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FC3100-60 Service Manual
P/N53802-031T Rev. A
CUTTING PRO
FC3100-60
SERVICE MANUAL
The specifications, etc., in this manual are subject to
change without notice.
asdasd
Irvine, California U.S.A.
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FC3100-60 Service Manual
P/N53802-031T Rev. A
CONTENTS
1. INTRODUCTION
1.1 Notes on Installation and Use ……………………………………………………….. 1-1
1.1.1 Notes on Installation …………………………………………………………. 1-1
1.1.2 Notes on Use …………………………………………………………………. 1-2
1.2 Daily Maintenance and Storage ……………………………………………………. 1-3
1.2.1 Daily Maintenance …………………………………………………………… 1-3
1.2.2 Storing your Plotter ………………………………………………………….. 1-3
1.3 Main Specifications …………………………………………………………………. 1-4
1.3.1 Main Specification …………………………………………………………….1-4
1.3.2 Options ……………………………………………………………………….. 1-4
1.4 External Dimensions …..…………………………………………………………….. 1-5
2. BASIC OPERATION
2.1 Control Panel ………………………………………………………………………… 2-1
2.2 Selecting a Function Menu ………………………………………………………….. 2-3
2.3 Using the Character Dump Mode .………………………………………………….. 2-4
2.4 Running the Self Test ….…………………………………………………………….. 2-6
2.5 Listing the Cutting Conditions ……………………………………………………… 2-7
2.6 Using the Special Functions ………………………………………………………… 2-9
2.7 Setting the Serial Interface ………………………………………………………….. 2-12
2.8 Selecting the Command Mode ….………………………………………………….. 2-14
2.9 Setting the Programmable Resolution ………………………………………………. 2-15
2.10 Centronics-Compatible Parallel Interface …………………………………………… 2-16
2.11 RS-232C Serial Interface …..……………………………………………………….. 2-18
3. USING CUTTER PENS AND SETTING CUTTING CONDITIONS
3.1 Types of Cutter Blades and Their Features …………………………………………. 3-1
3.2 Cutter Pen Nomenclature ……………………………………………………………. 3-2
3.3 Replacing the Cutter Blade ………………………………………………………….. 3-3
3.4 Adjusting the Blade Length …….…………………………………………………… 3-5
3.5 Attaching the Cutter Pen …………………………………………………………….. 3-6
3.6 Achieving Optimum Cutting Results ……..…………………………………………. 3-7
4. MECHANISMS
4.1 Removing the Outer Casing …….…………………………………………………… 4-1
4.1.1 Removing the Left and Right Side Covers …………………………………… 4-1
4.1.2 Removing the Front and Rear Guides ……………………………………….. 4-2
4.1.3 Removing the Top Cover ..…………………………………………………… 4-3
4.1.4 Removing the Control Panel Base …………………………………………… 4-4
4.2 Replacing and Adjusting the Mechanisms …………………………………………… 4-5
4.2.1 Replacing the Interconnection Board (PCB:PR216012) …………………….. 4-5
4.2.2 Replacing the Pen Board (PCB:PR216013) …………………………………. 4-5
4.2.3 Replacing and Adjusting the Y Slider Belt ………………………………….. 4-7
4.2.4 Replacing and Adjusting the Y Drive Belt ……………………………………4-12
4.2.5 Replacing the Adjusting the X Drive Belt ….……….……………………….. 4-14
4.2.6 Adjusting the Y Slider Assembly …………………………………………….. 4-16
4.2.7 Replacing and Adjusting the Push Roller Arm Assembly …….…………….. 4-19
4.2.8 Replacing and Adjusting the Pen Block …….……………………………….. 4-22
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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
4.3 Removing the Mechanisms ……..…………………………………………………… 4-42
4.3.1 Components Not to be Removed …..…………………………………………. 4-42
4.3.2 Replacing the Vacuum Fan …………………………………………………….4-42
4.4 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
4.5 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
4.6 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 Location of the Main Board, Test Pins, Trimmers, DIP Switch, and ROM Chips ….. 5-1
5.2 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 Unit’s 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
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6. TEMPORARY MEASURES FOR A SENSOR MALFUNCTION
Method 1 …………………………………………………………………………….. 6-1
Method 2 …………………………………………………………………………….. 6-1
Method 3 ……….……………………………………………………………………. 6-2
Method 4 ……….……………………………………………………………………. 6-3
7. TROUBLESHOOTING
7.1 The Cutting Results are Unsatisfactory ..….…………………………………………..7-1
8. DISASSEMBLY DIAGRAMS AND PARTS LISTS
8.1 Mainframe .……………………………………………………………………………8-1
8.2 Y Drive Section ……………………………………………………………………… 8-3
8.3 X Drive Section ……………………………………………………………………… 8-5
8.4 Push Roller Arm and Y Rail Section ……..…………………………………………. 8-7
8.5 Pen Block and Y Slider Section …………………………………………………….. 8-9
8.6 Chassis Section ………………………………………………………………………. 8-12
8.7 Film Stocker Section …..…………………………………………………………….. 8-14
8.8 Carton Box and Accessory ………………………………………………………….. 8-16
8.9 User’s Manual, Operation Manual, and Other Documentation ……………………… 8-16
8.10 Stand and Media Basket Option ……………………………………………………… 8-17
8.11 Pouncing Tool Option …………………………………………………………………8-19
9. CIRCUIT DIAGRAMS AND PARTS LISTS
9.1 Wiring Diagram ……….…………………………………………………………….. 9-1
9.2 Main Board (PCB:PR216001A) …………………………………………………….. 9-3
9.3 Interconnection Board (PCB:PR216012B) ..………………………………………… 9-21
9.4 Pen Board (PCB:PR216013) …….………………………………………………….. 9-23
9.5 Sheet Switch …………………………………………………………………………. 9-25
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FC3100-60 Service Manual
P/N53802-031T Rev. A
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 air-
conditioning systems.
• Avoid locations that are extremely dusty or humid.
• 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.
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1.1.2 Notes on Use
• Make sure your computer and power sources are adequately grounded (the RS-232C interface cable
should meet the CCITT V24, EIA RS-232C standards. Graphtec's RS-232C serial interface conforms
to the EIA standard.) Inadequate grounding may result in severe damage to your plotter or computer
and constitute misuse of the plotter.
• Lubrication of the mechanisms will result in plotter malfunctions, so avoid doing so.
• 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.
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1.2 Daily Maintenance and Storage
1.2.1 Daily Maintenance
During the course of daily plotter operation, be sure to observe the following precautions.
• Never lubricate the mechanisms of the plotter.
• If the plotter's casing becomes dirty, wipe the soiled areas using a dry cloth or a cloth that has been
moistened in a neutral detergent diluted with water.
Never use thinner, benzene, alcohol, or similar solvents; they will damage the casing's finish.
• If the cutting mat becomes dirty, wipe the soiled areas using a dry cloth. In case of stubborn stains, use
a cloth that has been moistened in alcohol or in a neutral detergent diluted with water.
• The correct functioning of the paper size sensors is obstructed by the adhesion of dust, dirt, or other
foreign matter. Keep the sensors clean by wiping them with a cloth moistened in alcohol or in a
neutral detergent diluted with water.
Never use benzene, thinner, or similar solvents to clean the sensors.
1.2.2 Storing your Plotter
To store the plotter when it is not being used, be sure to observe the following points:
• Remove the pen attached to the pen holder and cover its tip with the protective cap provided.
• To protect the plotter from dust and dirt, cover it with a cloth.
