GRAPHTEC FC2240, FC2240-120MG, FC2240-60VC Service Manual
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CUTTING MACHINE
FC2240
FC2240-UM-251-04-9370
SERVICE MANUAL
HISTORY OF REVISIONS
No. Date issued
1 05.11.24
Description of revision
First Printing
2 06.04.24
Part number for the Y flexible cable corrected.
3 06.05.26 Part number for the control panel switch corrected.
4 06.05.26 Part number for the main relay board corrected.
5 06.09.07
Part number for the control panel switch corrected.
Page
All
10-10
5-1, 10-5
5-1, 10-5
5-1
Edition
01
02
03
03
04
FC2240-UM-251-9370 i
CONTENTS
1. INTRODUCTION .............................................................1-1
1.1 Model Names and Basic Specifications .........................................................1-1
2. Description of Parts ......................................................2-1
3 Basic Operation .............................................................3-1
FC2240-UM-251-9370 ii
4. Daily Maintenance and Storage ...................................4-1
5. RECOMMENDED PARTS LIST .....................................5-1
6. LIST OF TOOLS .............................................................6-1
7. DISASSEMBLY AND ADJUSTMENT ............................7-1
7.4 Adjusting the Roller Pressure of the Front X Slider ......................................7-9
7.5 Adjusting the Roller Pressure of the Rear X Slider .....................................7-10
7.6 Adjusting the Roller Pressure of the Y Slider ..............................................7-12
7.8 Mounting the Y Slider on the Y Flexible Printed Circuit Cable ...................7-14
FC2240-UM-251-9370 iii
8. ELECTRICAL ADJUSTMENTS ......................................8-1
8.1 Flowchart of the Adjustment Sequence ........................................................8-1
8.3 Setting the Power Unit’s Supply Voltage (PS089B) .......................................8-4
8.4 Checking the Power Unit’s Supply Voltage ....................................................8-5
8.5 Explanation of the Values of the Main Board .................................................8-6
8.12 Adjusting the Distance and the Perpendicularity Accuracy .......................8-16
8.16 Testing the Control Panel Keys and Home Sensors ...................................8-21
9 TROUBLESHOOTING ....................................................9-1
FC2240-UM-251-9370 iv
9.2 The Plotter is Turned On But Doesn’t Operate ............................................9-13
9.4 Error Messages in GP-GL Command Mode .................................................9-15
9.5 Error Messages in HP-GL Emulation Mode ..................................................9-16
10. PARTS LISTS ...............................................................10-1
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS ........11-1
FC2240-UM-251-9370 v
FC2240-UM-251-9370 vi
1. INTRODUCTION
1. INTRODUCTION
1.1 Model Names and Basic Specifications
Model
FC2240-60VC
FC2240-120MG
FC2240-120ES
FC2240-120VC
FC2240-180ES
FC2240-180VC
No. of pens Media hold down method
2 Vacuum suction
2 Magnetic
2
2
2
2
Electrostatic adhesion
Vacuum suction
Electrostatic adhesion
Vacuum suction
Cutting area
610 (X) x 920 (Y) mm
1200 (X) x 920 (Y) mm
1740 (X) x 920 (Y) mm
1.2 Standard Accessories
Item
Power cable
Cutter pen set
Water based fiber-tip pen
Sheet holder plates
Hexagon wrench
Height adjustment plates
Paper alignment seals
Durable flexible hose
Description
PPA31-CB15B, CB15U-2SP, CB15U-K30-5SP
KF552-BK
For MG models only (2 large, 2 medium, 4 small)
For M4 bolts
10 mm, 4 mm height
For VC models only, 1.5 m to 5 m (can expand/contract)
Hose band
Connection bore diameter: Ø38mm (-60), Ø58mm (-120/180)
For VC models only
Vacuum pump installation base For VC models only
CD-ROM User’s manual, Driver, other software
Q’ty
1
1 set
1
1 set
1
1 of each
1 pack
1
2
1
1
CAUTION
• The vacuum pump is an option. It is not provided with the VC models.
• Make sure that the vacuum pump used with a VC model is affixed with either a label showing compliance with the relevant safety standard or with the CE marking.
FC2240-UM-251-9370 1-1
1. INTRODUCTION
1.3 Main Specifications
Configuration
FC2240-60VC
Flatbed
FC2240-120VC/MG/ES FC2240-180VC/ES
Effective cutting area 610 x 920 mm 1200 x 920 mm 1740 x 920 mm
Media hold-down method VC models: Vacuum suction, MG models: Magnetic,
Maximum cutting speed
Cutting force
Cutting media
ES models: Electrostatic adhesion
400 mm/sec (40-step range)
High force mode: 9.8 N (1 kgf) max : 40-step range 2 to 80
Minimum character size
Mechanical resolution
Standard force mode: 4.9 N (500 gf) max : 40-step range 1 to 40
About 10 mm square (varies with the character font and cutting media)
0.0025 mm
Programmable resolution GP-GL mode: 0.1/0.05/0.025/0.01 mm, HP-GL TM mode: 0.025 mm
Distance accuracy
Perpendicularity
Repeatability
Within 0.1% of the distance moved (plotter mode)
Within 0.5 mm/900 mm (plotter mode)
Within 0.1 mm (plotter mode)
Number of pens/cutters
Cutter and pen types
2
Cutter blades: Supersteel
Pens: water-based fibertip, oil-based ballpoint, disposable ink pen *1
Marking film (vinyl, fluorescent, reflective), Stiff paper/card up to 0.5 mm
Interfaces
Buffer memory
Command sets
LCD panel
Power supply thick, Sandblast rubber sheets up to 1 mm thick, High-intensity reflective film. Polystyrene foam sheets
RS-232C, Centronics, USB 2.0 (full speed); auto-switching
2 MB
GP-GL and HP-GL TM emulation
20 characters x 2 lines
100-120 VAC, 50/60 Hz, 1.2 A max
220-240 VAC, 50/60 Hz, 0.7 A max
10 to 35˚C, 35 to 75% RH (non-condensing)
16 to +32˚C, 35% to 70% RH (non-condensing)
Operating environment
Guaranteed precision operating environment
External dimensions
(H x W x D) Horizontal 857 x 920 x 1285 mm 944 x 1568 x 1285 mm 944 x 2068 x 1285 mm
Tilted ---*2 1687 x 1568 x 987 mm 1687 x 2068 x 987 mm
Weight (including stand)
Option
Approx. 58 kg Approx. 69 kg
Vacuum pump (Blower) [VC models only]
Approx. 74 kg
*1: Disposable ink pens cannot be used with the high-force pen (Pen 2 holder).
*2: The writing panel on VC models cannot be tilted.
