse the above procedure.
4-2
Fig. 4-7
(3) Remove the GND terminal from the control panel sheet.
One M3 x L8 pan-head thread forming screw and flat washer
(4) As shown in Fig.4-8, remove the top cover while being careful to avoid damaging the FPC cable and
the other cable.
Four M3 x L6 bind-head screws
Fig. 4-8
(5) To attach the top cover, reverse the above procedure.
* Avoid damaging the FPC cable.
* When inserting the FPC cable into the relay board's J21 connector, make sure the cable's connector
is correctly oriented.
* To ensure proper contact, run the control panel key test (see Section 5.13).
Fig, 4-9
4-3
Fig. 4-10
(4) To attach the control panel base, reverse the above procedure.
4-4
Fig. 4-11
(4) To mount the relay board, reverse the above procedure.
* Run the control panel key test (see Section 5.15).
* Run the sensor test (see Section 5.14).
Fig. 4-12
(3) Disconnect the Y FPC cable from the PR216013 pen board's J31connector.
4-5
Fig. 4-13
(5) As shown in Fig.4-14, disconnect the pen block FPC cable from the PR216013 pen board's J32
connector.
Fig. 4-14
(6) Remove the pen board as shown in Fig.4-15.
Two M3 x L6 pan-head with flat washer screws
Fig. 4-15
(7) To mount the pen board, reverse the preceding procedure.
* Avoid hitting the Y sensor plate with the pen board.
* Run the sensor test (see Section 5.14).
4-6
Fig. 4-16
(4) Loosen the tension of the Y slider belt.
One M4 x L15 socket-head cap screw
Fig. 4-17
(5) Remove the pen board (see Subsection 4.2.2).
4-7
Fig. 4-18
(7) Remove the Y slider belt as shown in Fig.4-19.
* Be careful not to drop the Y tension pulley as it may become damaged.
Fig. 4-19
(8) To attach the Y slider belt, reverse the preceding procedure.
* Before securing the ends of the Y slider belt, loosen the M4 x L15 socket-head cap screw to the
maximum.
* As shown in Fig.4-20, ensure that the belt's notched surface fits into the Y slide's slits.
Fig. 4-20
4-8
Fig. 4-21
* Secure the ends of the Y slider belt with a tightening torque of 8 kg-cm. This is to prevent
malfunction of the circuit boards at low temperatures and to ensure electrical contact between the Y
slider and the Y slider belt.
* When mounting belt stays B, make sure the M3 x L6 screws are not inserted at an angle.
* As shown in Fig.4-22, ensure that the tension spring fits properly on the screw head on the spring
adjustment plate.
Fig. 4-22
* Do not forget to secure the spring adjustment board.
4-9
Fig. 4-23
(3) As shown in Fig.4-24, pass a Y belt tension jig (part no. 462500006) or a non-shrinking cord below
the center of the Y slider belt.
Fig. 4-24
(4) Adjust the tension.
As shown in Fig.4-25, use a 1 kgf push-pull gauge to check that the center of the belt is displaced
by 20 mm when pulled by a force of 800 gf 20 gf.
Fig. 4-25
4 - 10
Fig. 4-26
* When the Y slider belt has been mounted for a long time, the possible range of adjustment becomes
smaller.
(5) Check the belt tension as shown in Fig.4-27.
Using a 1 kgf push-pull gauge, check that the belt's center is displaced by 20 mm at a pull force of
800 gf 20 gf.
Fig. 4-27
(6) Secure the spring adjustment plate.
Two M4 x L8 bind-head screws
(7) Perform re-assembly by reversing Steps (1) through (3) of "Replacing the Y Drive Belt".
4 - 11
Fig. 4-28
(6) As shown in Fig.4-29, remove both the Y drive pulley and Y drive belt.
Fig. 4-29
(7) To attach the Y drive belt, reverse the above procedure.
4 - 12
Fig. 4-30
(3) As shown in Fig.4-31 , push down on the Y motor using a 5 kgf push-pull gauge.
Push force : 1.8 0.2 kgf.
Fig. 4-31
(4) While continuing downward pressure on the Y motor, secure it into place.
Four M3 x L8 pan-head with flat washer screws
(5) Perform reassemble by reversing Steps (1) through (3) of "Replacing the Y Drive Belt."
4 - 13
Fig. 4-32
(3) Remove the X drive belt as shown in Fig.4-33.
Fig. 4-33
(4) To attach the X drive belt, reverse the above procedure.
4 - 14
Fig. 4.34
(3) While continuing downward pressure on the X motor, secure it into place.
Four M3 x L8 pan-head with flat washer screws
* At the factory, the tension has been pre-adjusted using a vertical push force of 2.0 0.1 kgf.
4 - 15
Fig. 4-35
Fig. 4-36
Fig. 4-37
4 - 16
Fig. 4-38
(6) As shown in Fig.4-39, secure the BB mounting plate.
* Apply pressure to the three rollers at the rear of the Y slider.
Two M3 x L6 bind-head screws
Fig. 4-39
(7) Secure the BB holder plates.
* Ensure that the BB holder plate do not contact the areas shown in Fig.4-40.
Two M3 x L6 bind-head screws
Fig. 4-40
Apply pressure to the two rollers at the front of the Y slider.
4 - 17
Fig. 4-41
(2) While holding the pen block as shown in Fig.4-42, apply pressure in the directions indicated by the
arrows.
* Do not mistake the Y slider's give for play.
Fig. 4-42
If play is detected, it may be caused by one of the following:
The roller pressure requires adjustment (see "Adjusting the Roller Pressure").
The rollers have deteriorated or are otherwise damaged. Replace them.
A BB holder plate or the BB mounting plate is deformed. Replace the pertinent part.
There is only one BB holder plate. Use two plates.
4 - 18
Fig. 4-43
(2) Remove the push roller pin as shown in Fig.4-44.
Press the push roller arm using your fingers.
Use an L-shaped hex wrench or its equivalent.
Fig. 4-44
(3) To attach the push roller, reverse the above procedure.
Note : Replacement of the entire push roller arm assembly can only be performed at the factory.
4 - 19
Fig. 4-45
(3) As shown in Fig.4-46, push downward on the push roller arm using a 5 kgf push-pull gauge.
* Structurally, pressure cannot be applied straight down; it must be applied at a slight angle.
Fig. 4-46
(4) Read the F (push force) value when the stainless steel plate jig begins to slide.
* F = 2.5 to 2.7 kgf
Fig. 4-47
4 - 20
Fig. 4-48
* One push roller arm assembly is equipped with two springs, so ensure that both of their upper nuts
are the same height.
Fig. 4-49
(6) Measure the push force again.
Check that the difference between the push force on the right and left sides is no greater than 50g.
If the difference is greater, adjust the roller pressure again.