• Avoid storing the plotter in places subject to direct sunlight or high temperatures.
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1.3 Main Specifications
1.3.1 Main Specifications
CPU 16-bit
Configuration Grit-rolling cutting plotter
Drive Digital servo
Maximum cutting area 50 m x 580 mm
Guaranteed precision cutting area 10 m x 580 mm *
Compatible film width 50 to 635 mm (2 to 25 inches)
Maximum cutting speed 80 cm/s
Specifiable speeds 21-step range (1 to 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 80
cm/s)
Cutting pressure 31-step range (5 to 300 g)
Minimum character matrix about 5 mm square (varies with the film and character font)
Mechanical resolution 0.005 mm
Programmable resolution GP-GL: 0.1/0.05/0.025/0.01 mm (selected by menu)
HP-GLTM emulation mode: 0.025 mm *
Repeatability Within 0.1 mm/2 m (excluding expansion or contraction caused by
changes in the operating environment)
Number of cutters/pens 1
Cutter and pen types 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
Compatible film 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 *
Standard interfaces RS-232C serial, Centronics compatible parallel (automatic interface
selection)
Buffer memory 1 M byte
Resident command sets GP-GL and HP-GLTM emulation (selected by menu)
LCD panel 20 characters x 2 lines; in six languages
Compatible paper for pouncing Regular paper from 0.06 to 0.13 mm thick
Power supply 100 to 120 VAC; 50/60 Hz
220 to 240 VAC; 50 Hz
Power consumption 120 VA max.
Operating environment
Temperature: +10°C to +35°C
Humidity: 35% to 75% RH (non-condensing)
Recommended environment
Temperature: +16°C to +32°C
Humidity: 35% to 70% RH (non-condensing)
External dimensions approx. 860 (W) x 622 (D) x 310 (H) mm
Weight approx. 22 kg
1
2
3
*1 When using Graphtec-specified film
*2 HP-GL is a trademark of Hewlett-Packard Company
*3 Use CB15U-K30 blades to cut sandblast rubber
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1.3.2 Options
Item Model no. Contents
Stand ST1001 With basket
Pouncing tool set PPA31-TP12 Pouncing plunger 1
Pouncing pin 1
Pouncing mats 5
1.4 External Dimensions
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unit: mm
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Unit: mm
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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.
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P/N53802-031T Rev. A
SELECT Keys
POSITION Keys
PAUSE Key
ENTER Key
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.
• 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.
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.
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.
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TEST key
ORIGIN Key
COPY Key
CONDITION Key
NEXT Key
FC3100-60 Service Manual
P/N53802-031T Rev. A
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.
Used to repeat the cutting operation defined by the data in the plotter's
receive buffer.
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.
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").
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2.2 Selecting a Function Menu
When the plotter is in PAUSE mode (the PAUSE lamp is lit), each of the functions listed below in the
"Function selection" column can be accessed by pressing the [ NEXT ] key until the desired menu appears
and then pressing the numeric key indicated by a box.
PAUSE Function selection Sub-menus Function Description
[NEXT] ___ [2] BUFFER CLR ………………………………………. Clearing the Buffer
_ [3] PEN U/D ……………………………………………. Raising/Lowering the Pen
_ [4] FEED ……………………………………………….. Advancing the Film
[NEXT] ___ [1] I/F __________ [1] STEP SIZE …………………… Setting the Programmable Resolution
_ [2] RS-232C …………………….. Setting the Serial Interface
_ [4] COMMAND …………..……. Selecting the Command Mode
_ [2] Film _________ [1] ORIGIN POINT ……………… Setting the Origin in HP-GL
_ [2] AREA ……………………….. Setting the Cutting Area
_ [3] AXIS ………………………… Axis Alignment
_ [4] PAGE LENG. ……………….. Setting the Page Length
_ [3] FUNCTION ___ [1] ROTATE …………………….. Rotating the Coordinate Axes
_ [2] THICK __ [1] ON …………… Cutting Thick Sheets
_ [3] OFF …………. Cutting Thick Sheets
_ [2] OVERCUT
_ [3] MIRROR …………………….. Cutting a Reversed Image
_ [4] SCALE ………………………. Setting the SCALE Factor
TM
Mode
[NEXT] __ [2] OPTION 1 _____ [1] UP SPEED ……………….…….Setting the PEN UP Speed
_ [2] OFST PRS ……………………. Setting the Offset Cut Pressure
_ [3] OFST ANG ……………….….. Adjusting the Blade Offset Angle
_ [4] STP PASS ……………………. Setting the Stop Pass
_ [4] OPTION 2 ___ [1] QUALITY ……………..….……Setting the Quality Mode
_ [2] L UNIT …………………….…. Setting the Displayed Length Unit
_ [3] DIST ADJ …………………….. Adjusting the Distance Correction
_ [4] TEST ___ [2] CONDITION ….. Listing the Cutting Conditions
_ [3] SELF TEST …… Running the Self Test
_ [4] DUMP ………… Using the Character Dump Mode
_ [1] *1 …………….. Special Test Mode (Check Pattern)
*1 Press [1] key, then hold down the [ENTER] key as you press [1] key again.
Note : For information on setting the COPY function and other special functions, see USER’S
MANUAL Section 4.11 "Using the COPY Function", and USER’S MANUAL Section 5.18
"Using the Special Function".
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Setting the Multilingual Display
Your plotter's display can be set to one of six different languages. When turning on the plotter, hold down
the panel key corresponding to the desired language as listed in the table below.
Panel Key Language selected
1
2
3
4
NEXT
ENTER
Japanese
German
English
French
Spanish
Italian
2.3 Using the Character Dump Mode
This mode enables experienced users to detect the exact cause of communication problems between the
plotter and the computer. In character dump mode, an exact printout of the codes reaching the plotter is
produced.
Note : 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.
If the cutting/plotting results are not what you expect, but the received data and the transmitted program
are identical, check the program at the computer once more (also refer to the separate "COMMAND SET
REFERENCE MANUAL").
If the cutting/plotting results are not what you expect, and the received data and the transmitted program
are different, check the interface conditions and the connection of the interface cable.
Warning : The pen starts moving as soon as the data is transmitted to the plotter from the computer.
To avoid injury to yourself and damage to the plotter, keep your hands, face, and other
obstacles out of the vicinity of the cutting mat and paper.
Procedure
Replace the cutter pen at the pen carriage's pen holder with a plotter pen and load paper in the plotter.
PAUSE Press the [ PAUSE ] key to select PAUSE mode.
[ NEXT ] : Press the [ NEXT ] key.
↓
[ NEXT ] : Press the [ NEXT ] key again.
↓
[ NEXT ] : Press the [ NEXT ] key again.
↓
[ 4 ] : Press the [ 4 ] key to select OPTI0N 2.
↓
[ 4 ] : Press the [ 4 ] key to select TEST.
↓
[ 4 ] : Press the [ 4 ] key to select DUMP.
↓
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The prompt message below appears.
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.
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2.4 Running the Self Test
Your plotter is provided with a self test function that enables it to check its own functions. Because a
correctly drawn self test pattern signifies that all of the functions of the plotter (excluding the interface
settings) have been tested and found normal, this function is useful for determining whether the source of
a problem lies in the plotter itself or in the connection between the plotter and computer.
Warning : The pen starts moving as soon as the SELF TEST mode is selected by pressing the [ 2 ] key
(YES).
To avoid injury to yourself and damage to the plotter, keep your hands, face, and other
obstacles out of the vicinity of the cutting mat and paper.