FC2240-UM-251-9370 1-2
1. INTRODUCTION
1.4 External Dimensions
FC2240-60VC
920
720
910
58 1040
Unit: mm
Dimensional accuracy: ± 5 mm
FC2240-UM-251-9370 1-3
FC2240-120
1. INTRODUCTION
Unit: mm
Dimensional accuracy: ±5mm
1285
1687
67
944
877
526
FC2240-UM-251-9370 1-4
FC2240-180
1. INTRODUCTION
Unit: mm
Dimensional accuracy: ±5mm
1285
1687
67
944
877
526
FC2240-UM-251-9370 1-5
1. INTRODUCTION
1.5 Stand Assembly Procedure
Assembly Procedure
Attach the two center plates (3) to the stand leg (1), using the M6 x 15 bolts and the L wrench provided as standard accessories.
Attach the center plates (3) to stand leg (2) in the same way.
Standard accessories
1. M6 x 15 hexagonal bolts: 8
2. L wrench
M6 x 15 hexagonal bolts
FC2240-UM-251-9370 1-6
1. INTRODUCTION
1.6 Mounting Procedure
Screws provided for assembly
1. M4 x 8 bind-head screws: 8
2. M3 x 8 bind-head screws: 6
Procedure
(1) When mounting the FC2240 unit onto the stand, make sure that it is correctly oriented. The three cables protruding from the FC2240 should be at the control box side.
(2) Position the FC2240 so that the underside of the frame is mounted on top of the stand.
After the FC2240 unit has been mounted on the stand, insert the cables protruding from the underside into the control panel box.
The control panel box is affixed to the side of the stand with four M3 x 8 screws at the top and two at the bottom.
To facilitate the mounting of the control box on the stand, insert the screws into the stand side first, leaving a gap, and then mount the control box.
FC2240 frame
Two L-shaped brackets
FC2240 frame
Two L-shaped brackets
Screw in the M4 x 8 screws into the brackets from the underside.
There are two screws each at four locations, for a total of eight screws.
Control box
Note:
The surface with the M3 tapping screws is the surface on which the control box is mounted.
FC2240-UM-251-9370 1-7
1. INTRODUCTION
1.7 Removing the Y Bar Retaining Brackets
(1) Use the L wrench supplied as a standard accessory to loosen the M3 hexagonal bolts.
Turn the M3 bolts counterclockwise to loosen them
Front
Expanded view F
Turn the M3 bolts counterclockwise to loosen them
Retaining bracket FR
Retaining bracket FL
Turn the M3 bolts counterclockwise to loosen them
Expanded view F
Turn the M3 bolts counterclockwise to loosen them
(2) Loosen the M3 bolts as shown in the illustration above, and then move the FL and FR retaining brackets to the front, in a horizontal direction. Next, pull the brackets out in an upward direction. Use the L wrench supplied as a standard accessory.
Retaining bracket R
Rear
Expanded view R
Expanded view R
Move th to the le
Tighten e plate ft edge.
nuts the two
M3 bolt s.
Remove the M3 hexagonal bolts
Pull the bracket out in an upward direction.
The plate nuts are on the far side of the bolts.
Move the plate nuts as is to the left edge, and then fasten in place with the M3 bolts that were removed.
CAUTION (IMPORTANT)
Move the plate nuts inside the pressed aluminum fitting to the left edge, and then tighten the M3 bolts.
(3) Loosen the two M3 hexagonal bolts as shown in the above diagram, and then pull bracket R out in an upward direction.
FC2240-UM-251-9370 1-8
1. INTRODUCTION
1.8 Selecting the Vacuum Pump
Select the vacuum pump according to the guidelines listed in the table below.
Item
Ratings
Airflow (m
3
/min)
Static pressure (kPa)
Hose connection bore
FC2240-60VC/120VC/180VC
0.5
6.4
50 mm
CAUTION
Make sure that the vacuum pump used with a VC model is affixed with either a label showing compliance with the relevant safety standard or with the CE marking.
The figure below shows the dimensions of the vacuum pump installation base provided.
FC2240-60VC
42.5
190
330
4� 10
FC2240-120VC
FC2240-180VC
174.5
95
496
150.5
83
4� 12
4� 10
FC2240-UM-251-9370 1-9
1. INTRODUCTION
1.9 Installation Location
When connecting the vacuum pump to your cutting plotter, please refer to the following diagram.
CAUTION
The exhaust from the vacuum pump is hot, so do not place anything flammable near the exhaust port.
Failure to observe this precaution could cause a fire.
FC2240-60VC
CA2294-01
Vacuum pump
Hose band
Durable flexible hose
CA2294-03
Hose band
CA2294-02
Connect to the power outlet
FC2240-120VC
FC2240-180VC
CA2294-01
Hose band
Durable flexible hose
Vacuum pump
Hose band
CA2294-02
Connect to the power outlet
CA2294-03
CHECKPOINT
A vacuum pump is not provided.
FC2240-UM-251-9370 1-10
2. Description of Parts
2.1 Plotter Nomenclature
The names of the plotter parts are as follows.
Pen carriage Y ber
2. Description of Parts
Rear view of the main box
CHART HOLD key
(ES models only)
Control panel
Tilt lever
Interface connector
Power inlet
USB interface
Parallel interface
PARALLEL
Power switch
RS-232C interface
RS-232C
Writing panel
Stand
FC2240-UM-251-9370 2-1
2. Description of Parts
2.2 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.
CHART HOLD
(ES [electrostatic adhesion] models only)
.............................................Press the [CHART HOLD] key to enable the electrostatic adhesion function
(the key’s lamp lights). Press it again to cancel the electrostatic adhesion function (the lamp goes off).
Panel Keys
..................... Depending on the menu being displayed, these keys are used to:
• Load a group of cutting conditions retained in the plotter’s memory;
• Shift the cursor when setting a numeric value for a function;
• Select the desired submenu.
................. • 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 [ ] key and the [ENTER] key concurrently to move the pen carriage to the upper right position and facilitate loading of the cutting medium.
......................... Used to repeat the cutting operation defined by the data in the plotter’s receive buffer.
....................... Used to set the eight groups of cutting conditions retained in the plotter’s internal memory or to select one group as the current cutting conditions.
......................... Used to select the desired menu screen for setting a function at the control panel when the plotter is in PAUSE mode.
FC2240-UM-251-9370 2-2
2. Description of Parts
......................... Press the [PAUSE] key to select PAUSE mode (its green lamp lights).
Press it again to cancel PAUSE mode (the lamp goes off).
Depending on the menu being displayed, this key is used to:
• Temporarily suspend a cutting or plotting operation;
• Set functions at the control panel;
• Temporarily store data received from the computer in the plotter’s 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.
......................... Runs a cutting test to check whether the currently selected cutting conditions are compatible with the medium loaded.
......................... Used to move the origin point.
To reset the plotter, concurrently press the [ENTER] and [ORIGIN] keys.
FC2240-UM-251-9370 2-3
2. Description of Parts
2.3 Types of Cutter Blades and Their Features
CAUTION
• Handle cutter blades with care!
