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GRAPHTEC FC2240 Service Manual

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CUTTING MACHINE
FC2240
FC2240-UM-251-04-9370
SERVICE MANUAL

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Summary of Contents for GRAPHTEC FC2240

  • Page 1 CUTTING MACHINE FC2240 FC2240-UM-251-04-9370 SERVICE MANUAL...
  • Page 3 Part number for the Y flexible cable corrected. 10-10 06.05.26 Part number for the control panel switch corrected. 5-1, 10-5 06.05.26 Part number for the main relay board corrected. 5-1, 10-5 06.09.07 Part number for the control panel switch corrected. FC2240-UM-251-9370...

  • Page 4: Table Of Contents

    PAUSE Menu Configuration ................3-8 Setting the Cutting Conditions ................3-9 Running a Cutting Test ..................3-12 3.10 Achieving Optimum Cutting Results ............3-13 3.11 Listing the Cutting Conditions ..............3-14 3.12 Using the Character Dump Mode ..............3-16 3.13 Running the Self Test ..................3-17 FC2240-UM-251-9370...
  • Page 5 7.11.1 Preparations ............................7-19 7.11.2 Replacing the Y Bar ..........................7-19 7.11.3 Checking the Sliding of the Y Bar Frame (Manual Check) ..............7-20 7.12 Adjusting the Perpendicularity Precision ............7-21 7.12.1 Checking the Deviation in the Perpendicularity ................. 7-21 FC2240-UM-251-9370...
  • Page 6 9.1.2 The Cutting Media Cannot be Satisfactorily Cut .................. 9-2 9.1.3 Initialization is Abnormal ........................9-8 9.1.4 Pen UP/DOWN Operations are Abnormal ....................9-9 9.1.5 The X-axis Backlash is Excessive ......................9-11 9.1.6 The Y-axis Backlash is Excessive ......................9-12 FC2240-UM-251-9370...
  • Page 7 11.5 X Flex. Board (PR223224A) ................11-7 11.6 X-Y Relay Board (PN5042-02A) ..............11-8 11.7 Pen Flex. Board (PR223226A) ................11-9 11.8 2-Pen Relay Board (PR223229A) ..............11-10 11.9 2-Pen Board (PR223227A) ................11-11 11.10 High Voltage Board (PR31001C) ..............11-12 11.11 Main Board (PR306101) ................11-13 11.12 Miscellaneous ....................11-25 FC2240-UM-251-9370...
  • Page 8 FC2240-UM-251-9370...

  • Page 9: Introduction

    1. INTRODUCTION 1. INTRODUCTION 1.1 Model Names and Basic Specifications Model No. of pens Media hold down method Cutting area FC2240-60VC Vacuum suction 610 (X) x 920 (Y) mm FC2240-120MG Magnetic FC2240-120ES Electrostatic adhesion 1200 (X) x 920 (Y) mm...

  • Page 10: Main Specifications

    1. INTRODUCTION 1.3 Main Specifications FC2240-60VC FC2240-120VC/MG/ES FC2240-180VC/ES Configuration Flatbed Effective cutting area 610 x 920 mm 1200 x 920 mm 1740 x 920 mm Media hold-down method VC models: Vacuum suction, MG models: Magnetic, ES models: Electrostatic adhesion Maximum cutting speed...

  • Page 11: External Dimensions

    1. INTRODUCTION 1.4 External Dimensions FC2240-60VC 1040 Unit: mm Dimensional accuracy: ±5 mm FC2240-UM-251-9370...
  • Page 12 1. INTRODUCTION FC2240-120 Unit: mm Dimensional accuracy: ±5mm FC2240-UM-251-9370...
  • Page 13 1. INTRODUCTION FC2240-180 Unit: mm Dimensional accuracy: ±5mm FC2240-UM-251-9370...

  • Page 14: Stand Assembly Procedure

    Attach the two center plates (3) to the stand leg (1), using the M6 x 15 bolts and the L wrench provided as standard accessories. Attach the center plates (3) to stand leg (2) in the same way. Standard accessories 1. M6 x 15 hexagonal bolts: 8 2. L wrench M6 x 15 hexagonal bolts FC2240-UM-251-9370...

  • Page 15: Mounting Procedure

    2. M3 x 8 bind-head screws: 6 Procedure (1) When mounting the FC2240 unit onto the stand, make sure that it is correctly oriented. The three cables protruding from the FC2240 should be at the control box side. (2) Position the FC2240 so that the underside of the frame is mounted on top of the stand.

  • Page 16: Removing The Y Bar Retaining Brackets

    Move the plate nuts inside the pressed aluminum fitting to the left edge, and then tighten the M3 bolts. (3) Loosen the two M3 hexagonal bolts as shown in the above diagram, and then pull bracket R out in an upward direction. FC2240-UM-251-9370...

  • Page 17: Selecting The Vacuum Pump

    1. INTRODUCTION 1.8 Selecting the Vacuum Pump Select the vacuum pump according to the guidelines listed in the table below. Item FC2240-60VC/120VC/180VC Airflow (m /min) Ratings Static pressure (kPa) Hose connection bore 50 mm CAUTION Make sure that the vacuum pump used with a VC model is affixed with either a label showing compliance with the relevant safety standard or with the CE marking.