Procedure
Replace the cutter pen at the pen carriage's pen holder with a platter pen and load paper in the plotter.
[ PAUSE ] : Press the [ PAUSE ] key to select PAUSE mode.
↓
[ NEXT ] : Press the [ NEXT ] key.
↓
[ NEXT ] : Press the [ NEXT ] key again.
↓
[ NEXT ] : Press the [ NEXT ] key again.
↓
[ 4 ] : Press the [ 4 ] key to select OPTION 2.
↓
[ 4 ] : Press the [ 4 ] key to select TEST.
↓
[ 3 ] : Press the [ 3 ] key to select SELF TEST.
↓
The prompt message below appears.
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.
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2.5 Listing the Cutting Conditions
The CONDITI0N function lets you print a list of the settings of the four groups of cutting conditions, so
you can check all of your current settings at a glance.
Warning : The pen starts moving as soon as the CONDITION function is selected by pressing the [ 2 ]
key.
To avoid injury to yourself and damage to the plotter, keep your hands, face, and other
obstacles out of the vicinity of the cutting mat and paper.
Procedure
Replace the cutter pen at the pen carriage's pen holder with a plotter pen and load paper in the plotter.
[ PAUSE ] : Press the [ PAUSE ] key to select PAUSE mode.
↓
[ NEXT ] : Press the [ NEXT ] key.
↓
[ NEXT ] : Press the [ NEXT ] key again.
↓
[ NEXT ] : Press the [ NEXT ] key again.
↓
[ 4 ] : Press the [ 4 ] key to select OPTION 2.
↓
[ 4 ] : Press the [ 4 ] key to select TEST.
↓
The sub-menu below appears, so select the CONDITION function.
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.
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Sample printout by the CONDITION function
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2.6 Using the Special Functions
Your plotter is also equipped with the special functions described below.
• ":"/";" Command Control (":",";" COMMAND) [GP-GL command mode]
When the GP-GL command mode is selected, set this function to enable or disable the recognition of ":"
and ";" commands sent from the computer. These commands may adversely affect the cutting results if
the leading section of data is missing. In such cases, set this function to DISABLED.
• Pen UP/DOWN for the "W" Command ("W" COMMAND) [GP-GL command mode]
When a command specifying the plotting of an arc is sent from the computer, this function determines
whether to raise the pen or leave it in the same status (for example, the pen remains lowered if it was
lowered when the command was received) before moving it to the starting position for plotting.
When PEN DOWN is selected, the pen is moved to the starting position in the same status.
When PEN UP is selected, the pen is raised before moving to the starting position.
These setting are effective on cutting mode only.
• Model No. Response (MODEL EMULATED)
When HP-GLTM command mode is selected, this function selects the plotter's response to an "OI"
request sent from the computer.
When 7550 is selected, the plotter's response is 7550.
When 7586 is selected, the plotter's response is 7586.
• CONDITI0N PRI0RITY
This function determines the priority of programmed cutting conditions and manual settings of cutting
conditions at the plotter's control panel.
When MANUAL is selected, commands specifying cutting conditions from the computer are ignored
and the cutting conditions can only be set at the control panel. The registered conditions are retained in
the plotter's internal memory even while the plotter is turned off.
When PROGRAM is selected, the cutting conditions can be set either at the plotter's control panel or by
command input from the computer. When the plotter is turned off, however, the registered cutting
conditions are not retained.
• Initial Blade Control Position (INIT. BLADE CONTROL)
This function specifies the position at which initial blade control is performed (for more information
about initial blade control, see USER’S MANUAL Section 5.11,"Adjusting the Blade Offset Angle").
When 2 mm BELOW is selected, initial blade control is performed 2 mm below the starting point of
cutting.
When OUTSIDE is selected, initial blade control is performed outside of the effective cutting area.
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• Pen UP Movement Control (PEN UP MOVE)
When the plotter receives commands that specify consecutive pen movements in raised status, this
function determines whether to move the pen to each coordinate point or to move the pen directly to the
final coordinate point.
When ENABLED is selected, the pen moves to each coordinate point in sequence.
When DISABLED is selected, the pen moves directly to the final coordinate point.
• ON/OFF Control of the Paper Size Sensor in the Film Feeding Direction (MAINTENANCE 1)
This function lets you disable the sensor which detects paper size in the film feeding direction.
When ON is selected, the sensor is disabled.
When OFF is selected, the sensor is enabled.
• ON/0FF Control of Paper Width Sensor (MAINTENANCE 2)
This function lets you disable the sensor which detects the width of the paper.
When ON is selected, the paper width sensor is disabled.
When OFF is selected, the paper width sensor is enabled.
• Setting the MAINTENANCE 3 Function
When this function has been set to ON and the medium has been loaded a second time after the plotter
has been turned on, the plotter will assume that the medium has been reloaded and will then display the
menu for setting the CONTINUE mode.
If it has been set to OFF, the plotter does not display the CONTINUE menu.
If the CONTINUE mode is enabled when loading the medium, the medium's size will not be detected.
During long-axis plotting or other cases where the medium is likely to come loose of the pinch rollers,
the medium can be reloaded by pressing the [ PAUSE ] key to temporarily suspend the operation in
progress.
Notes on Setting the CONTINUE Mode
* When the MAINTENANCE 3 function has been set to ON, the pen carriage will not be release even if
the film set lever is lowered.
* The CONTINUE menu does not appear when the plotter is turned on or during initial paper selection
after the plotter has been reset.
* Even if the film set lever is lowered during plotting, the plotting operation will not be stopped. To
discontinue plotting, make sure to press the [ PAUSE ] key before lowering the film set lever.
* If the right pinch roller is moved when loading the medium, the pen carriage may strike the Stopper.
To change the position of the pinch roller after having selected CONTINUE mode at the paper selection
menu, turn off the plotter first.
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Procedure
While holding down the [ ⇓ ] key, turn on the plotter.
The special functions are displayed in the sequence shown below.
In GP-GL command mode In HP-GLTM command mode
To change the setting of the displayed menu, press the [ 2 ] or [ 4 ] key.
To register the selected setting and proceed to the next menu, press the [ ENTER ] key.
To proceed to the next menu without changing the setting, press the [ NEXT ] key.
When you have finished setting all of the special functions, turn off the plotter.
Note : Your settings are registered in the plotter's internal memory and retained even while the plotter is
turned off.
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2.7 Setting the Serial Interface
To enable prompt compatibility with multiple software applications, you can register three different
groups of interface settings (RS-1, RS-2, and RS-3) in the plotter's non-volatile RAM. The desired group
of RS-232C interface settings can later be easily loaded from the control panel.
Incorrectly set interface conditions can cause the plotter to malfunction or not operate at all. Be sure to set
the plotter's interface conditions to match those of your computer and the target software application.
Note : For the specifications of your plotter's serial interface, see Section 2.11,"RS- 232C Serial
Interface."
Factory Preset Interface Settings
Your plotter comes with its three groups of interface conditions set to the factory presets listed in the table
below.
Procedure
[ PAUSE ] : Press the [ PAUSE ] key to enter PAUSE mode.
↓
[ NEXT ] : Press the [ NEXT ] key.
↓
[ NEXT ] : Press the [ NEXT ] key again.
↓
[ 1 ] : Press the [ 1 ] key to select INTERFACE.
↓
[ 2 ] : Press the [ 2 ] key to select RS-232C.
↓
The menu below appears, so select the group of RS-232C interface conditions to be changed.