Supersteel blades
CB15U (ø1.5)
Blade type
CB15U-K30 (ø1.5)
CB15U-SP (ø1.5)
CB15U-K30-SP (ø1.5)
CB09UA (ø0.9)
Blade features
• Less expensive than other types of blades
• The maximum cutting distance is about 4000 m
(depending on the medium and cutting pressure used).
• The spring ensures that the blade is lifted clear of the cutting medium when the pen is raised.
Note:
The CB15U-K30 and CB15U-K30-SP blades are designed for use with thick media e.g. rubber for sandblasting.
FC2240-UM-251-9370 2-4
2. Description of Parts
2.4 Cutter Pen Nomenclature
CAUTION
• Handle cutter blades with care!
Structure of the PPA31-CB09 Cutter Pen
(for cutter blades of 0.9 mm diameter)
Protective cap Plunger Holder A Spring Cutter blade* Holder B Plunger cap
Blade length adjustment knob (blue)
* The CB09UA supersteel blade is shown in the figure above.
Structure of the PPA31-CB15 Cutter Pen
(for cutter blades of 1.5 mm diameter)
Protective cap Plunger Holder A Cutter blade* Holder B Plunger cap
Blade length adjustment knob (red)
* The CB15U supersteel blade is shown in the figure above.
Structure of the PPA31-CB15B Cutter Pen
(for cutter blades of 1.5 mm diameter)
Protective cap Plunger Holder A Spring Cutter blade* Holder B Plunger cap
Blade length adjustment knob (green)
* The CB15U-SP supersteel blade is shown in the figure above.
FC2240-UM-251-9370 2-5
3. OPERATIONS
3 Basic Operation
3.1 Replacing the Cutter Blade
There are three types of cutter pen. Each type has different diameter blades. The blade diameter is indicated by the color of the blade length adjustment knob as shown in the table below. When replacing the cutter blade, check the table below to ensure that you are using the correct combination of cutter pen and cutter blade.
CAUTION
Handle cutter blades with care!
Color of the
Cutter pen part no.
adjustment knob
Blue PPA31-CB09
Red
Green
PPA31-CB15
PPA31-CB15B
Diameter
0.9 mm
1.5 mm
1.5 mm
Copmpatible blade types
Part no.
CB09UA
CB15U
CB15U-K30
CB15U-SP
CB15U-K30-SP
Material
Supersteel
Supersteel
Supersteel
Supersteel
Supersteel
Replacing the Blade
The procedure for blade replacement varies with the type of cutter pen used.
Color of the blade length adjustment knob: Blue
(PPA31-CB09 cutter pen for 0.9 mm blades)
1. Remove holder (B) by turning the blade length adjustment knob in the
Holder (B) counterclockwise direction.
2. Remove the blade and spring from holder (A).
3. Attach the spring to the new blade. Next, with the tip of holder (A) facing downward and at an angle as shown, insert the new blade with the spring into the plunger.
Plunger
Holder (A)
(Inside plunger body)
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, replace holder (B) 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.
CAUTION
Be careful not to stab your finger at this time.
FC2240-UM-251-9730 3-1
3. OPERATIONS
Color of the blade length adjustment knob: Red
(PPA31-CB15 cutter pen for 1.5 mm blades)
Holder (B)
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.
Plunger
Holder (A)
(Inside plunger body)
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.
CAUTION
Be careful not to stab your finger at this time.
Color of the blade length adjustment knob: Green
(PPA31-CB15B cutter pen for 1.5 mm diameter blades fitted with a spring)
Holder (B)
1. Remove holder (B) by turning the blade adjustment knob in the counterclockwise direction.
2. Remove the blade and the spring from holder (A).
3. With the plunger held at an angle, and with the plunger cap pointing upward, insert the blade with its spring attached into the plunger. Take care that the spring does not fall off the blade.
Plunger
Holder (A)
(Inside plunger body)
4. Make sure that the blade is inserted straight into the plunger. If the blade is inserted at an angle, gently tap the plunger to correct the orientation of the blade.
5. With the plunger still in the upright position, insert the holder cap until you hear it click into place. Turn the blade adjustment knob in the clockwise direction to adjust the length of the blade.
CAUTION
Be careful not to stab your finger at this time.
FC2240-UM-251-9730 3-2
3. OPERATIONS
3.2 Adjusting the Blade Length
CAUTION
Be sure to correctly adjust the blade length. If the blade length is too long for the thickness of the medium being used, you may damage the writing panel and the blade.
Adjusting the Blade Length
(1) The blade length is adjusted by turning the blade adjustment knob (blue, red or green).
• To extend the blade, turn the knob in the A direction.
• To retract the blade, turn the knob in the B direction.
Use 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.
B A
(2) Align the blade tip with the tip of the cutter pen, and then extend the blade tip to suit the thickness of the medium being used.
Obtaining the Correct Blade Length
(1) Assuming that the film thickness is “t”, the blade length should be equal to “ l ”. Make sure that “ l ” is never greater than the combined thickness of the film and its backing sheet.
Film
R t
Backing sheet
If the film thickness cannot be accurately determined, adjust the blade length by gradually increasing it until only traces of the blade appear on the backing sheet when a cutting test is executed.
FC2240-UM-251-9730 3-3
3.3 Mounting the Cutter Pen
CAUTION
Push the pen all the way to the pen stopper section.
Take care not to touch the blade tip during the mounting operation.
1. Loosen the pen holder screw and mount the pen.
3. OPERATIONS
2. After mounting the pen, tighten the screw.
• Mount each of the pens in the same way as that used for 1-pen models.
• When facing the pens, the left pen is designated as No. 1 and the right pen is designated as No. 2.
CHECKPOINT
When mounting one cutter pen and one plotter pen, mount the cutter pen as the No. 2 pen.
No. 2 pen
No. 1 pen
(Pen attaching example)
FC2240-UM-251-9730 3-4
3.4 Adjusting the Pen Carriage Height
S Initial adjustment of the pen carriage height
3. OPERATIONS
1. Use the hexagon wrench to loosen the height adjustment bolt.
2. When the pen carriage can be moved freely up and down, insert the height adjustment plate (thick) under the pen carriage. Adjust the height of the pen carriage so that the pen carriage rests on top of the plate.
3. Use the hexagon wrench to tighten the height adjustment bolt. Make sure that the pen carriage is parallel to the writing panel.
4. When the adjustment is complete, remove the height adjustment plate (thick) from under the pen carriage.
S Height adjustment during cutter pen installation
1. Loosen the pen holder section screw and mount the pen.
2. Insert the height adjustment plate (thin) under the pen and adjust the height.
3. After mounting the pen, tighten the screw.
4. When the adjustment is complete, remove the adjustment plate (thin) from under the pen.
CHECKPOINT
Always make sure that the writing panel is in a horizontal position before making this adjustment. When cutting thick media, place the medium on the writing panel before making this adjustment.