  • Page 18: Installation Location

    When connecting the vacuum pump to your cutting plotter, please refer to the following diagram. CAUTION The exhaust from the vacuum pump is hot, so do not place anything flammable near the exhaust port. Failure to observe this precaution could cause a fire. FC2240-60VC Hose band CA2294-01 Durable flexible hose...

  • Page 19: Description Of Parts

    The names of the plotter parts are as follows. Pen carriage Y ber Control panel Writing panel CHART HOLD key Tilt lever (ES models only) Rear view of the main box Interface connector Stand Power inlet USB interface Power switch Parallel interface PARA LLEL RS-232C interface RS-232C FC2240-UM-251-9370...

  • Page 20: Control Panel

    ....... Used to set the eight groups of cutting conditions retained in the plotter’s internal memory or to select one group as the current cutting conditions......Used to select the desired menu screen for setting a function at the control panel when the plotter is in PAUSE mode. FC2240-UM-251-9370...
  • Page 21 To reset the plotter, concurrently press the [ENTER] and [ORIGIN] keys......Runs a cutting test to check whether the currently selected cutting conditions are compatible with the medium loaded......Used to move the origin point. To reset the plotter, concurrently press the [ENTER] and [ORIGIN] keys. FC2240-UM-251-9370...

  • Page 22: Types Of Cutter Blades And Their Features

    • The spring ensures that the blade is lifted clear of the cutting medium when the pen is raised. CB15U-SP (ø1.5) Note: The CB15U-K30 and CB15U-K30-SP blades are CB15U-K30-SP (ø1.5) designed for use with thick media e.g. rubber for sandblasting. CB09UA (ø0.9) FC2240-UM-251-9370...

  • Page 23: Cutter Pen Nomenclature

    Structure of the PPA31-CB15B Cutter Pen (for cutter blades of 1.5 mm diameter) Protective cap Plunger Holder A Spring Cutter blade* Holder B Plunger cap Blade length adjustment knob (green) * The CB15U-SP supersteel blade is shown in the figure above. FC2240-UM-251-9370...

  • Page 24: Basic Operation

    6. Using your finger, check that the cutter blade rotates smoothly inside the cutter pen. CAUTION Be careful not to stab your finger at this time. FC2240-UM-251-9730...
  • Page 25 5. With the plunger still in the upright position, insert the holder cap until you hear it click into place. Turn the blade adjustment knob in the clockwise direction to adjust the length of the blade. CAUTION Be careful not to stab your finger at this time. FC2240-UM-251-9730...

  • Page 26: Adjusting The Blade Length

    “l” is never greater than the combined thickness of the film and its backing sheet. Film ｔ  Backing sheet 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. FC2240-UM-251-9730...

  • Page 27: Mounting The Cutter Pen

    • When facing the pens, the left pen is designated as No. 1 and the right pen is designated as No. 2. CHECKPOINT When mounting one cutter pen and one plotter pen, mount the cutter pen as the No. 2 pen. No. 2 pen No. 1 pen (Pen attaching example) FC2240-UM-251-9730...

  • Page 28: Adjusting The Pen Carriage Height

    4. When the adjustment is complete, remove the adjustment plate (thin) from under the pen. CHECKPOINT Always make sure that the writing panel is in a horizontal position before making this adjustment. When cutting thick media, place the medium on the writing panel before making this adjustment. FC2240-UM-251-9730...

  • Page 29: Turning On The Plotter And Initialization

    The pen carriage returns to the origin point for plotting, and then moves back and forth twice at a 45˚ angle from the origin to determine the friction coefficient of the plotter mechanisms. Pen carriage Y bar Control panel Writing panel (6) When the initialization process is complete, the plotter is ready to begin plotting or cutting. FC2240-UM-251-9730...

  • Page 30: Loading The Medium

    • After the medium has been held for a while by electrostatic adhesion, it may become charged with static electricity and therefore be harder to remove from the writing panel. There is nothing abnormal about this phenomenon. FC2240-UM-251-9730...

  • Page 31: Pause Menu Configuration

    F4 OPTION 2 F2 L UNIT Setting the Displayed Length Unit F3 DIST ADJ Adjusting the Distance Correction F4 TEST F2 COND.PAT. Listing the Cutting Conditions F3 SELF TEST Running the Self Test F4 DUMP Using the Character Dump Mode FC2240-UM-251-9730...

  • Page 32: Setting The Cutting Conditions

    Raising the SPEED and QUALITY values results in lower precision but reduces the overall cutting time. This is useful when making test runs. Lowering the SPEED and QUALITY values results in higher precision but increases the overall cutting time. FC2240-UM-251-9730...
  • Page 33 40 steps, even numbers only. SPEED 1 to 40 40 steps in cm/s units. OFFSET -5 to +5 Select 0 for automatic adjustment according to the blade type. QUALITY 1 to 6 The lower the number, the higher the quality. FC2240-UM-251-9730 3-10...
  • Page 34 Thick sheet mode Thick sheet mode Thick sheet mode Thick sheet mode CHECKPOINT In the initial settings, the setting condition numbers 1 to 4 are assigned to Pen 1, and the setting condition numbers 5 to 8 to Pen 2. FC2240-UM-251-9730 3-11...