4 - 21
Fig. 4-50
(3) Remove the FPC cable guide as shown in Fig.5-51.
Two M2 x L4 bind-head screws
* The screw may become stuck to the MC coil.
* Be careful not to scratch the slide shaft.
Fig. 4-51
(4) Disconnect the pen block FPC cable from the PR216013 pen board's J32 connector.
(5) Remove the pen block as shown in Fig.4-52.
Make sure not to damage the pen block FPC cable.
Two M3 x L6 bind-head screws
Fig. 4-52
4 - 22
Fig. 4-53
* When securing the pen block, avoid scratching the slide shaft with the screwdriver or other tool.
Fig. 4-54
* As shown in Fig.4-55, pass the pen block FPC cable below the MC block's reinforcing rib to
prevent damaged cable leads.
Fig. 4-55
* When securing the 60A FPC cable guide, be sure not to damage the pen block FPC cable.
(7) Adjust the pen servo system (see Section 5.9).
4 - 23
Fig. 4-56
(3) Turn the offset pin toward the right and then check the pressure at the point where it lightly stops.
Fig. 4-57
(4) Check the slide arm pressure as follows.
As shown in Fig.4-58, use your finger to hold down the bearing closest to the offset pin as you
check that the slide arm moves smoothly.
Fig. 4-58
4 - 24
Fig. 4-59
(5) If the check results are satisfactory, secure the offset pin in place.
One M2 x L6 set screw
* The bearing's pressure may change when the offset pin is secured.
(6) Repeat the checks described in Step (4).
(7) If the check results are satisfactory, attach the pen block cover.
4 - 25
Fig. 4-60
(4) Remove the X motor.
(5) To mount the X motor, reverse the above procedure with special attention to the following point.
* As shown in Fig.4-61, mount the motor so that its leads emerge from the top of the motor.
Fig. 4-61
(6) Adjust the X drive belt's tension (see Subsection 4.2.5).
4 - 26
Fig. 4-62
(4) To attach the X motor pulley, reverse the above procedure.
* As shown in Fig.4-63, position the motor pulley so that its set-screws fit into the D-shaped cutout
of the motor shaft.
Fig. 4-63
4 - 27
Fig. 4-64
(3) To mount the Y motor, reverse the above procedure with special attention to the following point.
* As shown in Fig.4-65, mount the motor so that its leads emerge from the top of the motor.
Fig. 4-65
(6) Adjust the Y drive belt's tension (see Subsection 4.2.4).
4 - 28
Fig. 4-66
(3) Remove both the Y drive belt and Y drive pulley.
(4) Remove the Y motor pulley.
* Be sure not to lose the set screws.
* Note that the motor pulley may be hard to remove.
Two M3 x L3 set screws
(5) To attach the Y motor pulley, reverse the above procedure with special attention to the following
points.
* As shown in Fig.4-67, position the motor pulley so that its set-screws fit into the D-shaped cutout
of the motor shaft.
Fig. 4-67
4 - 29
Fig. 4-68
(3) To mount the X drive pulley, reverse the above procedure with special attention to the following
point.
* As shown in Fig. 4-69, mount the X drive pulley so that there is a 2 mm clearance with respect to
the left side plate.
Fig. 4-69
4 - 30
Fig. 4-70
(3) To mount the Y tension pulley, reverse the above procedure.
4 - 31
Fig. 4-71
(5) As shown in Fig.4-72, disconnect the other end of the Y FPC cable from the PR216012 relay board's
J201 connector.
Fig. 4-72
4 - 32
Fig. 4-73
(2) Attach double-sided tape to the FPC cable bracket as shown in Fig.4-74.
Fig. 4-74
(3) Attach the Y FPC cable to the FPC cable bracket as shown in Figs.4-75 and 4-76.
* Attach the cable so that its A and B points respectively match the bracket's A' and B' points.
Fig. 4-75
Fig. 4-76
4 - 33
Fig. 4-77
(5) Mount the FPC cable bracket to the Y slider.
(6) As shown in Fig.4-78, attach double-sided tape to the Y bar at two points for securing the Y FPC
cable.
Tape dimensions: 10 mm by 20 mm each
Fig. 4-78
(7) As shown in Fig.4-79, slide the Y slider against the left mechanical stopper and then secure the Y
FPC cable at the position where it is naturally extended.
Fig. 4-79
(8) Connect the Y FPC cable to the PR216012 relay board's J201 connector.
(9) Manually slide the Y slider from side to side to check that the Y slider moves smoothly and that the Y
FPC cable does not come loose.
(10) Attach the top cover and right side cover.
4 - 34
Fig. 4-80
(3) Remove each paper size sensor.
One M3 x L10 bind screw each
(4) To mount the sensors, reverse the above procedure.
(5) After mounting the sensors, check the operation as follows.
(a) Run the sensor test to check proper switching between the HIGH and LOW states (see Section
5.14 Testing the Sensor).
(b) After reassembling the plotter, load a single sheet of paper, and then select the SHEET paper
mode (F3 key) to detect the paper size.
(6) If the sensors malfunction during the preceding Step (5)(b), the sensors are possibly incorrectly
positioned with respect to their corresponding holes in the front and rear guides. It also possible that
the rear paper size sensor is too sensitive, causing it to misread the paper position.
Remedy
(a) Manually bend the sensor bracket to correct the position of the sensor relative to its corresponding
guide hole.
(b) As shown in Fig.4-81, cover half of the photoreceptor with black tape (if black tape is not already
attached).
Fig, 4-81
(7) As shown in Fig.82, remove the M3 x L6 bind-head screw to remove the sensor bracket.
* Use a small screwdriver at the rear of the plotter.
Fig. 4-82
4 - 35
Fig. 4-83
(2) Remove the LCD panel as shown in Fig.4-84.
Four snap-in rivets (0.122 dia, black) and four flat washer (M3, paper)
* The rivets can easily be removed using tweezers.
Fig. 4-84
* Be careful not to damage the board's printed circuit.
* Note that a portion of the LCD panel is attached to the double-sided tape of the control panel sheet.
Remove the tape as shown in Fig.4-85.
Fig. 4-85
(3) To mount the LCD panel, reverse the above procedure.
4 - 36
Fig. 4-86
(3) Use alcohol to remove any adhesive remaining on the control panel base.
(4) To attach the control panel sheet, reverse the above procedure.
* Position the sheet beginning with its bottom edge (the edge closest to you).
* Visually check that the same margin has been provided at both sides of the sheet.
Fig. 4-87
4 - 37
Fig. 4-88
(4) Remove the main board as shown in Fig.4-89.
Six M3 x L6 pan-head with flat washer screws
Fig. 4-89
(5) To mount the main board, reverse the above procedure.
* Make absolutely sure to conduct all electrical adjustments!