FC2240-UM-251-9730 3-5
3. OPERATIONS
3.5 Turning On the Plotter and Initialization
CAUTION Do not put your hands on the writing panel while turning on the plotter.
The moment you turn the power on, the plotter’s Y bar and pen carriage will start to move.
Operations:
(1) Make sure that the “O” (OFF) side of the power switch is pressed down.
(2) Securely plug the connector end of the power cord into the plotter’s power inlet.
(3) Securely plug the other end of the power cord connector into an electrical outlet of the specified voltage.
(4) Press the “I” (ON) side of the power switch.
(5) The green power lamp on the control panel will light, and the Y bar and pen carriage will start to move as shown in the figure below. These operations are part of the initialization process.
The figure below shows what the plotter does when the power is turned on.
The pen carriage returns to the origin point for plotting, and then moves back and forth twice at a 45˚ angle from the origin to determine the friction coefficient of the plotter mechanisms.
Pen carriage Y bar
1
2
3
4
5
7
6
Control panel Writing panel
(6) When the initialization process is complete, the plotter is ready to begin plotting or cutting.
FC2240-UM-251-9730 3-6
3. OPERATIONS
3.6 Loading the Medium
CHECKPOINT
• This plotter is available with a magnetic writing panel, a vacuum suction writing panel, or an electrostatic writing panel. Note that the medium is loaded differently depending on the media holddown method.
• If air gets in between the writing panel and the medium during loading, force out the air and ensure that the medium is securely attached to the writing panel before cutting.
• When loading a medium with no backing sheet, spread a vinyl backing sheet or something similar on the panel before cutting.
• When loading a medium that cannot be securely attached using the basic hold-down method, reinforce adhesion by using tape on all four sides.
• Common spray glue is often used for this purpose. However, since the spray glue remover contains an anti-static agent, do not use it directly on the writing panel of models which feature electrostatic media hold-down.
Magnetic (models feature an ivory writing panel)
(1) Place the medium on the writing panel.
(2) Secure the edges of the medium with the steel holder plates, which are supplied with your plotter as standard accessories.
Vacuum suction (models feature a green writing panel)
(1) Place the medium on the writing panel.
(2) Turn on the vacuum pump’s power supply.
CHECKPOINT
• A vacuum pump is not supplied as a standard accessory. It must be purchased separately.
• Be sure to select a vacuum pump which is affixed with either a label showing compliance with the relevant safety standard or with the CE marking.
• Refer to Section 1.8 for pump selection and connection instructions.
Electrostatic adhesion (models feature a black writing panel)
(1) Make sure the power is turned ON.
(2) Place the medium on the writing panel.
(3) Press the [CHART HOLD] key on the control panel.
(4) The green [CHART HOLD] key lamp lights to indicate that the medium is being held by electrostatic adhesion.
CHECKPOINT
• Press the [CHART HOLD] key again to release the electrostatic adhesion. The green lamp will no longer be lit.
• After the medium has been held for a while by electrostatic adhesion, it may become charged with static electricity and therefore be harder to remove from the writing panel. There is nothing abnormal about this phenomenon.
FC2240-UM-251-9730 3-7
3. OPERATIONS
3.7 PAUSE Menu Configuration
When the plotter is in PAUSE mode, 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 function key indicated by a box.
PAUSE Function selection Submenus Function Description
NEXT
NEXT
NEXT
F1 PEN ADJ.
F2 BUFFER CLR.
F3 PEN U/D
F4 VIEW
F1 I/F
F2 FILM
F3 FUNCTION
F1 STEP SIZE
F2 RS-232C
F4 COMMAND
F1 ORIGIN POINT
F2 AREA
F3 AXIS
F1 ROTATE
F2 THICK F1 THICK No.
F2 THICK MODE
F3 OVERCUT
F4 OVERLAY
F3 MIRROR
F4 SCALE
F4 2PEN
F2 OPTION 1
F3 OPTION 3
F1 UP SPEED
F2 OFST FCE
F3 OFST ANG
F4 STP PASS
F2 KEY OPT.
F3 START FCE
F4 OPTION 2 F2 L UNIT
F3 DIST ADJ
F4 TEST
Setting the Pen Interval Adjustment Value
Clearing the Buffer
Raising/Lowering the Pen
Moving the Pen Carriage to the Upper
Right Position
Setting the Programmable Resolution
(GP-GL mode only)
RS-232C and Centronics Interface
Selecting the Command Mode
Setting the Origin in HP-GL TM Mode
Setting the Cutting Area
Axis Alignment and Distance Adjustment
Rotating the Coordinate Axes
Cutting Thick Sheets
Cutting Thick Sheets
Setting the Overcut Function
Setting the Overlay Function
Cutting a Reversed Image
Scaling the Plotting Image
Assigning the Pen No.
Setting the Pen UP Speed
Setting the Offset Cut Pressure
(Offset Force)
Adjusting the Blade Offset Angle
Setting the Step Pass
Setting the Move Step Length
Setting the Start Cut Force
F2 COND.PAT.
F3 SELF TEST
F4 DUMP
Setting the Displayed Length Unit
Adjusting the Distance Correction
Listing the Cutting Conditions
Running the Self Test
Using the Character Dump Mode
FC2240-UM-251-9730 3-8
3. OPERATIONS
3.8 Setting the Cutting Conditions
This function lets you register eight different groups of cutting conditions in the plotter’s memory. The cutting conditions stored in memory are referred to as setting conditions. Specify each group of setting conditions to match a particular media type.
The setting conditions can also be freely changed as required. Use the [F1] through [F4] keys on the control panel to move through the eight groups of setting conditions that are stored in memory until you locate the one that is suitable for the media type you will be using. Two groups of setting conditions are assigned to each of the four keys, and each of the eight groups is labeled with a CONDITION number to enable easy identification.
Cutting Conditions
Each group of cutting conditions consists of the following four parameters.
• FORCE
• SPEED
• OFFSET
• QUALITY
The description of each cutting condition is as follows.
• FORCE
Sets the pressure to be applied by the cutter blade or pen tip against the loaded medium during cutting or plotting.
• SPEED
Sets the traveling speed of the lowered pen during cutting or plotting.
• OFFSET (in cutting mode only)
Sets the offset of the cutter blade’s tip from the center of the cutter pen. Your plotter comes with a preset offset adjustment value for each blade type. To set the blade offset adjustment, select the type of cutter blade you will be using.
For fine adjustment of the cutter offset, set the blade type to OTHER. If the offset value is set to 0, the plotter goes into plotting mode.
• QUALITY
Sets the acceleration rate of the pen during cutting or plotting.
Tip
The selected conditions greatly affect the finished quality of cutting operations.
Raising the SPEED and QUALITY values results in lower precision but reduces the overall cutting time. This is useful when making test runs.
Lowering the SPEED and QUALITY values results in higher precision but increases the overall cutting time.