  • Page 35: Running A Cutting Test

    (2) Press the [TEST] key to put the plotter into TEST mode. Run a cutting test. Repeat this process until you achieve the desired results. (3) Press the [ENTER] key or [NEXT] key to return to the initial menu. FC2240-UM-251-9730 3-12...

  • Page 36: Achieving Optimum Cutting Results

    OFFSET value and run a cutting test until the desired results are achieved. The table below lists sample OFFSET settings when the blade type is set to OTHER. Actual blade type OFFSET value CB09UA CB15U CB15U-SP CB15U-K30 CB15U-K30-SP FC2240-UM-251-9730 3-13...

  • Page 37: Listing The Cutting Conditions

    (6) As soon as the [F2] key (CONDITION) is pressed, the message below appears and the plotter begins printing a list of the currently set cutting conditions. FORCE OFFSET PRINT CONDITIONS SPEED QUALITY (7) When all of the conditions have been printed, the READY message reappears. FC2240-UM-251-9730 3-14...
  • Page 38 3. OPERATIONS Sample printout by the CONDITION function FC2240-UM-251-9730 3-15...

  • Page 39: Using The Character Dump Mode

    • When the plotter receives READ commands that instruct it to output data, it will output dummy data (except in the case of READ commands that request the output of the plotter’s status data). Note that printing in dump mode will be based on that dummy data. FC2240-UM-251-9730 3-16...

  • Page 40: Running The Self Test

    (8) When you have finished printing the self test pattern, turn off the plotter to cancel SELF TEST mode. CHECKPOINT 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. FC2240-UM-251-9730 3-17...

  • Page 41: Daily Maintenance And Storage

    Remove the pen from the pen carriage and store it with the pen cap on. Cover the plotter with the soft cover supplied or a cloth to keep dust off. Store the plotter in a location which is not subject to either direct sunlight or high humidity. FC2240-UM-251-9730...
  • Page 42 4. DAILY MAINTENANCE AND STORAGE FC2240-UM-251-9730...

  • Page 43: Recommended Parts List

    5. RECOMMENDED PARTS LIST Part No. Description Q'ty Remarks 792240700 Main Board 792232705 2-Pen T Board 792232701 2-Pen T Block Assy 682247030 Control Panel Switch FC2240 772290110 X-Motor 772247550 Y-Motor 510000051 Power Supply PS0089B Same as FC2230 162291230 X-Flexible Cable FCA2291023 FC2240-60/120 162291240...

  • Page 44: List Of Tools

    23 Metallic ruler (about 15 cm long) For adjusting the belt tension 24 Multimeter For checking damaged or shorted wires 25 Digital voltmeter For main board adjustment 26 Oscilloscope For main board adjustment 27 Test pin connector jig For main board adjustment FC2240-UM-251-9730...

  • Page 45: Disassembly And Adjustment

    (3) After loosening the two M4 binding head screws indicated by the (C) arrows, push the X motor bracket with a 10 kgf push-pull gauge to the point where FX equals 5.0 kgf - 0.5, then tighten the two screws. FC2240-UM-251-9370...

  • Page 46: Adjusting The Belt Tension Of The Front X Slider

    (3) Check the belt tension. (See subsection 7.1.5, “Checking the Belt Tension of the Front and Rear X Sliders”.) (4) Perform the radiating lines test to check that the belt at the pulley section is balanced right and left. If not, repeat steps (2) to (4) above so that the belt is balanced. FC2240-UM-251-9370...

  • Page 47: Checking The Belt Tension Of The Front And Rear X Sliders

    (2) Loosen the screws that holding the tilt lever bracket and then move the tilt lever bracket to avoid touching the belt. (3) Pull the X-belt 20 mm from the X-rail in the center of the X-belt using a 1 kg push-pull gauge. The pull force should be: FC2240-60 FC2240-120 FC2240-180 920g to 940g...

  • Page 48: Adjusting The Y-Axis Drive

    (2) Disconnect X FPC and Y FPC cables from their connectors (J51, J52) on the PN5042-02 X-Y relay board. (3) Disconnect the Y motor and Y encoder cable cables from their connectors (P501, P502) on the PN5042-02 X-Y relay board. FC2240-UM-251-9370...
  • Page 49 Synchro belt PN5042-02 (5) As shown in the figure , remove the two M3 binding head screws (A) holding the Y-motor, then remove the motor from the motor bracket. FC2240-UM-251-9370...

  • Page 50: Adjusting The Y Drive Belt Tension

    Y motor and pull the Y motor assembly with a 10 kgf push-pull gauge to the point where FY equals 5.0 kgf - 0.5, then tighten the two M4 binding head screws. Synchro belt PN5042-02 FC2240-UM-251-9370...

  • Page 51: Adjusting The Y Slider

    (2) Remove the 5 mm bind screw and the countersunk head screw indicated by the (A) arrows. (3) After removing the two M4 binding head screws indicated by the (B) arrows at the front surface, use both hands to lift the Y bar up and off. FC2240-UM-251-9370...

  • Page 52: Adjusting The Y Slider Belt Tension

    20 mm Y belt Scale (4) Push down the Y-belt 20 mm from the Y-rail in the center of the Y-belt using a 1 kg push-pull gauge. The push down force should be from 600 g to 630 g. FC2240-UM-251-9370...