4 - 38
Fig. 4-90
Fig. 4-91
(4) Carefully slide out the power unit, disconnect the leads secured by screws as shown in Fig.4-92, and
then remove the power unit.
* Be sure not to damage the power unit's printed circuit.
Fig. 4-92
(5) To mount the power unit, reverse the above procedure.
* Make sure that the leads are correctly connected.
Green
: FG terminal
Blue
: N terminal
Brown : L terminal
4 - 39
Fig. 4-93
(4) When mounting the ROM chips, pay attention to the following points.
Never touch the pins of the ROM chips.
Check the position, orientation, model name, specifications, version number, and E/O distinction of
the ROM chips.
Securely mount each chip in its IC socket as shown in Fig.4-94, taking care not to bend any of its
pins.
Fig. 4-94
(5) Connect the power cord to the electrical socket.
(6) While holding down the [ ] POSITION key, turn on plotter.
* Check that the message below appears on the display panel.
4 - 40
Fig. 4-95
4 - 41
Fig. 4-96
(4) To mount the vacuum fan, reverse the above procedure.
4 - 42
Fig. 4-98
Attach the Right Bracket
(1) Slide a Roll Guide on the 3/4 inch Rod from the right side.
(2) Temporarily secure the roll guide in place using an M4 Thumb Screw.
(3) Temporarily attach the first 1/2 inch Rod using an M4 x 10mm Flat Head Screw.
(4) Temporarily attach the second 1/2 inch Rod using the same hardware.
4 - 43
Fig. 4-99
Placing the Plotter on the Film Stocker
Note : If your plotter Is to be mounted to a GRAPHTEC plotter stand, attach the film stocker assembly to
the plotter stand before placing the plotter on the Film Stocker. The hardware required and
assembly instructions will be included in the stand accessory shipping carton.
(1) Slide the front of the plotter on to the top flanges of the film stocker brackets.
(2) Align the chassis mounting brackets on the bottom of the plotter with the flanges on the film stocker
brackets.
(3) Slide the plotter forward.
Fig. 4-100
Assembly Tip : If the chassis mounting brackets bind against the sides of the film stocker brackets try the
following suggestion :
1. Turn the plotter up on its front face on a flat surface.
2. Slightly loosen the screws that mount the slide brackets to the bottom chassis.
3. Move the slide brackets inward as much as possible.
4. Tighten the screws that mount the slide brackets to the bottom chassis.
5. Turn the plotter right side up.
Now the plotter should slide onto the film stocker assembly.
4 - 44
Fig. 4-101
Install the Film Stocker Rollers
(1) Slide the second roll guide onto the Film Stocker Roller from the right side. Temporarily secure it in
place using the second M4 Thumb Screw.
(2) Place the first Film Stocker Roller into the first roll guide slot on the left and right film stocker
brackets.
(3) Place the second Film Stocker Roller into the desired slot depending on the size of the media roll
being used.
Fig. 4-102
Straighten and Tighten the Film Stocker Assembly
(1) Verify the Film Stocker Assembly is not skewed.
4 - 45
Fig. 4-103
Fig. 4-104
(2) Load a sheet of film in the plotter.
(3) Align the right edge of the sheet with the supply side and the front roll guides.
(4) Measure the distance of the front and rear roll guides from the media bracket to the edge of the roll
guide.
4 - 46
Fig. 4-105
Adjusting the Push Roller Positions
(1) Move the push rollers as required to hold down the film within the appropriate range.
Fig. 4-106
(2) Be sure to position the push rollers so they are not located right at the edges of the film or grit rollers.
Note : If necessary, slowly move the pen carriage out of the way. The pen carriage cannot be moved to
the right of the right push roller (as viewed from the front of the plotter.)
Caution : Be sure to move the pen carriage slowly. Moving the pen carriage quickly may damage the
plotter.
When "MAINTENANCE3" function has been set "ON", the pen carriage will not be released
even if the film set lever is lowered.
4 - 47
Fig. 4-107
Turning On the Power
(1) Turn on the plotter by pressing the I side of the power switch.
Fig. 4-108
(2) Select the menu sequence required for your operation.
(3) Plotter initializes and the film loading is complete.
Note : For instructions on connecting the plotter to a power supply and selecting the film type, See
Section 4.1, Turning On the Plotter.
4 - 48
Fig. 4-109
(2) Install the Top Connecting Tube to the Right Side Vertical Support using the same hardware.
Fig. 4-110
4 - 49
Fig. 4-111
(4) Invert Assembly.
(5) Invert the Right Side Base and attach to the Right Side Vertical Support using 3 M6 x 8mm screws
and the Hex Key.
Repeat the process to attach the Left Side Vertical Base.
Fig. 4-112
(6) If the Stand Assembly is skewed, loosen the supports screws. Make sure the stand is fiat.
4 - 50
Fig. 4-113
(8) Install the 4 End Caps.
(9) Return the Stand Assembly to it's upright position.
Note : The Front has a shorter base. The Front must have locking casters.
(10) Make sure the front of the plotter is aligned correctly.
Fig. 4-114
Caution : Improper alignment of these pieces may cause the unit to become unstable when heavy loads
are added. In extreme cases, the unit may tip over.
Fig. 4-115
Note : Always keep the wheels in a locked position when operating your plotter.
4 - 51
Fig. 4-116
(3) If there is Media Bracket attached, remove the two rubber feet from the front two media brackets as
shown using the Phillips screwdriver.
Fig. 4-117
Install a new Accuload
TM
To install a new Accuload TM Film Stocker Bracket, follow the directions below.
(1) Lay the assembled Film Stocker Bracket on a flat surface and cheek for flatness.
(2) If the Film Stocker Bracket is skewed, loosen the 6 screws holding the 3 Stiffener Rods. Make sure
the bracket is lying flat.
Fig. 4-118
4 - 52
Fig. 4-119
Install the Accuload
TM
Fig. 4-120
(3) Mount the Film Stocker Bracket to the mounting flanges. Align the outside holes in the Stand flange
with the outside holes in the Film Stocker Bracket.
(4) Install 4 M4 x 8mm Screws in the outside holes using the Phillips head screw driver.
Fig. 4-121
(5) Slide the platter onto the Film Stocker Brackets. Screw the Film Stocker Bracket to the plotter.
4 - 53
Fig. 4-122
Fig. 4-123
(2) Slide one Basket Tube over each wire end.
Fig. 4-124
(3) On the same surface, place one Right Side Basket on it's side with the five wire ends facing left.
4 - 54
Fig. 4-125
(5) Gently rock and slide the Right and Left Side Baskets together until both halves are completely seated
on all five Basket Tubes.
(6) Repeat the same process for the second Media Basket.
Fig. 4-126
Mounting the Media Basket
(1) Install one Rubber Bumper on the Left and Right Front Standoffs.