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Consecutively press the [ ⇑ ] or [ ⇓ ] key to cycle through the available choices in the sequence below.
→ No.=1 ↔ No.=2 ↔ No.=3 ←
|_________________________|
When the number of the desired group is displayed, press the [ ENTER ] key. The menu similar to the
example below appears.
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.
→ 7 ↔ 8 ←
|_________|
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 ] : When the displayed settings are all correct, press the [ ENTER ] key to register your
settings.
↓
[ PAUSE ] : Press the [ PAUSE ] key to cancel PAUSE mode.
Note : Your settings are retained in the internal memory even while the plotter is turned off.
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2.8 Selecting the Command Mode
This function selects the command mode for the plotter.
Note : Be sure to set the command mode to match the command mode setting of your software
application.
Procedure
[ PAUSE ] : Press the [ PAUSE ] key to select PAUSE mode.
↓
[ NEXT ] : Press the [ NEXT ] key.
↓
[ NEXT ] : Press the [ NEXT ] key again.
↓
[ 1 ] : Press the [ 1 ] key to select INTERFACE.
↓
[ 4 ] : Press the [ 4 ] key to select COMMAND.
↓
The sub-menu below appears, so select the desire command mode.
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 ] : Press the [ ENTER ] key to register your setting.
↓
[ PAUSE ] : Press the [ PAUSE ] key to cancel PAUSE mode.
Note : Your COMMAND setting is retained in the plotter's internal memory even while the plotter is
turned off.
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2.9 Setting the Programmable Resolution
When GP-GL command mode is selected, this function lets you set the distance of pen movement
corresponding to the coordinate value of 1.
When HP-GLTM command mode is selected, this function is not displayed.
Note : Be sure to set the programmable resolution to match the corresponding setting of your software
application. If they are not set identically, the cutting results will not be the same size that you
specified.
Procedure
[ PAUSE ] : Press the [ PAUSE ] key to select PAUSE mode.
↓
[ NEXT ] : Press the [ NEXT ] key.
↓
[ NEXT ] : Press the [ NEXT ] key again.
↓
[ 1 ] : Press the [ 1 ] key to select INTERFACE.
↓
[ 1 ] : Press the [ 1 ] key to select STEP SIZE.
↓
The sub-menu below appears.
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 ] : Press the [ ENTER ] key to register your setting.
↓
[ PAUSE ] : Press the [ PAUSE ] key to cancel PAUSE mode.
Note : Your STEP SIZE setting is retained in the plotter's internal memory even while the plotter is
turned off.
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2.10 Centronics-Compatible Parallel Interface
This eight-bit Centronics-compatible parallel interface is generally used for interfacing printers.
The input data signals are grouped into the eight bits of the DATA signals (DB0 to DB7), and each group
of eight DATA signals is followed by the input of an active-LOW STROBE signal. Upon receipt of the
STROBE signal, the plotter activates its BUSY signal, outputs an ACK signal, then reads the input
DATA signals to begin a cutting or plotting operation.
When the specified operation is completed, the plotter awaits the input of subsequent DATA signals.
Caution : The interface cable should be no longer than two meters.
Specifications
• While the parallel interface is used, data cannot be output from the plotter (that is, READ commands
cannot be used with the exception of the "BS" command).
• Synchronization method: Asynchronous transmission by handshaking based on STROBE and BUSY
signals.
Electrical characteristics
Based on TTL-level compatibility with the logic states below.
Positive logic "1" +2.2V or more DATA, BUSY
"0" +0.8V or less
Negative logic "1" +0.8V or less ERROR , ACK, STROBE
"0" +2.2V or more
Input / Output Circuitry
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Input / Output Timing Chart
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. Signal Name Pin No. Signal Name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
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
+ 5 V
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
Not used
ERROR
GND
Not used
GND
GND
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2.11 RS-232C Serial Interface
The RS-232C serial interface of your plotter conforms to the RS-232C Standard of the Electronic
Industries Association (EIA).
This serial interface performs the serial transfer of digital binary data, control signals, and SYNC signals.
Specifications
Standard CCITT V.24, EIA RS-232C, JIS X5101
Synchronization Asynchronous start-stop
Transfer rate 300, 600, 1200, 2400, 4800, 9600 bits/s
Stop bit 2 stop bits
Parity Even, odd, none
Character length 7 or 8 bits
Electrical Characteristics
(Negative logic)
Input voltage level + 5 V to + 12 V
Output voltage level + 5 V to + 8 V
Compatible Connectors
Plotter end : DB-25S
(ISO 2.6mm nut (M2.6 x 0.45) or ANSI #4-40 nut should be used as the locking nut.)
Cable end : DB-25P
(ISO 2.6mm screw (M2.6 x 0.45) or ANSI #4-40 screw should be used as the locking.)
RD,SD
- 5 V to - 12 V
- 5 V to - 8 V
RS,CS,DR,ER
(Positive logic)
Logical "0" "ON"
Logical "1" "OFF"
Logical "0" "ON"
Logical "1" "OFF"
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3. USING CUTTER PENS AND SETTING CUTTING
CONDITIONS
3.1 Types of Cutter Blades and Their Features
Blade part number and
type
CB09UA
(super-steel)
CB15U
(super-steel)
CB15U-K30
(super-steel)
CB15-10C
(ceramic)
CB15-05S
(sapphire)
Diameter and
blade offset value
Diameter
φ 0.9 mm
Blade offset
0.45
Diameter
φ 1.5 mm
Blade offset
0.75
Diameter
φ 1.5 mm
Blade offset
0.75
Diameter
φ 1.5 mm
Blade offset
0.50
Diameter
φ 1.5 mm
Blade offset
0.25
Plunger part
number
PHP32-CB09 Standard blade for cutting color
PHP32-CB15 For cutting film which is too thick for
PHP32-CB15 For cutting sandblast rubber. The
PHP31-CB15 This is the hardest blade, but may chip
PHP31-CB15 For cutting masking film.
Applications and features
adhesive film.
Suitable for cutting film up to 0.25 mm
thick.
Maximum cutting distance of
approximately 4000 m.
the CBO9UA blade to handle.
Suitable for cutting film from 0.25 mm
to 0.5 mm thick.
sharply angled point provides a longer
cutting edge.
Suitable for cutting material from 0.5
mm to 1.5 mm thick.
or shatter if dropped or subjected to
impact.
Suitable for cutting material up to 0.05
mm thick.
Suitable for cutting material up to 0.05
mm thick.
3 - 1
3.2 Cutter Pen Nomenclature
Warning : To avoid injury, handle the cutter blades carefully.
• Structure of the PHP32-CB09 Cutter Pen
(for cutter blades of 0.9 mm diameter)
* The CB09UA super-steel blade is shown in the figure above.
• Structure of the PHP32-CB15 Cutter Pen
(for super-steel cutter blades of 1.5 mm diameter)
FC3100-60 Service Manual
P/N53802-031T Rev. A
* The CB15U super-steel blade is shown in the figure above.
• Structure of the PHP31-CB15 Cutter Pen
(for ceramic and sapphire cutter blades of 1.5 mm diameter)
* The CB15-10C ceramic blade is shown in the figure above.
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3.3 Replacing the Cutter Blade
Warning : To avoid injury, handle the cutter blades carefully.
Various types of plunger are available which correspond to the diameter and type of the blade used.
Check the cutter blade you are going to use and its appropriate cutter offset value against the table below.