  • Page 53: Adjusting The Roller Pressure Of The Front X Slider

    NOTES: 1. Visually confirm that each roller is in contact with the sliding surface. 2. After adjusting the roller pressure, the sliding load shall be 35 gf±5. FC2240-UM-251-9370...

  • Page 54: Adjusting The Roller Pressure Of The Rear X Slider

    X rail. (Repeat this same procedure for the right roller.) Confirm that the rollers remain in contact with the sliding surface throughout their entire stroke, the sound made by the rollers turning is constantly the same, and the rollers slide smoothly. FC2240-UM-251-9370 7-10...
  • Page 55 NOTES: 1. Confirm the horizontal roller pressure by visually checking that both the fixed and adjustable rollers are in contact with the sliding surface. 2. After adjusting the roller pressure, the sliding load shall be 35 gf ± 5. FC2240-UM-251-9370 7-11...

  • Page 56: Adjusting The Roller Pressure Of The Y Slider

    • Make sure there are no discrepancies in the “grating” load of the rollers. • The sliding load shall be 30 gf ± 5. • After the adjustment is completed, apply adhesive to the four set-screws. FC2240-UM-251-9370 7-12...

  • Page 57: Adjusting The Position Of Sensor Dog Y

    7. DISASSEMBLY AND ADJUSTMENT 7.7 Adjusting the Position of Sensor Dog Y Align the sensor dog Y (A) with the center of the Y sensor’s slit, then apply adhesive to secure the sensor dog Y in that position. FC2240-UM-251-9370 7-13...

  • Page 58: Mounting The Y Slider On The Y Flexible Printed Circuit Cable

    (4) Attach double-sided tape to the FPC guard (E), and then securely attach the FPC guide (B) to the other side of the tape. (5) Pass the Y FPC cable between FPC holder (C) and FPC guide (B), and then secure the cable with a push-fit M3x6 screw (D). (6) Apply adhesive to screw (D). FC2240-UM-251-9370 7-14...

  • Page 59: Pen Block

    7.9.2 Removing the Pen Block (1) Pull out the CA2293-39 cable from its connector on the PR223229 2-pen relay board in the direction indicated by the arrow. (2) When the two screws (A) are removed, the pen block can be removed. FC2240-UM-251-9370 7-15...

  • Page 60: Adjusting The Pen Block

    (2) If the slide arm does not lower smoothly, pull out the J21 (FPC210100) and J22 (FPC10002) FPC cables from their connectors on the PR223227 2-pen relay board in the direction indicated by the arrow. Remove the two screws (B) to remove the relay board. FC2240-UM-251-9370 7-16...
  • Page 61 • Raise or lower the guide shaft of the slide arm and confirm that the 692ZZ bearing rotates smoothly. • If there is still play, there may be play between the guide shaft and 692ZZ bearing of the slide arm. Replace the pen block assembly. FC2240-UM-251-9370 7-17...

  • Page 62: Using The Mechanical Adjustment Jigs

    7. DISASSEMBLY AND ADJUSTMENT 7.10 Using the Mechanical Adjustment Jigs (1) Pen block height adjustment jig (standard accessory) FC2240-UM-251-9370 7-18...

  • Page 63: Replacing The Y Bar

    NOTE: When the Y bar is moved manually from side to side while the plotter is turned off, be sure to detach the three connectors which connect the control box to the plotter’s main unit. Failure to remove these connectors may cause the gears to slip or not mesh properly. FC2240-UM-251-9370 7-19...

  • Page 64: Checking The Sliding Of The Y Bar Frame (Manual Check)

    NOTE: Before moving the Y bar by hand, be sure to detach the three connectors which connect the control box to the plotter’s main unit. • Next, re-connect the three connectors, turn on the plotter, and use the POSITION keys to check the operation of the Y bar within the effective plotting area. FC2240-UM-251-9370 7-20...

  • Page 65: Adjusting The Perpendicularity Precision

    (D) and (C) on the front and back of the sheet. (5) If the deviation exceeds 0.25 mm, loosen the screws at the top and bottom of the Y bar and adjust the vertical orientation of the Y bar by moving it toward the pertinent side. FC2240-UM-251-9370 7-21...
  • Page 66 3 mm setscrews indicated by the (E) arrows. (8) You will be able to adjust the perpendicularity precision by performing the electrical adjustnet for fine adjustment. (See section 8.12 Adjusting the Distance and the Perpendicularity Accuracy.) FC2240-UM-251-9370 7-22...

  • Page 67: Replacing The Electrostatic Adhesion Plate

    (5) Remove any remaining double-sided tape and glue. Sprinkle on ECT-1 toner cleaning fluid (available from Graphtec) and leave for 1 or 2 minutes. Scrape off with some sort of scraper (e.g. spatula). (6) When everything has been removed from the aluminum plate, wipe it off with ethyl alcohol.
  • Page 68 Tape on the double-sided tape in such a way that the gap is as negligible as possible at the high- voltage power supply cable installation section. • Finally, use a combination of wide and narrow double-sided tape so that there is no untaped interval greater than 5 mm. NOTE: Never let the tape overlap! FC2240-UM-251-9370 7-24...

  • Page 69: Attaching The Electrostatic Adhesion Plate

    • If dust or dirt gets in, remove it with tweezers or your fingernail tips. • If air gets in, drive out the air at 5 mm intervals by kneading softly. (5) When the entire surface has been spread out, attach it by sliding your hand across it again and pressing FC2240-UM-251-9370 7-25...
  • Page 70 7. DISASSEMBLY AND ADJUSTMENT FC2240-UM-251-9370 7-26...