Locate the Standoffs at the front of the Accuload TM Film Stocker Bracket.
1. Hold the Rubber Bumper at a slight angle.
2. Catch the Rubber Bumper edge on the standoff.
3. Firmly turn the Rubber Bumper clockwise until it is fully seated on the media bracket.
Fig. 4-127
(2) Install the Front Media Basket as shown.
Fig. 4-128
4 - 55
Fig. 4-129
4 - 56
Fig. 4-130
Disassembling the Pouncing Pin
(1) Disassemble the cartridge on a clean, uncluttered, well lit work surface.
(2) Remove the cap at the top of the pounce tool by turning the cap counterclockwise.
Set the plastic cap on it's top so it will not roll away.
Fig. 4-131
(3) Remove the plastic body of the pounce tool by slipping it off the bottom of the pounce tool. Set the
plastic body down on it's side to prevent the spring and safety cap from sliding out and getting lost.
Fig. 4-132
4 - 57
Fig. 4-133
Replacing the Pouncing Pin
(1) Locate the M2 set screw and the hex key provided in your kit. Use the hex key to loosen the set screw.
Turn the hex key counterclockwise 2 or 3 turns.
(2) Hold the knurled end (top with etched diamond patterns) of the retainer securely with one hand and
remove the old pin with the other hand. Place the old pin in a safe container and throw it away.
Fig. 4-134
(3) Locate the new pin. One side of the pin's shaft is flat.
Fig. 4-135
(4) Align the flat side of the pin with the M2 set screw on the retainer. Once the two points are aligned,
slide the pin into the retainer until it stops.
(5) Using the hex key, tighten the M2 set screw until snug by turning the hex key clockwise 2 or 3 turns.
Fig. 4-136
Caution : Do not over tighten. Set screw is easily stripped !!
Assembling the Pouncing Pin
(1) Install the sleeve by turning the retainer counterclockwise.
Fig. 4-137
4 - 58
Fig. 4-138
(3) Install the cap at the top of the pounce tool by turning the cap clockwise until snug.
Adjusting the Pin Length
The pin length is adjusted by turning the retainer.
Turn the retainer counterclockwise to shorten the pin.
Turn the retainer clockwise to length the pin.
(1) Pin should measure 7.75mm (.305 in.) when the safety cap is depressed.
Fig. 4-139
Caution : Always use the appropriate pressure setting to pierce the media.
To much pressure will cause the pin to hit the hard plotter surface under the pouncing mat.
This will dull the pin and bend the pin shaft.
4 - 59
Fig. 4-140
Caution : If you perform pouncing on a cutting mat instead of the special pouncing mat, the holes may
not pounce correctly and you may damage your plotter. Be sure to replace the cutting mat with
a pouncing mat before beginning a pouncing operation. Always reinstall cutting mat before
beginning a cut operation.
Installing the Pouncing Mat
(1) Remove the backing sheet from the underside of the pouncing mat.
(2) Move the pen carriage to the right of the plotter.
(3) Starting from the left side of the plotter, align the mat with the rear edge of the groove (leave 2-3 mm
gap between the side plate and the mat), then carefully attach the mat. Take care that the mat does
not buckle, and work with a small area at a time.
(4) When you reach the center, move the pen carriage to the left before attaching the rest of the mat.
4 - 60
5. ELECTRICAL ADJUSTMENTS
5.1 Location of the Main Board (PCB No. PR216001), Test Pins,
Trimmers, DIP Switch, and ROM Chips
5-1
Voltage
+5V
+ 12 V
+ 32 V
- 12 V
+ 24 V
GND
(2) If voltage levels cannot be measured at TP1 to TP5, use the following method to check operation.
Disconnect the main board's J101 connector.
Ned, use the multi-meter to measure the voltage levels of the J101 connector pins.
Pin Number
1 pin
2 pin
3 pin
4 pin
5 pin
6 pin
7 pin
8 pin
9 pin
10 pin
Voltage
+5V
+ 12 V
+ 32 V
GND
GND
+5V
- 12 V
+ 32 V
+ 32 V
GND
(3) If the measured voltage levels do not conform to the above tables, the power unit is probably
defective.
Protection against
excess current
Protection against
excess current
+ 32 V power
8 A or more
+ 5 V power
6 A or more
+ 12V power
6 A or more
- 12V power
3 A or more
When the protective circuit is activated, all of the plotter's supply voltages are switched off.
If the protective circuit is activated, turn off the plotter. After the plotter is left as is for three to five
minutes, it will automatically recover.
5-2
Corresponding area
UL model: USA, Japan, Asian
CE Model: Europe, Asian
5-3
Connector
CN2
CN3
Electrical adjustments
Pen height adjustment
Pen force adjustment
Selection of Centronics compatible interface mode
Sensor test
After replacing a sensor, run this test to check its operation
5-4
(3) After the "NOVRAM CLEAR END" message is displayed, return the DIP switch to its original
settings and then turn off the plotter.
Note : Clearing the non-volatile RAM initializes the pen height adjustment, distance accuracy
adjustment, and other settings to their respective default values.
5-5
VR1 (Y-OFFSET)
VR2 (X-OFFSET)
VR3 (P-OFFSET)
VR10 (X-GAIN)
VR20 (Y-GAIN)
Brown
Red
Orange
Yellow
Green
:
:
:
:
:
:
:
:
:
:
TP11
TP12
TP13
TP14
TP15 (GND)
5-6
(2) Test pins TP11 to TP15 of the test pin connector jig correspond to Pins 1 to 5 of the P100 connector.
(3) Connect the probe of an oscilloscope to TP11 and connect either TP10 or TP15 to ground level. The
wave-form shown in Fig. 1 appears at the oscilloscope.
Fig. 1
Fig. 2
(4) Turn the VR2 (X-OFFSET) trimmer until the wave-form peaks are the same height as shown in Fig.
2.
(5) To adjust the Y motor offset, repeat Steps (2) to (4) with the following changes.
Test pin : TP12 (connect TP10 or TP15 to ground level)
Trimmer : VR1 (Y-OFFSET)
(6) When adjustments are completed, return the DIP switch to its default settings and then turn off the
plotter. Also reconnect the X and Y motor encoder lines and remount the X and Y synchronous belts.
5-7
(2) Connect the probe of an oscilloscope to TP13 (Pin 3 of P100) and connect either TP10 or TP15 to
ground level.
Fig.2
(4) Turn the VR3 (P-OFFSET) trimmer until the wave-form peaks are the same height as shown in Fig.
2.
(5) When adjustment is completed, return the DIP switch to its default settings and then turn off the
plotter. Also reconnect the X and Y motor encoder lines.
5-8
(2) After the ROM and RAM checks, a menu for electrical adjustment appears on the LCD panel.