Cutter pen Color
classification
PHP32-CB09 Blue CB09UA Super-steel
PHP32-CB15 Red CB15U
PHP31-CB15 Red CB15-10C
Replacing the Blade
The procedure for blade replacement varies with the type of cutter pen used.
• PHP32-CB09 and PHP32-CB15 cutter pens for super-steel blades
(1) Remove the plunger cap from the plunger by turning it in the counterclockwise direction.
(2) Remove the blade from the cap.
(3) Stand the cap upright, and insert the new blade, together with the spring if the blade is a CB09UA
blade, into the hole.
(4) Reattach the cap with the blade inside to the plunger.
Compatible blade
types
CB15U-K30
CB15-05S
Blade material Cutter offset values
18 ± 2
Super-steel
Super-steel
Ceramic
Sapphire
28 ± 2
28 ± 2
18 ± 2
9 ± 2
3 - 3
• PHP31-CB15 cutter pen for ceramic and sapphire blades
(1) Remove holder (B) by turning the blade length adjustment knob in
the counterclockwise direction.
(2) Remove the blade from holder (A).
(3) With the tip of holder (A) facing downward as shown, insert the
new blade.
(4) Make sure the blade is inserted straight into the holder. If the blade
is positioned at an angle, gently tap the plunger to correct the
orientation of the blade.
(5) With the tip of holder (A) facing downward, attach the holder cap
and then turn the blade length adjustment knob in the clockwise
direction until the blade tip is visible.
(6) Using your finger, check that the cutter blade rotates smoothly
inside the cutter pen (be careful not to stab your finger at this time).
(7) If the blade does not rotate smoothly or the blade falls off after
attaching the cutter pen to the pen carriage, the inside of the holder
is insufficiently lubricated. In this case, apply the grease provided
to the three points indicated by arrows in the figure.
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* The blades can also be replaced from the front of the plunger. To
replace the blade from this direction, turn the blade adjustment knob
fully in the clockwise direction, remove the blade from the front of
the plunger, and then replace it with a new one.
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3.4 Adjusting the Blade Length
Caution : Make sure to correctly adjust the blade length. If the blade length is too long for the thickness
of the medium being used, you may cut through the cutting mat and damage the plotter.
• Adjusting the Blade Length
(1) Before adjusting the blade length, align the blade tip with the tip of
the cutter pen by turning the red or blue blade adjustment knob in
the B direction (see the figure below).
(2) Next, extend the blade tip to the length suitable for the medium to
be used by turning the blade adjustment length in the A direction.
Observe the scale on the plunger cap to determine how far to move
the blade.
When the knob is turned the distance of one scale unit, the blade
moves 0.1 mm. When it is given one full turn, the blade moves 0.5
mm.
a. To extend the blade, turn the knob in the A direction.
b. To retract the blade, turn it in the B direction.
• Obtaining the Correct Blade Length
Assuming that the film thickness is "t", the blade length "l" should be equal to "t". Make sure that "l" is
never greater than the combined thickness of the film and its 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. For more
information about the cutting test, see USER’S MANUAL Section 4.7, "Running a Cutting Test ".
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3.5 Attaching the Cutter Pen
Warning : The tip at the cutter blade is sharp. When handling the cutter pen, be careful to avoid
injuring yourself.
(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.
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3.6 Achieving Optimum Cutting Results
The quality of cutting operations is determined by the settings of the five parameters below.
• Blade length
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 these conditions according to the combination of medium and cutter
blade you are using (see USER’S MANUAL Section 4.5, "Setting the Cutter
Pen Conditions").
Set this condition according to the type of cutter blade you are using (see
USER’S 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 Thickness
Blade type FORCE SPEED QUALITY
(mm)
Outdoor film 0.05 to 0.08 CB09UA 10 to 14 over 30 3 to 4
Indoor film 0.08 to 0.1 CB09UA 14 to 17 over 30 3 to 4
Transparent film, translucent film 0.08 to 0.1 CB09UA 14 to 20 over 30 3 to 4
Reflective film 0.08 to 0.1 CB09UA 14 to 20 over 30 3 to 4
Fluorescent film 0.20 to 0.25 CB09UA,
20 to 24 10 to 20 2 to 3
CB15U
Sandblast rubber (for masking)*
1
0.5 to 1.0 CB15U-K30 17 to 24 5 to 15 1
*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
Panel display
Material & Blade Number Blade type CUTTER OFFSET
Default Setting range
Super-steel CB09UA 09U 0
CB15-10U 15-10U 0
CB15U 15U 0
CB15U-SP 15U 0
CB15U-K30 15U-K30 0
CB15U-K30-SP 15U-K30 0
Ceramic CB15-10C 15-10C 0
Sapphire CB15-05S 15-05S 0
± 5
± 5
± 5
± 5
± 5
± 5
± 5
± 5
Other OTHER 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.
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The table below lists sample CUTTER OFFSET settings in case the blade type is set to OTHER.
Actual blade type CUTTER OFFSET value
CB09UA 17
CB15-10U 18
CB15U 28
CB15U-SP 28
CB15U-K30 28
CB15U-K30-SP 28
CB15-10C 18
CB15-05S 9
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
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(2) To attach a side cover, reverse the above procedure.
4 - 1
Fig. 4-2
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4.1.2 Removing the Front and Rear Guides
(1) Remove the screws from the front and rear guides as shown in Figs.4-3 and 4-4.
• Three M3 x L6 pan-head with flat washer screws (black) each
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
(3) To attach the front or rear guide, reverse the above procedure.
Fig, 4-6
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4.1.3 Removing the Top Cover
(1) Remove the side covers (see Subsection 4.1.1).
(2) At the PR216012 relay board, disconnect the FPC (Flexible Printed-Circuit) cable and the cable from
the P22 connector as shown in Fig.4-7.
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
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4.1.4 Removing the Control Panel Base
(1) Remove the right side cover (see Subsection 4.1.1).
(2) Remove the top cover (see Subsection 4.1.3).
(3) As shown in Fig.4-10, remove the control panel base while making sure to avoid damaging the FPC
cable and other cables.
• Five M3 x L6 bind-head screws
Fig. 4-10
(4) To attach the control panel base, reverse the above procedure.
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4.2 Replacing and Adjusting the Mechanisms
4.2.1 Replacing the Interconnection Board (PR216012: Cam Sensor)
(1) Remove the right side cover (see Subsection 4.1.1).
(2) Disconnect the five cables from the PR216012 relay board, making sure not to damage the FPC cable.
(3) As shown in Fig.4-11, remove the relay board.
• Three M3 x L6 pan-head with flat washer screws
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).
4.2.2 Replacing the Pen Board (PR216013: Paper Width Sensors)
(1) Remove the top cover (see Subsection 4.1.3).
(2) Remove the FPC cable bracket as shown in Fig.4-12.
• Two M3 x L6 bind-head screws
Fig. 4-12
(3) Disconnect the Y FPC cable from the PR216013 pen board's J31connector.
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(4) As shown in Fig.4-13, remove the 60A FPC cable holder.
• Two M2 x L4 bind-head screws
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
4.2.3 Replacing and Adjusting the Y Slider Belt
Replacing the Y Slider Belt
(1) Remove the left and right side covers (see Subsection 4.1.1).
(2) Remove the top cover (see Subsection 4.1.3).
(3) As shown in Fig.4-16, loosen the spring adjustment plate.
• Tow M4 x L8 bind-head screws
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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).
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(6) As shown in Fig.4-18, remove the two B belt stays from the top of the Y slider belt.