  • Page 71: Electrical Adjustments

    8. ELECTRICAL ADJUSTMENTS 8. ELECTRICAL ADJUSTMENTS 8.1 Flowchart of the Adjustment Sequence Flowchart of the Adjustment Sequence for the FC2240 series. 8.3 Setting the Power Unit’s Supply Voltage 8.4 Checking the Power Unit’s Supply Voltage 8.6 Setting the DIP Switches 8.8 Clearing the Non-Volatile RAM...

  • Page 72: Location Of The Boards

    8. ELECTRICAL ADJUSTMENTS 8.2 Location of the Boards 8.2.1 Main Board (PR306101) FC2240-UM-251-9370...

  • Page 73: Main Relay Board (Pn5042-01)

    8. ELECTRICAL ADJUSTMENTS 8.2.1 Main Relay Board (PN5042-01) Jumper switch setting of JP6. 8.2.2 X Flex. Board (PR223226) Jumper switch setting of JP1. FC2240-UM-251-9370...

  • Page 74: Setting The Power Unit's Supply Voltage (Ps089B)

    (1) Check that the plotter’s POWER switch is off. (2) Remove the upper chassis of the Control Unit. (3) Connect the power unit’s cable to the required connector. Voltage series Corresponding area Connector 100 V JAP 110T/K WGl117UL 200 V CEE SEV BS AS FC2240-UM-251-9370...

  • Page 75: Checking The Power Unit's Supply Voltage

    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. FC2240-UM-251-9370...

  • Page 76: Explanation Of The Values Of The Main Board

    You can input the same values when you have replaced the main board without making any adjustments except the pen height, home position and pen interval adjustments. If you have changed any values by making adjustments, record those values for the next maintenance check. FC2240-UM-251-9370...

  • Page 77: Setting The Dip Switches

    1 2 3 4 5 6 7 8 • Pen height adjustment • Pen force adjustment • Distance adjustment • Home position adjustment Keyboard and Sensor Test Mode Set all bits to OFF 1 2 3 4 5 6 7 8 FC2240-UM-251-9370...

  • Page 78: Updating The System Firmware

    :Utility to transfer files using Windows OPS662 :USB Driver software for the FC2240 (when using USB to update the firmware) (1) Check that the power supply and control panel unit are connected to the main board. Connect a personal computer to the Centronics terminal or the USB terminal.
  • Page 79 CLEAR” and “FLASH MEMORY WRITE,” and the system begins writing to flash memory. Note: If you are writing to a new board, the system will automatically perform a NOVRAM clear operation following the write function. (5) Turn off the plotter when the message below appears. COMPLETED POWER OFF THEN ON! FC2240-UM-251-9370...

  • Page 80: Clearing The Non-Volatile Ram

    (3) After the “ ” message is displayed, a menu for model selection appears on the LCD panel. SET FC TYPE FC2240-60-*2 (4) Select your plotter model using the the keys, and then press the ENTER key to register your plotter model setting.
  • Page 81 ” message is displayed as shown below, turn off the plotter and then return the DIP switch to its normal settings. COMPLETED POWER OFF THEN ON ! NOTE: Clearing the non-volatile RAM initializes the pen height adjustment, distance accuracy adjustment, and other settings to their respective default values. FC2240-UM-251-9370 8-11...

  • Page 82: Adjusting The Home Position

    (3). If the position is correct, press the [ENTER] key to finish. (6) Turn off the plotter and then return the DIP switch to its normal settings, or press [NEXT] key to proceed to the next adjustment. (This adjustment does not affect the plotter’s pen exchange adjustment.) FC2240-UM-251-9370 8-12...

  • Page 83: Adjusting The Pen Height

    (6) When adjustment is completed, turn off the plotter and then return the DIP switch to its default settings or press the [NEXT] key to proceed to the next adjustment. (7) Be sure to perform this adjustment whenever the pen block has been replaced. FC2240-UM-251-9370 8-13...

  • Page 84: Adjusting The Pen Force

    (9) The adjustment menus for the No.2 pen will be displayed after you have finished the adjustments for the No.1 pen. Adjust the pen pressure for the No.2 pen in the same way as you did for the No.1 pen. FC2240-UM-251-9370 8-14...
  • Page 85 24 g ± 1 g 24 g ± 1 g 210 g ± 10 g 210 g ± 10 g 400 g ± 20 g 400 g ± 20 g 700 g ± 30 g 1000 1000 g ± 50 g FC2240-UM-251-9370 8-15...

  • Page 86: Adjusting The Distance And The Perpendicularity Accuracy

    :Move to the distance adjustment value setting menu. (9) Press the [F1] key to start the test. The plotter immediately plots the test pattern, and the following menu appears. DIST. ADJ. (0.01mm) X =+10 Y =-10 X=500 mm Y=700 mm FC2240-UM-251-9370 8-16...
  • Page 87 If the measured value is outside the specification range, adjust again from step (6). (16) When the adjustment is complete, turn off the power to the plotter. (17) Return the DIP switch to its default settings (see subsection 8.6 “Setting the DIP Switches”). FC2240-UM-251-9370 8-17...