FC2240-UM-251-9730 3-9
3. OPERATIONS
Procedure
With the plotter in Ready status, press the [F1] through [F4] key corresponding to the number of the group for which you wish to make settings. The setting condition numbers (CONDITION 1 to 8) are assigned to the
[F1] through [F4] keys.
For example, if the [F1] key is pressed when CONDITION 1 has been selected, the display changes to
CONDITION 5. If a condition number other than 1 was selected, CONDITION 1 will be displayed when the
[F1] key is pressed. In the same way, press [F2] to select CONDITION 2 and 6, [F3] to select CONDITION 3 and 7, and [F4] to select CONDITION 4 and 8.
(1) Press the [CONDITIONS] key. The lower row of the display changes from "READY" to "SET COND”.
(2) A menu similar to the example below is displayed. In this example, the factory default setting COND 2 has been selected. (Items displayed may differ for other COND numbers).
FORCE
Blinking cursor
OFFSET
14 COND2 09U 0
20 SET COND 3
SPEED QUALITY
(3) Move the blinking cursor next to the setting you wish to change.
(4) The cursor will move each time you press one of the keys [F1] to [F4] keys.
(5) Change the displayed setting next to the blinking cursor as follows.
To raise a numeric value, press the [ ] key.
To lower a numeric value, press the [ ] key.
(6) Press the [F3] key to select the blade type. Use the [ ] or [ ] key to move through the selection.
The table below describes the specifiable range for each condition.
Condition
FORCE
Range
Pen 1: 1 to 40 40 steps
Remarks
SPEED
OFFSET
QUALITY
Pen 2: 2 to 80
1 to 40
-5 to +5
1 to 6
40 steps, even numbers only.
40 steps in cm/s units.
Select 0 for automatic adjustment according to the blade type.
The lower the number, the higher the quality.
FC2240-UM-251-9730 3-10
3. OPERATIONS
(7) When all of the displayed settings are correct, press the [ENTER] key to register the group of conditions in the plotter’s internal memory. To change any of the settings, press the [NEXT] key.
Use the [TEST] key to perform test cutting. Adjust the OFFSET value to suit the type and thickness of the medium being used, and fine-adjust the finish of the corner sections.
OFFSET is too low.
Increase the
OFFSET value.
(+1 to +5)
Correct
OFFSET
OFFSET is too high.
Decrease the
OFFSET value.
(-1 to -5)
• If [OTHER] has been specified as the blade type, the OFFSET value can be set in a range of 1 to 45.
• The OFFSET value is not displayed for plotting mode.
CHECKPOINT
• Your settings are retained even while the plotter is turned off.
• Before you actually begin cutting, be sure to check that your cutting conditions are appropriately set as described in Section 3.9 “Running a Cutting Test”.
• The FORCE and SPEED values, in particular, should be initially set to low values and gradually raised while running cutting tests.
Factory Presets
Setting Condition No. Cutting force Speed Blade type Cutter offset Quality
1 12 20 Pen 3
Display mode
Plotter mode
2
3
4
7
8
5
6
14
17
12
50
30
30
30
20
20
20
5
10
10
10
09U
15U
Pen
15U
15U
15U
15U
0
0
-
0
0
0
0
3
3
3
1
3
3
1
Cutter mode
Cutter mode
Plotter mode
Thick sheet mode
Thick sheet mode
Thick sheet mode
Thick sheet mode
CHECKPOINT
In the initial settings, the setting condition numbers 1 to 4 are assigned to Pen 1, and the setting condition numbers 5 to 8 to Pen 2.
FC2240-UM-251-9730 3-11
3. OPERATIONS
3.9 Running a Cutting Test
CAUTION
The cutter pen starts moving as soon as a cutting test is selected.
To avoid injury to yourself and damage to the plotter, load the medium before pressing the [TEST] key and then keep your hands, face, and other obstacles out of the vicinity of the pen carriage.
Setting conditions
The TEST function allows you to check the suitability of your condition settings. If the test results are not satisfactory, adjust the settings as described in Section 3.8, “Setting the Cutting Conditions.”
Procedure
(1) Press the [TEST] key to put the plotter into TEST mode.
(2) The following menu is displayed.
FORCE OFFSET
TEST1 TEST2
CUTTING PRO
SPEED QUALITY
TEST1 : ................................As soon as the [F1] key (TEST1) is pressed, one triangle inside a square is cut from the current pen position.
CUTTING PRO : ...................When the [F2] key (CUTTING PRO) is pressed, the display changes to the
CUTTING PRO prompt menu.
TEST2 : ................................As soon as the [F3] key (TEST2) is pressed, three triangles within squares are consecutively cut from the current pen position. The first triangle is cut with the specified force -1, the second triangle is cut with the specified force, and the third triangle is cut with the specified force +1.
(3) If the [F2] key (CUTTING PRO) is pressed, the following menu is displayed.
FORCE OFFSET
CUTTING PRO OK ?
YES NO
SPEED QUALITY
(4) Press the [F2] key to begin cutting out the CUTTING PRO characters from the current pen position.
Press the [F4] key to return to the previous display.
(5) Press the [ENTER] key or the [NEXT] key to return to the initial menu.
When setting conditions are changed
(1) Press the [CONDITIONS] key and adjust your settings.
(2) Press the [TEST] key to put the plotter into TEST mode. Run a cutting test.
Repeat this process until you achieve the desired results.
(3) Press the [ENTER] key or [NEXT] key to return to the initial menu.
FC2240-UM-251-9730 3-12
3. OPERATIONS
3.10 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”).
• FORCE, SPEED, QUALITY
Set these conditions according to the combination of medium and cutter blade you are using (see
Section 3.8, “Setting the Cutting Conditions”).
• OFFSET
Set this condition according to the type of cutter blade you are using (see Section 3.8, “Setting the
Cutting 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
Thickness
Cutting medium
(mm units) indoor 0.1
Adhesive film outdoor 0.05 to 0.1
Fluorescent film 0.2 to 0.25
Masking film for block
0.01 to 0.1
copy production
Rubber for sandblasting Up to 1
Thick paper Up to 0.5
Blade type
Supersteel
CB09UA
CB15U
CB15U-SP
CB15U-K30
FORCE
14 to 17
10 to 14
16 to 20
5 to 7
CB15U-K30-SP 21 to 34
28 to 38
SPEED
30 or less
30 or less
30 or less
5 to 20
Up to 10
3 to 13
QUALITY
3
3
3
2
1
1
Cutter Offset by Blade Type
Material & Blade Number
Supersteel
Other
CB09UA
CB15U
CB15U-SP
CB15U-K30
CB15U-K30-SP
Blade type
09U
15U
15U
15U-K30
15U-K30
OTHER
Panel display
Default
0
0
0
0
0
18
OFFSET
Setting range
±5
±5
±5
±5
±5
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 OFFSET value and run a cutting test until the desired results are achieved.