• Four M3 x L6 pan-head with flat washer screws
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
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* When securing each end of the Y slider belt, make sure it is not slanted and is positioned at the
approximate center of the B belt stay.
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.
* Do not forget to secure the spring adjustment board.
Fig. 4-22
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Adjusting the Y Slider Belt's Tension
(1) Perform Steps (1) through (4) of the preceding "Replacing the Y Slider Belt."
(2) As shown in Fig.4-23, slide the Y slider against the right side plate.
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.
(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. 4-24
Fig. 4-25
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• As shown in Fig.4-26, adjust the tension using the M4 x L15 socket-head cap screw.
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.
(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".
Fig. 4-27
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FC3100-60 Service Manual
4.2.4 Replacing and Adjusting the Y Drive Belt (120TN15-10.0W)
Replacing the Y Drive Belt
(1) Remove the right side cover (see Subsection 4.1.1).
(2) Remove the top cover (see Subsection 4.1.3).
(3) Remove the PR216012 relay board (see Subsection 4.2.2).
(4) Remove the Y slider belt (see Subsection 4.2.3).
(5) Remove the Y motor as shown in Fig.4-28.
• Four M3 x L8 pan-head with flat washer screws
P/N53802-031T Rev. A
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.
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P/N53802-031T Rev. A
Adjusting the Y Drive Belt's Tension
(1) Perform Steps (1) through (3) of the preceding "Replacing the Y Drive Belt."
(2) As shown in Fig.4-30, loosen the tension of the Y motor.
• Four M3 x L8 pan-head with flat washer screws
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.
(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."
Fig. 4-31
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FC3100-60 Service Manual
4.2.5 Replacing and Adjusting the X Drive Belt (120TN15-10.0W)
Replacing the X Drive Belt
(1) Remove the left side cover (see Subsection 4.1.1).
(2) As shown in Fig.4-32, loosen the tension of the X drive belt.
• Four M3 x L8 pan-head with flat washer screws
* Structurally, the screwdriver contacts the chassis and drive belt.
Fig. 4-32
P/N53802-031T Rev. A
(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.
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P/N53802-031T Rev. A
Adjusting the X Drive Belt's Tension
(1) Loosen the belt's tension as described in the preceding "Replacing the X Drive Belt."
(2) As shown in Fig.4-34, push downward on the X motor pulley using a 5 kgf push-pull gauge.
• Push force : 2.0 ± 0.1 kgf
* Note that, structurally, the motor can only be pushed downward at an angle.
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.
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P/N53802-031T Rev. A
4.2.6 Adjusting the Y Slider Assembly
Adjusting the Y Slider Roller Pressure
(1) Remove the top cover (see Subsection 4.1.3).
(2) As shown in Figs.4-35 and 4-36, disconnect the Y FPC cable and pen block FPC cable from the
PR216013 pen board.
* Take care not to damage the cables.
Fig. 4-35 Fig. 4-36
(3) Remove the pen board (see Subsection 4.2.2).
• Two M3 x L6 bind-head screws
(4) As shown in Fig.4-37, reduce the pressure applied by the rollers at the front of the Y slider.
• M3 x L6 bind-head screw
Fig. 4-37
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P/N53802-031T Rev. A
(5) As shown in Fig.4-38, reduce the pressure applied by the rollers at the rear of the Y slider.
• Two M3 x L6 bind-head screws and two tooth lock washers
* Note that the BB mounting plate may be stuck to the Y slider by adhesive used to secure the screws.
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.
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P/N53802-031T Rev. A
(8) Check that there is no play in the Y slider (see the following "Checking the Y Slider Roller
Pressure").
(9) To mount the Y slider assembly, reverse the preceding procedure.
Checking the Y Slider Roller Pressure
Using the procedure described below, check that there is no play in the Y slider.
(1) While holding the Y slider as shown in Fig.4-41, move it using both hands in the directions indicated
by the arrows.
• When you move your left hand upward, move your right hand downward (the black arrows).
• When you move your left hand downward, move your right hand upward (the white arrows).
While applying pressure to the Y slider as shown in Fig.4-41, check that there is no play.
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.
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4.2.7 Replacing and Adjusting the Push Roller Arm Assembly
Replacing a Push Roller
(1) As shown in Fig.4-43, remove the two E clips.
• Be sure not to lose them.
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.
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P/N53802-031T Rev. A
(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.
Fig. 4-44
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P/N53802-031T Rev. A
Adjusting the Push Force
(1) Remove the top cover (see Subsection 4.1.3).
(2) As shown in Fig.4-45, attach the stainless steel plate jig (part no. 462500002).
• Ensure that the push roller is above the grit roller.
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
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P/N53802-031T Rev. A
(5) If the push force is outside the specified range, adjust it as follows.
• To raise the push force: Turn the lower nut so that it descends, then secure the upper nut
accordingly.
• To lower the push force: Turn the upper nut so that it rises, then secure the lower nut accordingly.
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.
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4.2.8 Replacing and Adjusting the Pen Block
Replacing the Pen Block
(1) Remove the top cover (see Subsection 4.1.3).
(2) Remove the pen block cover as shown in Fig.4-50.
• Two M2 x L8 bind-head screws
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.
FC3100-60 Service Manual
P/N53802-031T Rev. A
(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. 4-51
Fig. 4-52
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P/N53802-031T Rev. A
(6) To attach the pen block, reverse the procedure while paying attention to the following points.
* Attach a ceramic pen and ensure a clearance of 3 mm (nominal error: +0.3 mm, -0 mm) between
the cutting mat's upper surface and the ten tip.
* Visually check that the pen block's bottom surface is parallel to the cutting mat's surface.
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).
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P/N53802-031T Rev. A
Adjusting the Slide Arm Pressure (Pen Block Play)
(1) Remove the pen block cover.
• Two M2 x L8 bind-head screws
(2) Loosen the offset pin as shown in Fig.4-56.
• One M2 x L6 set screw
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
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P/N53802-031T Rev. A
• As shown in Fig.4-59, lower the pen by pushing the slide am downward with your finger as you
check that the bearing does not idle.
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.
If the MC Coil does not move smoothly
(1) If the MC coil does not move smoothly (appears to stick or to be contacting its casing), one or more of
the following symptoms appear.
• Abnormal noise
• Abnormal odor (of something burnt)
• Cutting results are unsatisfactory
• Electrical adjustments cannot be made
• The pen cannot be raised or lowered
• Overheating, etc.
(2) When the MC coil does not move smoothly, replace the pen block.
* Because production of the pen block incorporates advanced technology, it is easier to replace the
pen block than to attempt adjustment.
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4.2.9 Replacing the X Motor and X Motor Pulley
Replacing the X Motor
(1) Remove the side covers (see Subsection 4.1.1).
(2) Remove the rear guide (see Subsection 4.1.2).
(3) Loosen the tension of the X drive belt.
* Structurally, the screwdriver contacts the chassis and synchro belt.
* Be careful not to damage the X motor pulley.
• Four M3 x L8 pan-head with flat washer screws
FC3100-60 Service Manual
P/N53802-031T Rev. A
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).
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Replacing the X Motor Pulley
(1) Perform Steps (1) through (3) of "Replacing the X Motor".
(2) Remove the X drive belt (see Subsection 4.2.5).
(3) Remove the X motor pulley as shown in Fig.4-62.
* Be sure not to lose the set screws.
* Note that the motor pulley may be hard to remove.