  • Page 88: Adjusting The Pen Interval

    (7) Press the ENTER key to register your INTERVAL ADJUST setting. (8) Press the PAUSE key to cancel PAUSE mode, and the turn off the plotter. Note: Your INTERVAL ADJUST setting is retained in the plotter’s internal memory even while the plotter is turned off. FC2240-UM-251-9370 8-18...

  • Page 89: Dip Switch Factory Settings

    15U 0 READY READY CONDITION 2 CONDITION 6 COND2 09U 0 COND6 15U 0 READY READY CONDITION 3 CONDITION 7 COND3 15U 0 COND7 15U 0 READY READY CONDITION 4 CONDITION 8 COND4 COND8 15U 0 READY READY FC2240-UM-251-9370 8-19...
  • Page 90 (4) Press the [F1] key to select INTERFACE. RS-232C STEPSIZE COMMAND (5) Press the [F4] key to select COMMAND. COMMAND GP-GL HP-GL (6) Press the [F4] key to select HP-GL. (7) Press the ENTER key to register your setting. FC2240-UM-251-9370 8-20...

  • Page 91: Testing The Control Panel Keys And Home Sensors

    In this case, initialize the NOV-RAM and then run the sensor test again. As a temporary measure for dealing with a defective sensor, turn off the plotter, set Bit 6 of the DIP switch to OFF, and then turn the plotter back on. FC2240-UM-251-9370 8-21...
  • Page 92 • Fault in D1 or D2 on the PR223281 Key Relay Board; or they may be attached in reverse • Improperly connected CA2232112 cable. Reconnect the cable and then run this test again • Initialize the non-volatile RAM • Defective main board FC2240-UM-251-9370 8-22...

  • Page 93: List Of Items Requiring Readjustment

    Home position adjustment Pen interval adjustment Belt tension adjustment No mark: Adjustment unnecessary M: Must always be adjusted N: To be adjusted as necessary Note: The main board must have the latest version of firmware unless otherwise specified. FC2240-UM-251-9370 8-23...

  • Page 94: Troubleshooting

    If the cutter blade still does Is the not rotate smoothly, the CB09 blade in cutter plunger is faulty. PPA31-CB15/B? Replace it. Mount the CB15 blade. Replace the blade. Faulty cutter plunger. Is there still play? Replace it Normal. FC2240-UM-251-9370...

  • Page 95: The Cutting Media Cannot Be Satisfactorily Cut

    • Driver section pulley and setscrew looseness. • Slider section roller pressure inadequacy. • Motor rotation defect (wornout Possible software problem bearing in motor). • Rollers at front of X rail and X slider touching. FC2240-UM-251-9370...
  • Page 96 See section 9.1.1 cutter blade rotate “Checking for Faulty smoothly? Rotation of the Blade”. Is there Perform the necessary play in the mechanical adjustments. section? Problems with the media • Extremely soft • Weak adhesion to backing sheet • Other problems. FC2240-UM-251-9370...
  • Page 97 Replace the writing panel. writing panel? Is the pen Adjust the height using the block installation height correct? 10.5 mm height adjustment plate (standard accessory). There is a problem with the medium. It is too hard. FC2240-UM-251-9370...
  • Page 98 Is drawing Incorrect command selection in plotter mode Specify the commands that normal? match the plotter. Is the Set the interface on the interface setting control panel. correct? Lower the cutting speed to 24 or lower. FC2240-UM-251-9370...
  • Page 99 Some lines waver, so lower acceleration 4 or the acceleration. more? Is the X belt Adjust the belt tension. tension too low? Is the synchro Adjust the belt tension. belt loose? Replace the belt. Replace the X and Y motors. FC2240-UM-251-9370...
  • Page 100 Eliminate unevenness in the cutting media. Remove any air from the cutting media. Adjust the offset force Be particularly careful when the (cutter offset force). cutting media is being secured by magnets. With this method, the cutting media may float up. FC2240-UM-251-9370...

  • Page 101: Initialization Is Abnormal

    Faulty X motor or Y motor direction? Is movement Faulty Y encoder or X erratic in the X or Y encoder direction? Power board check Faulty power board Is the voltage level at all pins correct? Replace main board FC2240-UM-251-9370...

  • Page 102: Pen Up/Down Operations Are Abnormal

    Is the Play in the slide shaft or its guide shaft bearing bearing. pressure faulty? Replace the pen block assembly. Loosen the M2 set-screw and adjust the bearing to eliminate play in the guide shaft section. FC2240-UM-251-9370...
  • Page 103 Readjust the main board’s pen servos. Faulty main board. Check for a damaged line in the X or Y FPC cable. Check that the cables are securely connected to the proper connectors. Check for a damaged line in the moving coil. FC2240-UM-251-9370 9-10...

  • Page 104: The X-Axis Backlash Is Excessive

    Check the screw and The X motor is worn out. necessary. pressure roller. Replace it. Check the X belt and X synchro belt tension and adjust if necessary. Check the setscrews for all the pulleys and tighten if necessary. FC2240-UM-251-9370 9-11...

  • Page 105: The Y-Axis Backlash Is Excessive

    9. TROUBLESHOOTING 9.1.6 The Y-axis Backlash is Excessive (1) Adjust the perpendicularity of the Y bar (see section 7.12, “Adjusting the Perpendicularity Precision”). (2) Adjust the Y belt tension. FC2240-UM-251-9370 9-12...