(4) When adjustment is completed, return the DIP switch to its default settings and then turn off the
plotter.
5-9
approx. + 5 V
approx. - 5 V
If the voltage levels are not approx. 5 V, perform all of the following and then adjust the pen servo
again.
Check the CAUTION remarks on the previous page.
Check that the pen block is properly mounted.
Check that the pen height sensor is properly mounted.
Check the power unit's supply voltages.
Adjust the pen offset again.
(6) Be sure to perform this adjustment whenever the pen block has been replaced.
5 - 10
(2) After the ROM and RAM checks, a menu for electrical adjustment appears on the LCD panel.
(3) Attach a cutter plunger to the pen holder and then press the [ 2 ] (PEN FORCE) key. The message
below appears.
(4) When the [ 3 ] (PEN U/D) key is pressed, the cutter is lowered or raised. After lowering the cutter,
use a dial tension gauge or its equivalent to measure the actual force of the displayed FORCE value.
If the measured value does not match, use the [ ] or [ ] POSITION key to increase or lower the
numeric value at the bottom left of the LCD panel.
Note : Before measuring the pen force again after changing the bottom left numeric value, be sure to
raise and then lower the cutter.
When the measured pen force is the specified value, press the [ ENTER ] key. The next specified pen
force appears on the LVD panel.
Repeat the above procedure in the sequence of 10 g (setting 1), 40 g (setting 10), 120 g (setting 20),
and then 300 g (setting 31).
(5) When adjustments are completed, return the DIP switch to its default settings and then turn off the
plotter.
5 - 11
SPG
Traveling distance
SS, AA
FC2100-60A
5
300 x 300
60, 30
FC3100-60
5
300 x 300
60, 30
(3) After inserting the floppy disk in the computer's disk drive, load and run the program.
(4) When the program is booted, the wave-form shown below appears on the computer's monitor.
5 - 12
While observing exploded view 2, use VR1 (X-OFFSET) or VR2 (Y-OFFSET) to correct any
deviation of the motor wave-form's origin from the ideal line's origin.
5 - 13
(2) After the ROM and RAM checks, the following menu appears on the LCD panel.
(3) When the [ 3 ] (SHEET) key is pressed, the plotter is initialized and then the menu below appears.
5 - 14
Use the [ 1 ] or [ 3 ] key to shift the cursor to the desired digit, then use the [ 2 ] and [ 4 ] keys to
input the numeric value.
(5) After inputting appropriate corrective values for both the X and Y distances, press the [ ENTER ] key.
The messages below consecutively appear.
(6) To adjust the distance accuracy again, press the [ ENTER ] key and repeat steps (3) and (4).
(7) When adjustment is completed, return the DIP switch to its default settings and then turn off the
plotter.
5 - 15
(3) After turning the plotter back on and waiting until it has been initialized, check that the plotter's
conditions are set as follows.
CONDITION 1
CONDITION 2
CONDITION 3
5 - 16
5 - 17
Display
Hm
Cm
+X
-X
Sensor name
Y home sensor
Cam sensor
Rear paper size sensor
Front paper size sensor
L
L
L
L
(3) If a sensor is not operating properly, check its wiring, its connector contact, and the position of the
sensor dog. If everything checks out all right, either the sensor or main board may be defective.
In this case, initialize the NOV-RAM and then run the sensor test again.
(4) As a temporary measure for dealing with a defective sensor, turn off the plotter, set Bit 4 of the DIP
switch to OFF, and then turn the plotter back on.
Note : When the plotter is turned back on, the pen position becomes the plot area's origin (0,0) and the
plotter is not initialized.
For more information, see Chapter 6, "TEMPORARY MEASURES FOR A SENSOR
MALFUNCTION".
5 - 18
(2) The menu below appears, so press the panel key corresponding to each bit and check that its value
properly changes to 1 or 0.
Normal status
:0
While the key is pressed : 1
The [ PAUSE ] key can be checked by observing its lamp.
(4) If a panel key's corresponding bit does not properly change status, check the following.
Fault in D1 or D2 on the PR216012 main board; or they may be attached in reverse
Improperly connected CA216011 cable
Initialize the non-volatile RAM (see Section 5.13 Factory Preset Settings) and then run this test
again
Defective main board
5 - 19
(4) Press the [ 3 ] (SELF TEST) key to display the prompt below.
(5) When the [ 2 ] (YES) key is pressed, the ROM's version number and the test pattern are printed.
5 - 20
(2) When the [ 2 ] (CONDITION) key is pressed, the plotter's currently selected conditions are printed.
Printing the ISO Demo Pattern
(1) Perform Steps (1) to (3) of the preceding "Printing the SELF TEST Pattern" to display the menu
below.
(2) When the [ 4 ] (PATTERN) key is pressed, the ISO demo pattern is printed.
5 - 21
(2) After pressing the [ PAUSE ] key, consecutively press the [ NEXT ] key until the menu below
appears.
(5) After pressing the [ 1 ] key, hold down the [ ENTER ] key as you press the [ 1 ] key again. The menu
below appears.
5 - 22
(2) Press the [ 3 ] (KAMIZURE) key to print the paper deviation check pattern.
Printing the Aging Pattern
(1) Perform Steps (1) to (5) above so that the menu below appears.
(2) Press the [ 2 ] (AGING) key to print the aging pattern for eight hours.
5 - 23
5 - 24
5 - 25
5 - 26
(4) Use the [ ] or [ ] POSITION key to shift the cursor to the desired position and then select its
ON/OFF status using the [ ] or [ ] POSITI0N key.
(5) Press the [ ENTER ] key to enable your new DIP switch settings to take effect.
5 - 27
Information detected
Width and front edge
Width
Width, front edge, back edge
Compatible media
Roll
Roll
Single sheets
L represents the page length setting and S represents the maximum paper width.
(6) Set the plot area.
Caution : Unless the plot area is set, the cutting mat may be damaged and a position error may be
caused by the pen block striking the side plate.
(3) Press the [ 2 ] (ON) key so that the flashing cursor moves to the ON position, then press the [ ENTER
] key.
(4) Turn the plotter off then back on again. The initial pen position is the origin (0,0).
6-1
No matter which mode you select, detection of the paper width will be disabled.
(6) Set the plot area.
Caution : Unless the plot area is set, the cutting mat may be damaged.
(3) Press the [ 2 ] (ON) key so that the flashing cursor moves to the ON position, then press the [ ENTER
] key.
(4) Turn the plotter off then back on again.
(5) After the RAM check, the menu below appears.
(6) The paper detection status varies with the mode you select as follows.
ROLL-1
ROLL-2
SHEET
6-2
(3) After displaying each MAINTENANCE menu, press the [ 2 ] (ON) key so that the flashing cursor
moves to the ON position, then press the [ ENTER ] key.
(4) Turn the plotter off then back on again.