• Two M3 x L3 set screws
Fig. 4-62
FC3100-60 Service Manual
P/N53802-031T Rev. A
(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
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P/N53802-031T Rev. A
4.2.10 Replacing the Y Motor and Y Motor Pulley
Replacing the Y Motor
(1) Perform Steps (1) through (4) of "Replacing the Y Drive Belt" in Subsection 4.2.4.
(2) Remove the Y motor as shown in Fig.4-64.
* Be careful not to damage the Y motor pulley.
* Four M3 x L8 pan-head with flat washer screws
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).
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P/N53802-031T Rev. A
Replacing the Y Motor Pulley
(1) Perform Steps (1) through (4) of "Replacing the Y Drive Belt" in Subsection 4.2.4.
(2) Remove the Y motor as shown in Fig.4-66.
* Be careful not to damage the Y motor pulley.
* Four M3 x L8 pan-head with flat washer screws
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
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4.2.11 Replacing the X Drive Pulley
(1) Remove the X drive belt (see Subsection 4.2.5).
(2) Remove the X drive pulley as shown in Fig.4-63.
* Be sure not to lose its set screws.
* The X drive pulley may be hard to remove.
• Two M3 x L5 set screws
Fig. 4-68
FC3100-60 Service Manual
P/N53802-031T Rev. A
(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
4.2.12 Replacing the Y Drive Pulley
(1) Remove the Y drive belt (see Subsection 4.2.4).
(2) Remove the Y drive pulley.
(3) To mount the Y drive pulley, reverse the above procedure.
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4.2.13 Replacing the Y Tension Pulley
(1) Remove the Y slider belt (see Subsection 4.2.3).
(2) Remove the Y tension pulley.
* Be careful that the Y tension pulley does not fall off when the Y slider belt is removed as shown in
Fig.4-70.
Fig. 4-70
(3) To mount the Y tension pulley, reverse the above procedure.
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4.2.14 Replacing the Y Flexible Printed-Circuit Cable
Removing the Y FPC Cable
(1) Remove the right side cover (see Subsection 4.1.1).
(2) Remove the top cover (see Subsection 4.1.3).
(3) Remove the FPC cable bracket.
• Two M3 x L6 bind-head screws
(4) As shown in Fig.4-71, disconnect the Y FPC cable from the PR216013 pen board's J31 connector.
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
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Mounting the Y FPC Cable
(1) While comparing the new Y FPC cable with the old one, fold it according to the dimensions shown in
Fig.4-73.
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
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(4) When securing the Y FPC cable with fixing tape as shown in Fig.4-77, face the Y FPC cable slightly
toward the plotter.
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.
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4.2.15 Replacing the Front and Rear Paper Size Sensors
(1) Remove the front and rear guides (see Subsection 4.1.2).
(2) As shown in Fig.4-80, disconnect one connector each from the front and rear paper size sensors.
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
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4.2.16 Replacing the LCD Panel
(1) As shown in Fig.4-83, remove the control panel base (see Subsection 4.1.4).
* Be careful not to damage the FPC cables.
• Five M3 x L6 bind-head screws
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.
FC3100-60 Service Manual
P/N53802-031T Rev. A
* 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.
(3) To mount the LCD panel, reverse the above procedure.
Fig. 4-84
Fig. 4-85
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4.2.17 Replacing the Control Panel Sheet
(1) Remove the control panel base (see Subsection 4.1.4).
(2) Pull off the control panel sheet as shown in Fig.4-86.
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.
FC3100-60 Service Manual
P/N53802-031T Rev. A
Fig. 4-87
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4.2.18 Replacing the Main Board (PR216001)
(1) Remove the front and rear guides (see Subsection 4.1.2).
(2) Disconnect all cables attached to the main board's connectors.
(3) As shown in Fig.4-88, remove the screws from the interface connectors.
• Two standoffs and two M2.6 x 10 pan-head screws
Fig. 4-88
(4) Remove the main board as shown in Fig.4-89.
• Six M3 x L6 pan-head with flat washer screws
FC3100-60 Service Manual
P/N53802-031T Rev. A
(5) To mount the main board, reverse the above procedure.
* Make absolutely sure to conduct all electrical adjustments!
Fig. 4-89
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4.2.19 Replacing the Power Unit (PS089A)
(1) Remove the front and rear guides (see Subsection 4.1.2).
(2) Disconnect the power unit's J15 connector.
(3) Remove the power unit as shown in Fig.4-90.
* Be careful not to damage the board spacers, shown in Fig.4-91, which are attached to the power
unit's bottom surface.
• Four M3 x L6 pan-head with flat washer screws
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
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4.2.20 Replacing the ROM Chips
(1) Check that the power cord is disconnected from the electrical outlet.
(2) Remove the front guide (see Subsection 4.1.2).
(3) As shown in Fig.4-93, remove both ROM chips using a flat blade screwdriver.
* Do not insert the screwdriver beneath the IC socket.
* Be careful not to damage the circuit board.
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.
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4.2.21 Tightening the Drive Rollers
Further tighten the drive rollers if film or other media is being fed at an angle due to loose set-screws of
the drive rollers.
As shown in Fig.4-95, use a 1 mm hex wrench to tighten the set-screws from the openings in the standard
stays.
Fig. 4-95
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4.3 Removing the Mechanisms
4.3.1 Components Not to be Removed
The following components are only to be removed at the factory.
• Push roller arm assembly
• Main unit (chassis)
• Y bar
• Standard stays
• Drive rollers
Unless these components are correctly replaced at the factory, the perpendicularity and other
specifications related to precision will be adversely affected.
4.3.2 Replacing the Vacuum Fan
(1) Remove the front and rear guides (see Subsection 4.1.2).
(2) Disconnect the main board cable connected to either the P51 or P52 connector.
(3) As shown in Fig.4-96, remove the vacuum fan using a small screwdriver.
• Four M3 x L30 pan-head screws , M3 lock washers, and M3 flat washers
(4) To mount the vacuum fan, reverse the above procedure.
Fig. 4-96
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4.4 The Accuload TM Film Stocker
4.4.1 Overview
This film stocker assembly was designed to improve media tracking for long length cutting on your new
plotter; see your user's manual for further details.
For best results with your plotter in long length cutting, please follow all instructions carefully and
assemble the Film Stocker to your GRAPHTEC FC3100-60 Cutting Plotter on a large, flat surface.
4.4.2 Assembling the Accuload TM Film Stocker
Turn Off The Power
(1) Turn off the power supply to the cutting Plotter. Remove the cutter pen from the pen holder.
Attach the Left Bracket
Place the Film Stocker on a large, flat surface.
(1) Temporarily attach the first 1/2 inch Rod to the Left Bracket using a M4 x 10mm Flat Head Screw.
(2) Temporarily attach the second 1/2 inch Rod using the same hardware.
(3) Temporarily attach the 3/4 inch Rod using the same hardware.
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.
Fig. 4-98
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(5) Temporarily attach the 3/4 inch Rod using the same hardware.
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.
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Temporarily Secure the Film Stocker Brackets
(1) Temporarily secure the Film Stocker Bracket to the Left Side Plate of the plotter using two M4 x
10mm Flat Head Screws.
(2) Temporarily secure the Film Stocker Bracket to the Right Side Plate using the same hardware.
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.