  • Page 106: The Plotter Is Turned On But Doesn't Operate

    • Nothing appears on the display panel. • The POWER LED lamp lights • The System firmware is Reinstall the system firmware or and the LCD displays a sum defective. replace the main board. check error. Sum-Ck ROM RAM ERR!! FC2240-UM-251-9370 9-13...

  • Page 107: Error Messages

    X or Y belt tension and X or Y motor belt tension. Yes ..Verify item (3). (3) Is the X or Y flexible No ..Connect it securely. cable securely Yes ..Replace the X or connected? Y flexible cable if defective. FC2240-UM-251-9370 9-14...

  • Page 108: Error Messages In Gp-Gl Command Mode

    (3) Has the correct No ..Set the correct model model name been set name. for the plotter? Configure your software application menu to permit Graphtec plotter control. Re-specify the software application’s interface conditions. • The software The numeric parameter Configure your software ERROR 4 configuration...

  • Page 109: Error Messages In Hp-Gl Emulation Mode

    (3) Has the correct No ..Set the correct model name been set model name. for the plotter? Configure your software application menu to permit Graphtec plotter control. Re-specify the software application’s interface conditions. A command was Execute the command Configure your software...
  • Page 110 Configure your software ERROR 6 executed with with its coordinate data application menu to permit Position overflow coordinate data that specified within the Graphtec plotter control. exceeds the effective effective cutting/plotting Re-specify the software cutting/plotting area area. application’s interface The data being...

  • Page 111: The Cutting Results Are Unsatisfactory

    The blade falls out of the cutter The blade is too small for the Use a blade that fits securely in the plunger. holder. holder. Insufficient grease. For CB15 holders (red blade adjustment knob), grease the cutter blade and holder. FC2240-UM-251-9370 9-18...
  • Page 112 The Offset Cut Pressure is too Raise the Offset Cut Pressure low. setting. The film is too flimsy. Switch to a stronger film. Blade rotation is not smooth. For CB15 holder (red blade adjustment knob), grease the cutter blade and holder. FC2240-UM-251-9370 9-19...

  • Page 113: Parts Lists

    CA2292-32 (-60/-120) 692807300 Y Flexible Cable 180 CA2232-32 (180) 122907030 X Flexible Cable CA2290-03 621474130 Corner Cover (Rear Right) 022900082 Electrostatic Panel 12 FC2240-120ES 022900202 Electrostatic Panel 18 FC2240-180ES 022900132 Magnetic Sheet 90 FC2240-120MG 772293710 Vacuum Panel 60 FC2240-60VC 772293030...
  • Page 114 10. PARTS LIST Mainframe FC2240-UM-251-9370 10-2...

  • Page 115: Stand

    10. PARTS LIST 10.2 Stand Part No. Description Q’ty Remarks 621470940 Left Side Foot 60 FC2240-60 621480920 Left Side Foot 90/EX FC2240-120/180 621470950 Right Side Foot 60 FC2240-60 621470930 Right Side Foot F223 FC2240-120/180 054221031 Rear Main Bar 60 FC2240-60...

  • Page 116: Control Panel

    772232010 Key Rely Board PR223281 772232020 122907010 Control Cable CA2290-01 682247030 Sheet Switch PN5042-03 621476000 Panel Frame 022901330 Tray 60 FC2240-60 022900742 Tray 120 FC2240-120 022900750 Tray 180 FC2240-180 022900572 Cable Holder 772230260 Chart Hold Switch 772230860 Panel, Blind VC/MG...

  • Page 117: Control Unit

    10. PARTS LIST 10.4 Control Unit Part No. Description Q’ty Remarks 508102306 Power Switch SW,2WI36/92 518000033 AC Inlet SUP-B3G-E 792240700 Main Board 792240701 Main Relay Board 510000051 Switching Power Supply PS089B 500050273 TUDC24B4 Control Unit FC2240-UM-251-9370 10-5...

  • Page 118: Drive Unit

    Part No. Description Q’ty Remarks 312208069 Bearing F608ZZ 022904221 Bearing Spacer 022903590 Pulley Shaft, Right 022904500 X Belt S2ML2350, FC2240-60 022904510 X Belt 120 S2ML3200, FC2240-120 022904520 X Belt EX S2ML4200, FC2240-180 022903671 Roller Lever 022900400 Roller ø27 022903533 X Slider...
  • Page 119 10. PARTS LIST Part No. Description Q’ty Remarks 022904540 XR End 022904560 XR Pulley Bracket 022904530 XF End 022904550 XF Pulley Bracket 622301630 Belt Plate FC2240-UM-251-9370 10-7...
  • Page 120 10. PARTS LIST X Drive Unit FC2240-UM-251-9370 10-8...