(5) After the RAM check, the menu below appears.
No matter which mode you select, all paper size detection is disabled.
(6) When the plotter is turned back on, the pen position becomes the origin (0.0) and the menu below
appears.
6-3
7. TROUBLESHOOTING
7.1 The Cutting Results are Unsatisfactory
Problem
The cut corners are
rounded or too pointed.
Cause
Solution
7-1
See User's
Manual
section:
4.5
4.8
3.3
5.11
3.3
3.4
4.5
5.12
3.4
3.3
4.5
4.8
4.5
3.3
4.5
Problem
The blade is cutting
into the backing sheet.
Abnormal noise
generated by the cutter
pen during cutting.
The film is discolored
where the blade has
passed.
The cutting results
differ from the specified
size.
Cause
Solution
See User's
Manual
section:
3.4
4.5
3.1
3.2
3.3
3.4
3.4
4.5
4.5
The programmable
resolution (STEP SIZE) has
been set differently at the
plotter and the software
application.
Scaling has been specified at
the software application.
The programmable
resolution (STEP SIZE) has
been set differently at the
plotter and the software
application.
The computer sent
coordinate data that exceeds
the specified effective cutting
area.
The computer sent
coordinate data that exceeds
the maximum effective
cutting area.
The Parameter Priority
setting is set to program
mode.
The ENTER key was not
pressed after changing the
settings.
7-2
7.7
7.4
5.4
5.18
4.5
Problem
Characters or lines are
deformed during pen
plotting.
Film is fed at an angle.
Cause
Solution
See User's
Manual,
Section:
4.5
4.2
4.2
4.2
4.2
4.5
5.10
7-3
5.16
5.19
1.3
5.13
4.6
5.11
3.4
Part Number
021603990
N/A
N/A
021603980
N/A
N/A
51406-013T
51406-020T
51407-037T
51407-048T
52402-015T
51407-039T
51407-038T
021603580
52120-003
52450-002
121606101
121606111
52402-017T
52402-010
52402-007
52402-012
022905071
52402-024T
52402-014T
52402-009
52402-006
021602511
52402-008
51405-034
52450-001
56040-012
Description
Left Enclosure Assembly
Side Cover
Side Panel Left
Right Enclosure Assembly
Side Panel Right
Interface Cover
Control Panel Assembly
Control Panel Assembly (JPN)
Cover Top
Cover Top (JPN)
Plate Model Number FC3100-60
Cover Front
Cover Rear
Operator Panel Base
Rivet Snap Dia:0.122
LCD Assembly
Switch Sheet (JPN)
Switch Sheet (ENG)
Decal Model Number
Label Serial Number
Decal AC Voltage (100V-120V)
Decal AC Voltage (220V-240V)
Decal VCCI
Label CE/TUV
Label UL
Decal Caution Operating-A
Decal Caution Operating-B
Decal Servo Free
Decal Caution Hand
Guide Feed
LCD EA-D20025AR
Cable Assembly CA216013
Remarks
M4 x L6
M3 x L6
M3 x L6
M3 x L8
2.9 x L8
8-1
Ref only
Ref only
Ref only
Ref only
Assy of #27,28
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Model
All
All
UL/CE
JPN
UL/CE
JPN
All
All
All
All
All
All
JPN
UL/CE
All
All
UL/JPN
CE
JPN
CE
UL
UL/CE
UL/CE
JPN
UL/CE
All
All
All
Mainframe
8-2
Part Number
51407-046T
51407-047T
51405-022
52505-002
51405-045T
51405-046T
51405-033
51405-021
51407-025
021601650
51405-027
021601623
51405-028
302200119
51405-024
021601341
53501-001T
375311001
095503030
311060620
021601421
121606311
51700-001
51407-016
51406-006
56040-024
52104-002
Description
Panel Side Right
Panel Side Left
Bracket Bottom Panel
Standoff 6mm Hex 19mm(L)
Bracket T Cover Right
Bracket T Cover Left
Bracket T Cover Rear
Bracket FPC
Plate Belt Fixture
Pulley Y Belt Tension
Bracket Belt Tension Base
Tension Plate
Bracket Spring Adjust
Spring Y Belt Tension
Bracket Motor Base Y
Pulley Drive Motor
Motor Drive UGJMEEA7MGR51
Belt Drive Motor 120TN15-10W
Pulley Y Belt Drive
Bearing Drive Pulley F606ZZ
Belt Drive Y Slider
Cable FPC Y-axis FCA216031
PCA Interconnection Board
Plate Electrical Connection
Pulley Y-drive Assembly
Ribbon Cable Assembly
Clamp Cable Dia:0.25
Pan-head Thread Forming Screw
Bind-head Screw
Pan-head Thread Forming Screw
Bind-head Screw
N/A
Socket-head Cap Screw
N/A
N/A
N/A
Socket Set Screw
Filament Tape
Pan-head Screw with Flat Washer
Pan-head Screw with Flat Washer
8-3
Remarks
Ref only
Ref only
Assy of #19,20
Assy of #8,22
M4 x L8
M4 x L8
M3 x L8
M3 x L6
M4 x L15
M3 x L4
M3 x L6
M3 x L8
Qty
1
1
4
3
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
Model
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
Y Drive Section
8-4
Part Number
021601330
021601341
375311001
53501-001T
51407-046T
51407-047T
021601212
021601260
N/A
53520-003
51407-049T
310068820
52120-004
021601252
51407-017
51407-018
51407-026
51405-038
51405-023
509000044
508000009
52104-002
Description
Pulley X Drive Shaft
Pulley Drive Motor
Belt Drive Motor 120TN15-10W
Motor Drive UGJMEEA7MGR51
Panel Side Right
Panel Side Left
Stay Base
Roller Drive X-axis
Shaft Drive X-axis
Cutting Mat with Base
Bearing X Drive Shaft 688ZZ
Rivet Snap Dia:0.161
Bearing Holder
Cover Air Left
Cover Air Right
Cover Air Duct
Collar X Drive Shaft
Bracket Media Sensor Right
Fan Suction 24V
Sensor Optical PSR11
Clamp Cable Dia:0.25
Socket Set Screw
Socket Set Screw
Pan-head Screw with Flat Washer
Pan-head Thread Cutting Screw
Bind-head Screw
Pan-head Thread Forming Screw
Bind-head Screw
Pan-head Screw
N/A
N/A
Black Tape
Spring Lock Washer M3
Flat Washer M3
8-5
Remarks
with cable
M3 x L3
M3 x L5
M3 x L8
M4 x L12
M3 x L6
M4 x L8
M3 x L10
M3 x L30
Qty
1
1
1
1
1
1
1
1
1
1
3
8
3
1
1
1
2
2
1
2
2
Model
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
X Drive Section
8-6
Part Number
51405-026
51405-025
021601413
52402-001
52120-005
021500802
021500811
52501-005T
53520-006
53520-007
52801-018
010012070
021900882
51407-021
51407-022
53520-001
51407-019