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(2) To prevent skewing the Film Stocker Assembly during final assembly, tighten the screws in the
following order:
1. Tighten the Right Front screws.
2. Tighten the Left Front screws.
3. Tighten the Right Middle screws
4. Tighten the Left Middle screws.
5. Tighten the Right Rear screws.
6. Tighten the Left Rear screws.
7. Tighten the Right Side Plate screws.
8. Tighten the Left Side Plate screws.
Fig. 4-103
4.4.3 Loading Sheet Film
Loading the Film
(1) Lower the film set lever to raise the push roller.
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.
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(5) Adjust both front and rear roll guides until they are the same distance from the media bracket edge.
(6) Secure both the front and rear roll guides in place using the M4 Thumb Screw.
Fig. 4-105
Adjusting the Push Roller Positions
(1) Move the push rollers as required to hold down the film within the appropriate range.
(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.
Fig. 4-106
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Holding Down the Film
(1) Raise the film lever to lower the push rollers onto the film to hold it in place.
Fig. 4-107
Turning On the Power
(1) Turn on the plotter by pressing the “I” side of the power switch.
P/N53802-031T Rev. A
(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.”
Fig. 4-108
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4.5 The Stand and Media Basket Option
4.5.1 Overview
This Stand and Media Basket option was designed to keep media clean and reduce media handling
problems caused by debris adhering to media.
4.5.2 Assembling the Stand
Assembly Area : Assemble the Stand on a secure, flat surface.
Assembling the Stand
(1) Install the Bottom Connecting Tube to the Right Side Vertical Support with 2 M6 x 8mm Screws and
the M4 Hex Key.
Fig. 4-109
(2) Install the Top Connecting Tube to the Right Side Vertical Support using the same hardware.
Fig. 4-110
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(3) Repeat the process to install the Left Side Vertical Support.
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.
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(7) To prevent skewing the Stand Assembly during final assembly, tighten the screws in the following
order:
1. Tighten the 2 Lower Left screws.
2. Tighten the 2 Lower Right screws.
3. Tighten the 2 Middle Left screws.
4. Tighten the 2 Middle Right screws.
5. Tighten the 3 Upper Left screws.
6. Tighten the 3 Upper Right screws.
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.
Note : Always keep the wheels in a locked position when operating your plotter.
Fig. 4-115
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Caution : Do not install the plotter on to the Accuload TM Film Stocker Bracket before installing the Film
Stocker Bracket on to the Stand. The extra weight from the plotter may cause the unit to
become unstable. In extreme cases, the unit may tip over !!
4.5.3 Mounting the Plotter on the Stand
Remove the Accuload TM Film Stocker Bracket
To remove the Accuload TM Film Stocker Bracket from the Plotter, follow the directions below.
(1) Remove the Roller Bars from the media bracket.
(2) Remove the screws holding the Film Stocker Bracket to the plotter and slide the plotter off the
bracket.
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 Film Stocker Bracket
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
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(3) To prevent skewing the Film Stocker Assembly during final assembly, tighten the screws in the
following order:
1. Tighten the Front Right screws.
2. Tighten the Front Left screws.
3. Tighten the Middle Right screws.
4. Tighten the Middle Left screws.
5. Tighten the Rear Right screws.
6. Tighten the Rear Left screws.
Fig. 4-119
Install the Accuload TM Film Stocker Bracket
Install the Accuload TM Film Stocker Bracket on the Stand Assembly.
(1) Lock the casters on the stand.
The front of the machine has the locking casters. Push down to lock.
(2) Make sure the front of the Film Stocker Bracket is aligned correctly.
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.
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(6) Refer to step 3 & 4 in the Film Stocker Assembly Instructions.
(7) Return the Roller Bars to the Media Bracket.
Fig. 4-122
4.5.4 Assembling the Media Basket
Assembling the Media Basket
(1) Place the Left Side Basket on it's side with the five wire ends facing right.
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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.
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(4) Slide each of the five Right Side Basket wire ends into the open Basket Tubes on the Left Side Basket.
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
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(3) Install the Rear Media Basket as shown.
Fig. 4-129
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4.6 The Pounce Tool Option
4.6.1 Replacing the Pouncing Pin
Special Precautions : The plotter uses a special pouncing cartridge and mat. Observe the following
precautions, whenever handling the pounce tool to prevent operator injury:
• The pounce tool point is very sharp, do no touch.
• The pin shaft will bend when mishandled.
Handling the Pounce Tool
The pin of the cartridge is very sharp. Do not extend further than the safety cap.
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
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(4) Remove the sleeve by turning the retainer clockwise. Place the sleeve on its end to prevent the sleeve
from rolling away.
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
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(2) Install the plastic body of the pounce tool by slipping it on to the bottom of the pounce tool.
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.
4.6.2 Replacing the Mat
Before using the pouncing tool, you must remove the cutting mat and replace it with a pouncing mat.
Refer to your FC3100-60 User's Manual section 4.6 for Setting the Pouncing Pen Conditions for more
Pounce Pen operating information.
Removing the Old Cutting Mat
(1) Turn off the power supply to the cutting plotter.
(2) Remove the cutter pen from the pen holder and lower the film set lever.
(3) Move the pen carriage to the right of the plotter.
(4) Starting from the left side of the plotter, lift up the cutting mat assembly and pull it slowly towards the
center of the plotter.
(5) When you reach the center, mover the pen carriage to the left and then continue pulling on the cutting
mat toward the right until it is completely removed.
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(6) Check that the groove is free from glue and dirt. Clean off any dirt or glue with a cloth moistened in
ethyl alcohol.
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.
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5. ELECTRICAL ADJUSTMENTS
5.1 Location of the Main Board (PCB No. PR216001), Test Pins,
Trimmers, DIP Switch, and ROM Chips
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5.2 Power Unit (PS089A)
5.2.1 Checking Operation
(1) Use a multi-mater to check the voltage levels of TP1 to TP5.
Test pin Voltage
TP1 + 5 V
TP2 + 12 V
TP3 + 32 V
TP4 - 12 V
TP5 + 24 V
TP10 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 Voltage
1 pin + 5 V
2 pin + 12 V
3 pin + 32 V
4 pin GND
5 pin GND
6 pin + 5 V
7 pin - 12 V
8 pin + 32 V
9 pin + 32 V
10 pin GND
(3) If the measured voltage levels do not conform to the above tables, the power unit is probably
defective.
5.2.2 The Protective Circuit
The protective circuit is activated in either of the following cases.
+ 32 V power + 5 V power + 12V power - 12V power
Protection against
excess current
Protection against
excess current
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.
8 A or more 6 A or more 6 A or more 3 A or more
115% of the rated
voltage (32V)
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5.3 Switching the Power Unit's Supply Voltage
(1) Check that the plotter's POWER switch is off.
(2) Remove the rear guide (see Subsection 4.1.2).
(3) Connect the power unit's cable to the required connector.
Voltage series Corresponding area Connector
100 V UL model: USA, Japan, Asian CN2
200 V CE Model: Europe, Asian CN3
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5.4 Setting the DIP Switches
The NOVRAM CLEAR function
• Initializes the main board by clearing the nonvolatile RAM
• Execute this function before starting any electrical adjustment
Electrical adjustments
• Pen height adjustment
• Pen force adjustment
• Selection of Centronics compatible interface mode
Distance accuracy adjustment
• Perform this adjustment after clearing the nonvolatile RAM or after
replacing the main board
Sensor test
• After replacing a sensor, run this test to check its operation
FC3100-60 Service Manual
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Control panel key test
• After reconnecting the FPC cable to the relay board's J21 connector,
run this test to check the operation of the control panel keys.
Servo D/A ZERO OUT
• Offset adjustment of the X and Y motors
• Pen offset adjustment
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