  • Page 121: Y Drive Section

    O Ring,S4 034004591 Offset Pin 021500631 Cutter Holder 621113581 Thumb Screw L14 302200060 Spacer BSB315 621473200 2-Pen Cover 621473300 2-Pen Block Plate 022902451 2P2 Slide Arm 302200076 MC Up Spring E537 621473320 Y Slider Cover T 621473330 Plate PUR FC2240-UM-251-9370 10-9...
  • Page 122 792240702 Height Sensor 772230310 Y Limit Switch Assembly PR229008 Assembly 772232130 Pen Flex. Board PR223226 Assembly 162291100 Y-Flexible Cable FCA2291010 122937391 2-Pen T Cable CA2292-39 792232705 2-Pen T Board Assembly PR223227 Assembly 122936110 MC T Flexible Cable FPC2293110 FC2240-UM-251-9370 10-10...
  • Page 123 10. PARTS LIST Y Drive Section FC2240-UM-251-9370 10-11...

  • Page 124: Standard Accessories

    10.7 Standard Accessories Part No. Description Q’ty Remarks 022909550 Pen Block Height Adjustment Plate 022909561 Pen Height Adjustment Plate 621479900 User’s Manual FC2240-CDM01M CD-ROM 621479910 Safety Manual ANCUTF-UM-AM1 621479920 Quick Manual 302200020 Hexagonal Wrench (2.5) AC Power Cable 972100151 PPA31-CB15B...

  • Page 125: Block Diagrams And Circuit Diagrams

    11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11.1 Wiring Connection (1/2) FC2240-UM-251-9370 11-1...
  • Page 126 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS (2/2) FC2240-UM-251-9370 11-2...

  • Page 127: Key Relay Board (Pr223281)

    11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11.2 Key Relay Board (PR223281) FC2240-UM-251-9370 11-3...

  • Page 128: Main Relay Board (Pn5042-01A)

    11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11.3 Main Relay Board (PN5042-01A) Main Relay Board 1/2 FC2240-UM-251-9370 11-4...
  • Page 129 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Relay Board 2/2 FC2240-UM-251-9370 11-5...

  • Page 130: Relay Board (Pr223203)

    11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11.4 X Relay Board (PR223203) P303 XHOMEZ DSS306-102M IL-G-3P-S3T2-E XHOMEZ XENA P302 XENB XENA XM(+) XENB XM(+) IL-G-4P-S3T2-E XM(-) XM(-) FRC5-C14L53T-OL FBR07HA P301 XM(+) FBR07HA XM(-) IL-G-2P-S3T2-E FC2240-UM-251-9370 11-6...

  • Page 131: Flex. Board (Pr223224A)

    11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11.5 X Flex. Board (PR223224A) FC2240-UM-251-9370 11-7...

  • Page 132: X-Y Relay Board (Pn5042-02A)

    11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11.6 X-Y Relay Board (PN5042-02A) FC2240-UM-251-9370 11-8...

  • Page 133: Pen Flex. Board (Pr223226A)

    11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11.7 Pen Flex. Board (PR223226A) MC1 (+) MC1 (+) MC1(-) MC1(-) PLFB2 PLFB2 -12V -12V +12V +12V PLFB1 PLFB1 MC2(+) MC2(+) MC2(-) MC2(-) 52044-1010 IL-6-10P-S3L2-E FC2240-UM-251-9370 11-9...

  • Page 134: 2-Pen Relay Board (Pr223229A)

    11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11.8 2-Pen Relay Board (PR223229A) MC1 (+) MC1 (+) MC1(-) MC1(-) -12V -12V +12V +12V PLFB1 PLFB1 PLFB2 PLFB2 MC2(+) MC2(+) MC2(-) MC2(-) IL-G-10PS3L2E IL-G-10PS3L2E FC2240-UM-251-9370 11-10...

  • Page 135: 2-Pen Board (Pr223227A)

    11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11.9 2-Pen Board (PR223227A) FC2240-UM-251-9370 11-11...

  • Page 136: High Voltage Board (Pr31001C)

    11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11.10 High Voltage Board (PR31001C) FC2240-UM-251-9370 11-12...

  • Page 137: Main Board (Pr306101)

    11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS 11.11 Main Board (PR306101) Main Board, Top FC2240-UM-251-9370 11-13...
  • Page 138 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Board, Connect 1/2 FC2240-UM-251-9370 11-14...
  • Page 139 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Board, Connect 2/2 FC2240-UM-251-9370 11-15...
  • Page 140 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Board, CPU FC2240-UM-251-9370 11-16...
  • Page 141 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Board, DRAM FC2240-UM-251-9370 11-17...
  • Page 142 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Board, Driver FC2240-UM-251-9370 11-18...
  • Page 143 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Board, G_Array FC2240-UM-251-9370 11-19...
  • Page 144 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Board, IF FC2240-UM-251-9370 11-20...
  • Page 145 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Board, IO FC2240-UM-251-9370 11-21...
  • Page 146 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Board, Memory FC2240-UM-251-9370 11-22...
  • Page 147 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Board, Pen DAC FC2240-UM-251-9370 11-23...
  • Page 148 11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS Main Board, USB FC2240-UM-251-9370 11-24...

  • Page 149: Miscellaneous

    692807142 Cable CA2232112B 692807131 Cable CA2232113A 122907010 Cable CA2290-01 122907030 Cable CA2290-03 692236120 Cable CA2292-32A 122927343 Cable CA2292-34C 122927511 Cable CA2292-51A (FC2240-180) 692236210 Cable CA2292-41B (FC2240-60/120) 122937391 Cable CA2293-39A 108901173 Cable CA08917C 692236041 Cable CA306004 692236051 Cable CA306005 692247010 Cable CA504201...

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