003310130
51407-020
021601883
52801-014
51407-011
52801-014
Description
Bracket Y Rail Left
Bracket Y Rail Right
Stay Y Rail
Decal Pinch Roller Position
Bumper Rubber Recessed
Push Roller Base
Push Roller Arm
Spring Pressure Pinch Roller
Shaft Pinch Roller Arm
Shaft Pinch Roller
Spacer #4 x 1.5 long
Roller Pinch Media
P Cam 2190
Plate LS Right
Plate LS Left
Shaft Rotary
Plate Rotation Sensor
Roller Shaft End Fitting
Lever
Lever Cover
Spacer 8mm round x 10mm long
Plate Stopper Rotary Shaft
Spacer 6mm round x 10mm long
Remarks
Phillister-head Screw
Wave Washer M12
N/A
Bind-head Screw
Pan-head Tapping Screw
Hex Nut M3
Flat Washer M3
N/A
E-clip 4mm
E-clip 3mm
Pan-head Screw
Pan-head Thread Forming Screw
Bind-head Screw
N/A
Teflon (or Coated) Tape
Felt (Black) 18mm x 25mm
Felt (Black) 10mm x 30mm
Bind-head Screw
Bind-head Screw
Pan-head Screw with Flat Washer (Black)
Flat Washer M5
M3 x L12
8-7
M3 x L6
2.9 x L6.5
M3 x L60
M4 x L8
M4 x L8
M4 x L16
M3 x L16
M3 x L6
Qty
1
1
1
7
3
2
2
4
2
2
4
2
2
1
1
1
1
3
1
1
1
1
1
Model
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
8-8
Part Number
021503600
021601760
021500631
51405-029
51407-012
53520-004
053203350
53520-005
52802-008
52120-002
52801-012
52801-011
310069220
090113200
021500622
305320007
121606320
503301189
N/A
51406-004
51407-028
51407-045T
51407-010
53520-002
51405-030
52505-001
021500511
021500520
309011003
51700-002
52801-016
52801-017
Description
Pen Cover
Plate Moving Coil Mount
Cutter Holder
Bracket Sensor
Plate Slide Arm Support
Shaft Adjuster Guide Roller
Spring Pen Arm Lifter
Shaft Guide Pen Arm
Thumb Screw M4
Metric Viton O-Ring 1.6mm
Spacer Isolation MC
Spacer Moving Coil
Bearing Slide Arm 692ZZ
Magnet Pen Lift sensor
Arm Slide
Moving Coil Custom PL326B
Cable FP FPC216032
IC Hall Effect Sensor
Pen Head assembly
Plate Y Slider
Plate Bearing Support
Plate Bearing Mount
Shaft Guide Roller-2
Guide Flexible PC
Standoff 6mm Hex M/F M3
Guide Bearing
Guide Roller Assembly
Bearing 10SRFA1Z
PCA Pen Control Board
Spacer 4.5mm round x 1mm long
Spacer 4.5mm round x 4mm long
8-9
Remarks
Qty
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
2
1
2
2
2
3
1
4
1
Model
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
Part Number
Description
Bind-head Screw (Brass)
Hex Nut (Brass) M3
Socket Set Screw
Flat-head Screw
E-clip 2mm
Flat Washer M2
Bind-head Screw
Flat Washer (Paper) M2
Bind-head Screw
Bind-head Screw
Flat Washer M2
Bind-head Screw
Bind-head Screw
Hex Nut M3
Flat-head Screw
N/A
N/A
Flat Washer M3
Flat-head Screw
Tooth Lock Washer M3
Pan-head Screw with Flat Washer
Insulation (Capten) Tape
8 - 10
Remarks
M3 x L8
M2 x L6
M2 x L6
M2 x L6
M2 x L4
M2 x L3
M3 x L6
M2 x L8
M3 x L12
M3 x L10
M3 x L6
Qty
Model
8 - 11
Part Number
792160110
510000051
55106-001
518000033
509000045
52402-004
52801-013
N/A
51407-014
51402-002T
51405-047T
52104-001
52505-004
Description
PCA Main Board
Power Supply PS089B
Switch Power
AC Inlet & Line Filter SUPB3GE
Fan Cooling 12V
Decal GND
Spacer Power Supply Unit
Remarks
8 - 12
Qty
1
1
1
1
1
1
3
2
1
2
16
2
M3 x L6
M3 x L30
M4 x L8
M4 x L8
M2.6 x L10
M3 x L6
M3 x L3
Model
All
All
All
All
All
All
All
All
All
All
All
All
Chassis Section
8 - 13
Part Number
51405-049T
51405-050T
52801-020T-02
52801-020T-01
51407-043T
52120-012T
021603021
52802-007
52120-006
Description
Bracket Stock Media Right
Bracket Stock Media Left
Rod Stiffener 0.75
Rod Stiffener 0.5
Roller Stock Media
Bearing Stocker
Roll Guide
Thumb Screw Washer Face M4
Bumper Rubber Recessed
Remarks
Flat-head Screw
Bind-head Screw
Flat-head Screw
M4 x L10
M4 x L8
M4 x L12
8 - 14
Qty
1
1
1
2
2
12
2
2
4
Model
All
All
All
All
All
All
All
All
All
8 - 15
Part Number
51403-007T
51409-001T
56070-001T
56070-002T
520100241
513100850
N/A
N/A
N/A
51407-040T
Description
Box Shipping
Insert Packaging
Cord AC Power
Cord AC Power
Cord AC Power (VM1182-1276)
Adapter AC Power Cord
Pen Set KF550-F6
Blade Cutter CB09UA-5
Plunger Cutting PHP32-CB09
Mat Cutting
Remarks
UL
CE
UL
UL to JPN
6 Color Set
5 Blades
Without Base
Qty
1
1
1
1
1
1
1
1
1
1
Model
All
All
UL
CE
JPN
JPN
All
All
All
All
Part Number
53801-059T
021603910
53801-060T
021603920
53801-061T
53801-062T
51907-008T
53802-032T
52402-002
Description
Manual User (English)
Manual User (Japanese)
Manual Cutting/Operation (English)
Manual Cutting/Operation (Japanese)
Manual Operating Precaution (English)
Manual Operating Precaution (German)
Instruction Stocker Assembly (English)
Binder 1 Ring
Decal Operating Key (Multilanguage)
8 - 16
Remarks
Qty
1
1
1
1
1
1
1
1
1
Model
UL/CE
JPN
UL/CE
JPN
UL/CE
CE
UL/CE
UL/CE
UL/CE
Part Number
51407-033T
51407-032T
51407-031T
51407-030T
51407-035T
51407-034T
52801-023T
52801-021T
52801-022T
51404-001T
55700-001T
Description
Stanchion Right Stand
Stanchion Left Stand
Beam Bottom Support
Beam Top Support
Base Right Support Stand
Base Left Support Stand
Insert Tube Finishing
Caster Locking
Caster Non-Locking
Basket Media Catch Set
Tube Media Basket Attachment
Remarks
M6 x L8
8 - 17
Qty
1
1
1
1
1
1
4
2
2
1
10
Model
8 - 18
Part Number
972200620
52804-002T
52120-009T
52502-001T
52502-001T
52501-004T
53100-001T
51407-041T
Description
Cutter Cartridge Set (Body and Cap)
Retainer Pouncing Tool
O-Ring Pouncing Tool
Pin Pouncing
Sleeve Pouncing Tool
Spring Pouncing Tool
Cap Safety Pouncing Tool
Mat Pouncing
Remarks
M2 x L2
8 - 19
Qty
1
1
1
1
1
1
1
Model
8 - 20
X Motor
Y Motor
Fan 1
Fan 10
+X Sensor
-X Sensor
Power SW
AC Inlet
PWR SPLY
Y Flex.