The table below lists sample OFFSET settings when the blade type is set to OTHER.
Actual blade type
CB09UA
CB15U
CB15U-SP
CB15U-K30
CB15U-K30-SP
OFFSET value
17
28
28
28
28
FC2240-UM-251-9730 3-13
3. OPERATIONS
3.11 Listing the Cutting Conditions
The CONDITION function lets you print a list of the settings of the eight groups of cutting conditions, so you can check all of your current settings at a glance.
CAUTION
The pen starts moving as soon as the CONDITION function is selected by pressing the [F2] key.
To avoid injury to yourself and damage to the plotter, keep your hands, face, and other obstacles out of the vicinity of the pen carriage and Y bar.
CHECKPOINT
This function requires a plotting pen to be mounted in the pen holder.
Load a sheet of paper that is A4 in size or larger.
Procedure
Replace the cutter pen at the pen carriage’s pen holder with a plotting pen and load paper in the plotter.
(1) Press the [PAUSE] key to select PAUSE mode.
(2) Press the [NEXT] key.
(3) Press the [NEXT] key twice more.
(4) Press the [F4] key to select OPTION2.
(5) Press the [F4] key to select TEST. The submenu below appears, so select the CONDITION function.
FORCE OFFSET
SELF TEST
CONDITION DUMP
SPEED QUALITY
(6) As soon as the [F2] key (CONDITION) is pressed, the message below appears and the plotter begins printing a list of the currently set cutting conditions.
FORCE OFFSET
PRINT CONDITIONS
SPEED QUALITY
(7) When all of the conditions have been printed, the READY message reappears.
FC2240-UM-251-9730 3-14
Sample printout by the CONDITION function
3. OPERATIONS
FC2240-UM-251-9730 3-15
3. OPERATIONS
3.12 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.
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.
CAUTION
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 pen carriage and Y bar.
Procedure
Replace the cutter pen at the pen carriage’s pen holder with a plotting pen and load paper in the plotter.
(1) Press the [PAUSE] key to select PAUSE mode.
(2) Press the [NEXT] key.
(3) Press the [NEXT] key twice more.
(4) Press the [F4] key to select OPTION 2.
(5) Press the [F4] key to select TEST.
(6) Press the [F4] key to select DUMP. The prompt message below appears.
FORCE OFFSET
DUMP
ON OFF
SPEED
Blinking cursor
QUALITY
(7) To select DUMP mode, press the [F2] key to shift the blinking cursor next to ON.
If you decide not to select DUMP mode, press the [F4] key to shift the blinking cursor to OFF.
(8) 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.
(9) Transmit the data from the computer. A Dump list is printed.
(10) When all of the data has been printed, turn off the plotter to cancel DUMP mode.
CHECKPOINT
• The character data is printed as ASCII codes and the non-character (control) data is plotted as twodigit hexadecimal values (e.g., Line Feed = 0A, Carriage Return = 0D, ETX = 03).
• When the plotter receives READ commands that instruct it to output data, it will output dummy data
(except in the case of READ commands that request the output of the plotter’s status data). Note that printing in dump mode will be based on that dummy data.
FC2240-UM-251-9730 3-16
3. OPERATIONS
3.13 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.
CAUTION
The pen starts moving as soon as the SELF TEST mode is selected by pressing the [F2] 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 pen carriage and Y bar.
Procedure
Replace the cutter pen at the pen carriage’s pen holder with a plotting pen and load paper in the plotter.
(1) Press the [PAUSE] key to select PAUSE mode.
(2) Press the [NEXT] key.
(3) Press the [NEXT] key twice more.
(4) Press the [F4] key to select OPTION2.
(5) Press the [F4] key to select TEST.
(6) Press the [F3] key to select SELF TEST. The prompt message below appears.
FORCE OFFSET
SELF TEST ?
YES NO
SPEED QUALITY
(7) To select the SELF TEST mode, press the [F2] key (YES) to initiate printing of the self test pattern.
To return to the OPTION2 selection menu, press the [F4] key.
(8) When you have finished printing the self test pattern, turn off the plotter to cancel SELF TEST mode.
CHECKPOINT
The self test pattern is repeatedly printed until the plotter is turned off. To discontinue printing, even if a pattern is not completely printed, simply turn off the plotter.
FC2240-UM-251-9730 3-17
4. DAILY MAINTENANCE AND STORAGE
4. Daily Maintenance and Storage
During daily maintenance, pay particular attention to the following points.
1. Do not lubricate the plotter mechanisms.
2. To clean the plotter’s casing, either wipe the soiled areas with a dry cloth or with a cloth that has been dampened with a neutral detergent diluted with water.
CAUTION
Do not use paint thinner, benzine, alcohol, or similar solvents as they may damage the casing’s finish.
3. If the writing panel surface is soiled, wipe it with a dry cloth. If the surface is extremely dirty, dampen the cloth with a diluted solution of neutral detergent or alcohol.
CAUTION
Do not use paint thinner, benzine, or similar solvents on the writing panel. They will damage the surface.
When the plotter is not in use, follow the instructions listed below.
1. Remove the pen from the pen carriage and store it with the pen cap on.
2. Cover the plotter with the soft cover supplied or a cloth to keep dust off.
3. Store the plotter in a location which is not subject to either direct sunlight or high humidity.
FC2240-UM-251-9730 4-1
FC2240-UM-251-9730 4-2
4. DAILY MAINTENANCE AND STORAGE
5. RECOMMENDED PARTS LIST
5. RECOMMENDED PARTS LIST
No.
5
6
7
3
4
1
2
8
9
10
11
12
13
Part No.
792240700
792232705
792232701
682247030
772290110
772247550
510000051
162291230
162291240
162291100
022904331
022904500
022904510
022904520
022904500
792240701
Description
Main Board
2-Pen T Board
2-Pen T Block Assy
Control Panel Switch FC2240
X-Motor
Y-Motor
Power Supply PS0089B
X-Flexible Cable FCA2291023
X-Flexible Cable EX FCA2291123
Y-Flexible Cable FCA2291010
Y-Flexible Cable Reinforcement
X-Belt S2ML2350
X-Belt S2ML3200
X-Belt S2ML4200
Y-Belt S2ML2350
Main Relay Board
Q'ty
1
1
2
2
1
2
1
1
1
1
1
1
1
1
1
1
Remarks
Same as FC2230
FC2240-60/120
FC2240-180
FC2240-60
FC2240-120
FC2240-180
FC2240-UM-251-9730 5-1
6. LIST OF TOOLS
6. LIST OF TOOLS
6.1 Tools
No. Tool
1 Colex gauge (force gauge) 500 gf
2 Colex gauge (force gauge) 300 gf
3 Colex gauge (force gauge) 50 gf
4 Cutter pen
5 Push-pull gauge 5 kg
6 Push-pull gauge 2 kg
7 Push-pull gauge 1 kg
8 Glass scale (1000 mm)
9 Ceramic pen (ø0.2 mm)
10 PC, Centronics I/F cable
11 Phillips screwdriver M5
12 Phillips screwdriver M4
13 Phillips screwdriver M3
14 Phillips screwdriver M2
15 Small flat-head screwdriver
16 Hexagon wrench 1.5 mm span
17 Hexagon wrench 2.0 mm span
18 Hexagon wrench 2.5 mm span
19 Box wrench 5.5 mm span
20 Bond-type adhesive
21 Double-sided tape (10 mm wide)
22 Ethyl alcohol
23 Metallic ruler (about 15 cm long)
24 Multimeter
25 Digital voltmeter
26 Oscilloscope
27 Test pin connector jig
Adjustment Item
Pen force adjustment
Pen force and belt tension adjustment
Pen force adjustment
Pen force adjustment
Belt tension adjustment
Belt tension adjustment
Belt tension adjustment
Distance adjustment
Distance adjustment
Firmware update
For adjusting the variable resistors on the board
For M3 set-screws
For M4 set-screws
For the pen block set-screws
For removing M3 nuts
For securing screws
For securing the FPC cables
For cleaning the electrostatic adhesion plate and rail
For adjusting the belt tension
For checking damaged or shorted wires
For main board adjustment
For main board adjustment
For main board adjustment
FC2240-UM-251-9730 6-1
7. DISASSEMBLY AND ADJUSTMENT
7. DISASSEMBLY AND ADJUSTMENT
7.1 Adjusting the X-Axis Drive
7.1.1 Removing the X Motor Cover
Remove the two M3 binding head screws indicated by the (A) arrows, then remove the motor cover.
7.1.2 Adjusting the X Drive Belt Tension
(1) Remove the rear left corner cover.
(2) After loosening the two M3 binding head screws indicated by the (B) arrows, attach a string around the X motor and pull the X motor with a 5 kgf push-pull gauge to the point where FX
1
equals 2.0 kgf - 0.2, then tighten the screws.
(3) After loosening the two M4 binding head screws indicated by the (C) arrows, push the X motor bracket with a 10 kgf push-pull gauge to the point where FX
2
equals 5.0 kgf - 0.5, then tighten the two screws.
FC2240-UM-251-9370 7-1
7. DISASSEMBLY AND ADJUSTMENT
7.1.3 Adjusting the Belt Tension of the Front X Slider
(1) Remove the front and rear right corner covers.
(2) Adjust the two M3 binding head screws indicated by the (D) arrows so that the belt is balanced right and left.
* Turn the screws to the right to tighten the belt.
* Turn the screws to the left to loosen the belt.
(3) Check the belt tension. (See subsection 7.1.5, “Checking the Belt Tension of the Front and Rear X
Sliders”.)
(4) Perform the radiating lines test to check that the belt at the pulley section is balanced right and left.
If not, repeat steps (2) to (4) above so that the belt is balanced.
7.1.4 Adjusting the Belt Tension of the Rear X Slider
(1) Remove the rear right corner cover.
(2) Adjust the two M3 binding head screws indicated by the (E) arrows so that the belt is balanced right and left.
* Turn the screws to the right to tighten the belt.
* Turn the screws to the left to loosen the belt.
(3) Check the belt tension. (See subsection 7.1.5, “Checking the Belt Tension of the Front and Rear X
Sliders”.)
(4) Perform the radiating lines test to check that the belt at the pulley section is balanced right and left.
If not, repeat steps (2) to (4) above so that the belt is balanced.
FC2240-UM-251-9370 7-2
7. DISASSEMBLY AND ADJUSTMENT
7.1.5 Checking the Belt Tension of the Front and Rear X Sliders
Checking the Belt Tension
(1) Move the Y bar against the mechanical stopper on the left side.
(2) Loosen the screws that holding the tilt lever bracket and then move the tilt lever bracket to avoid touching the belt.
(3) Pull the X-belt 20 mm from the X-rail in the center of the X-belt using a 1 kg push-pull gauge.
The pull force should be:
FC2240-60
920g to 940g
FC2240-120
480g to 500g
FC2240-180
350g to 370g
Front and rear X rails
20 mm
Scale X belt
NOTES:1. If the belt tension has been adjusted, confirm that the Y bar is perpendicular.
2. If the belt has been completely removed from the holder, secure it with adhesive to prevent looseness.
FC2240-UM-251-9370 7-3
7. DISASSEMBLY AND ADJUSTMENT
7.2 Adjusting the Y-Axis Drive
7.2.1 Removing the Y Motor Cover
Remove the three M3 binding head screws indicated by the (A) arrows, then remove the Y motor cover in the direction indicated by the arrow.
7.2.2 Removing the Y Motor
(1) Remove the three M3 binding head screws holding the X FPC (Flexible Printed Circuit) cable holder, then remove the X FPC cable holder.
(2) Disconnect X FPC and Y FPC cables from their connectors (J51, J52) on the PN5042-02 X-Y relay board.
(3) Disconnect the Y motor and Y encoder cable cables from their connectors (P501, P502) on the
PN5042-02 X-Y relay board.
FC2240-UM-251-9370 7-4
7. DISASSEMBLY AND ADJUSTMENT
(4) As shown in the figure, remove the two M4 binding head screws indicated by the (C) arrows, then slip the synchro belt indicated by the arrow off of the motor pinion gear and remove the entire motor bracket.
Synchro belt
PN5042-02
(5) As shown in the figure , remove the two M3 binding head screws (A) holding the Y-motor, then remove the motor from the motor bracket.
(A)
FC2240-UM-251-9370 7-5
7. DISASSEMBLY AND ADJUSTMENT
7.2.3 Adjusting the Y Drive Belt Tension
(1) After loosening the two M3 binding head screws indicated by the (A) arrows in the figure below, attach a string around the Y motor and pull the Y motor with a 5 kgf pushpull gauge to the point where FY
1
equals
2.0 kgf - 0.2, then tighten the two M3 binding head screws.
(A)
FY
1
= 2.0 kgf - 0.2
(5 kgf push-pull gauge)
(2) After loosening the two M4 binding head screws indicated by the (B) arrows in the figure below, attach a string around the Y motor and pull the Y motor assembly with a 10 kgf push-pull gauge to the point where FY
2
equals 5.0 kgf - 0.5, then tighten the two M4 binding head screws.
Synchro belt
PN5042-02
FC2240-UM-251-9370 7-6
7. DISASSEMBLY AND ADJUSTMENT
7.3 Adjusting the Y Slider
7.3.1 Removing the Y Bar
(1) Remove the motor cover, then pull out the X FPC cable connector from the X relay board. (The pen block should be removed first.)
(2) Remove the 5 mm bind screw and the countersunk head screw indicated by the (A) arrows.