CA216001
CA216011
CA216012
CA261021
CA261022
CA216031
CA216041
CA216042
CA216091
CA261092
CA261093
CA261094
CA216095
CA216096
MOV. Coil
HIT Sensor
FPC216032
Sheet SW.
Sheet SW.
CA216013
LCD
Main Board
Joint Board
Pen Board
Part Number
53501-001T
53501-001T
509000044
509000045
508000009
508000009
55106-001
518110110
510000044
121606311
56040-009
121607110
121607120
56040-013
56040-014
56040-015
56040-016
56040-017
56040-018
56040-019
56040-020
56040-021
56040-022
56040-023
305320007
503301189
121606320
121606111
121606101
56040-012
52450-001
792160110
51700-001
51700-002
Description
DC Motor
DC Motor
Fan 24V Suction (Vacuum)
Fan 12V Cooling]
Sensor Optical
Sensor Optical
Switch Power
AC Inlet & Line Filter
Power Supply Unit
Cable FPC Y-axis
Cable 10con. (Power Supply - Main Board)
Cable 30con. (Main Board - Interconnection)
Cable 16con. (Main Board - Interconnection)
Cable 2con. (X Motor - Main Board)
Cable 4con. (X Motor - Main Board)
Cable 2con. (Y Motor - Main Board)
Cable 3con. (+X Sensor - Main Board)
Cable 3con. (-X Sensor - Main Board)
Cable 1con. (AC Inlet - Frame GND)
Cable 1con. (AC Inlet - PWR Switch)
Cable 1con. (AC Inlet - PWR Switch)
Cable 1con. (PWR Switch - PWR Supply)
Cable 1con. (PWR Switch - PWR Supply)
Cable 1con. (PWR Supply - Frame GND)
Moving Coil Custom
IC Hall Effect Sensor
Flexible Printed Cable Pen Block
Switch Sheet (English)
Switch Sheet (Japanese)
Cable 10con. (LCD - Interconnection Board)
LCD
PCA Main Board
PCA Interconnection Board
PCA Pen Control Board
9-1
Remarks
UGJMEE-A7MGR51
UGJMEE-A7MGR51
MD925A-24-F15
MD625B-12-F16
RS-R11
RS-R11
236K0A1L
SUPB3GE
PS089A
FCA216031A
CA216001A
CA216011
CA216012
CA216021A
CA216022B
CA216031A
CA216041A
CA216042A
CA216091C
CA216092B
CA216093B
CA216094
CA216095
CA216096A
PL326B
OH003
FPC216032
FPC216011
FPC216010
CA216013
EA-D20025AR
Wiring Diagram
9-2
Part Number
792160110
54000-029T
Description
PCA Main Board
Firmware Set
Remarks
Assembly
9-3
Main Board
Wiring Diagram
9-4
Main Board
Interface Section
9-5
Main Board
CPU Section
9-6
Main Board
Memory Section
9-7
Main Board
1MB Buffer Section
9-8
Main Board
GRC1504 Section
9-9
Main Board
Clock Section
9 - 10
Main Board
Reset Section
9 - 11
Main Board
Driver Section Diagram
9 - 12
Main Board
Motor DAC Section
9 - 13
Main Board
Motor Drive Section
9 - 14
Main Board
A/D Section
9 - 15
Main Board
Pen DAC Section
9 - 16
Main Board
Pen Drive Section
9 - 17
Main Board
Input and Output Section
9 - 18
Main Board
Connector Section 1
9 - 19
Main Board
Connector Section 2
9 - 20
Part Number
51700-001
Description
PCA Interconnection Board
Remarks
Assembly
PCB
IC1
D1
D2
R1
R2
R3
R4
C1
C2
C3
C11
C12
C13
P11
P22
P101
J21
J201
121606123
53700-001
54801-001
54801-001
54701-003
54701-002
54701-003
54701-001
51501-001
51501-001
61501-017
51502-001
51502-001
51502-001
52101-005
52101-004
52101-006
52101-002
52101-001
PCB Joint
Photo-interrupter
Diode High-voltage Switching
Diode High-voltage Switching
Resistor 432ohms 1% 1/8W
Resistor 8.25K 1% 1/8W
Resistor 432ohms 1% 1/8W
Resistor 200ohms 1% 1/8W
Capacitor Ceramic 0.22uF 50V
Capacitor Ceramic 0.22uF 50V
Capacitor Ceramic 0.1uF 100V
Capacitor Electrolytic 10uF 50V
Capacitor Electrolytic 10uF 50V
Capacitor Electrolytic 10uF 50V
Connector Pin Header 30pin
Connector Pin Header 10pin
Connector Pin Header 16pin
Connector FFC/FPC ZIF 16circuit
Connector FFC/FPC 10circuit
PR216012C
GP1A53HR
1SS245
1SS245
9 - 21
DF11-30DP-2DSA
IL-S-S2T2-EF
DF11-16DP-2DS
5597-16APB
52044-1010
Interconnection Board
9 - 22
Part Number
51700-002
Description
PCA Pen Control Board
Remarks
Assembly
PCB
IC1
IC2
R1
C1
FL1
FL2
J31
J32
121606131
503301274
53700-001
54701-001
51501-001
52701-001
52701-001
52101-001
52101-003
PR216013A
GRC1003
GP1A53HR
9 - 23
DSS306-55FZ103N
DSS306-55FZ103N
52044-1010
IL-FPC8SL-N
Pen Board
9 - 24
Part Number
121606111
121606101
Description
Switch Sheet (English)
Switch Sheet (Japanese)
9 - 25
Remarks
FPC216011
FPC216010
9 - 26