A
(3) After removing the two M4 binding head screws indicated by the (B) arrows at the front surface, use both hands to lift the Y bar up and off.
FC2240-UM-251-9370 7-7
7. DISASSEMBLY AND ADJUSTMENT
7.3.2 Adjusting the Y Slider Belt Tension
(1) Remove the two M4 binding head screws indicated by the (C) arrows, then remove the front Y bar cover.
(2) Adjust the two M3 binding head screws (D) so that the belt is balanced right and left.
Turn the screws to the right to tighten the belt.
Turn the screws to the left to loosen the belt.
(3) Check the Y slider belt tension.
Slide the pen block to the motor side.
Y rail
20 mm
Scale Y belt
(4) Push down the Y-belt 20 mm from the Y-rail in the center of the Y-belt using a 1 kg push-pull gauge.
The push down force should be from 600 g to 630 g.
FC2240-UM-251-9370 7-8
7. DISASSEMBLY AND ADJUSTMENT
7.4 Adjusting the Roller Pressure of the Front X Slider
(1) Insert the front X slider assembly from the right side of the front X rail (the tension adjustment holder side).
(2) Loosen the two bind screws indicated by (C) by turning them each fully twice, tighten the three M3x6 setscrews in the three taps indicated by (B), then lock the setscrews using M3 nuts at the position where the rollers contact the front X rail.
(3) Using the three screws indicated by (A), apply pressure to the rollers by adjusting the rollers so that they are parallel to the sliding surface.
(4) Tighten the two bind screws indicated by (C), and then secure them with adhesive after confirming that the rollers remain in contact with the sliding surface throughout their entire stroke, the sound made by the rollers turning is constantly the same, and the rollers slide smoothly.
NOTES: 1. Visually confirm that each roller is in contact with the sliding surface.
2. After adjusting the roller pressure, the sliding load shall be 35 gf±5.
FC2240-UM-251-9370 7-9
7. DISASSEMBLY AND ADJUSTMENT
7.5 Adjusting the Roller Pressure of the Rear X Slider
(1) Using gauze or a soft cloth moistened with ethyl alcohol, clean the sliding surface of the rear X rail. At this time, confirm the absence of scratches or dents in the sliding surface.
(2) Loosen the screw of the pressure (adjustable) roller of the rear X slider. When inserting the rear X rail from the belt tension adjustment holder side, take care that the plastic roller is not scratched by the edge of the rear X rail.
(3) Adjusting the horizontal roller pressure
• After adjusting the screws indicated by (A) and (B), be sure to lock them in place with adhesive.
• After tightening screw (A), loosen it by a quarter turn. Use a blade screwdriver to press the screw head
(C) in the direction indicated by the arrow, then tighten screws (A) and (B) at the position where the pressure roller contacts the sliding surface of the rear X rail. (Repeat this same procedure for the right roller.)
Confirm that the rollers remain in contact with the sliding surface throughout their entire stroke, the sound made by the rollers turning is constantly the same, and the rollers slide smoothly.
FC2240-UM-251-9370 7-10
7. DISASSEMBLY AND ADJUSTMENT
(4) Adjusting the vertical roller pressure
• Use the vertical roller pressure nuts (also shown in the preceding figure) to move the rollers into contact with the sliding surface of the rear X rail, then secure the nuts with adhesive.
NOTES: 1. Confirm the horizontal roller pressure by visually checking that both the fixed and adjustable rollers are in contact with the sliding surface.
2. After adjusting the roller pressure, the sliding load shall be 35 gf ± 5.
FC2240-UM-251-9370 7-11
7. DISASSEMBLY AND ADJUSTMENT
7.6 Adjusting the Roller Pressure of the Y Slider
(1) Mounting the Y slider onto the Y bar
• Loosen the two screws (A), lower the roller plate and temporarily secure it in that position.
• Loosen the setscrews (B) at the two eccentric pins A, then temporarily secure the roller (1) in a lowered position.
• Loosen the set-screws (C) at the two eccentric pins C, then move roller (2) outside of the Y slider and temporarily secure it in that position.
(2) Adjusting the Y slider’s roller pressure
• With the Y slider oriented as shown in the figure above, insert it onto the Y bar, then move each roller back into contact with the sliding surface by performing the steps in (1) above in reverse sequence.
• Visually confirm that each roller rotates while maintaining contact with the sliding surface. Check that there is no play in the front, back, or side directions.
• Make sure there are no discrepancies in the “grating” load of the rollers.
• The sliding load shall be 30 gf ± 5.
• After the adjustment is completed, apply adhesive to the four set-screws.
FC2240-UM-251-9370 7-12
7. DISASSEMBLY AND ADJUSTMENT
7.7 Adjusting the Position of Sensor Dog Y
Align the sensor dog Y (A) with the center of the Y sensor’s slit, then apply adhesive to secure the sensor dog Y in that position.
FC2240-UM-251-9370 7-13
7. DISASSEMBLY AND ADJUSTMENT
7.8 Mounting the Y Slider on the Y Flexible Printed Circuit
Cable
(1) Remove the screw (A) from the board bracket and pull it out as shown in the figure above.
(2) Pass the Y flexible printed circuit (FPC) cable through the FPC guide (B) shown in the figure below, then insert the FPC cable into the connector.
(3) Secure the board bracket to the Y slider using the screw which was removed in Step (1) above.
(4) Attach double-sided tape to the FPC guard (E), and then securely attach the FPC guide (B) to the other side of the tape.
(5) Pass the Y FPC cable between FPC holder (C) and FPC guide (B), and then secure the cable with a push-fit M3x6 screw (D).
(6) Apply adhesive to screw (D).
FC2240-UM-251-9370 7-14
7. DISASSEMBLY AND ADJUSTMENT
7.9 Pen Block
7.9.1 Removing the Pen Block Cover
(1) Remove the two M3 binding head screws, then lift the cover up in the direction indicated by the arrow.
7.9.2 Removing the Pen Block
(1) Pull out the CA2293-39 cable from its connector on the PR223229 2-pen relay board in the direction indicated by the arrow.
(2) When the two screws (A) are removed, the pen block can be removed.
FC2240-UM-251-9370 7-15
7. DISASSEMBLY AND ADJUSTMENT
7.9.3 Adjusting the Pen Block
(1) When a force of 60 gf is applied by a push-pull gauge, the slide arm should lower smoothly to its lowest position.
If it does not lower smoothly, the pre-pressure of the 692ZZ bearing against the guide shaft may be too high. Also check for foreign matter on the parts concerned.
When the slide arm is pressed down by hand, it should lower smoothly.
(2) If the slide arm does not lower smoothly, pull out the J21 (FPC210100) and J22 (FPC10002) FPC cables from their connectors on the PR223227 2-pen relay board in the direction indicated by the arrow.
Remove the two screws (B) to remove the relay board.
FC2240-UM-251-9370 7-16
7. DISASSEMBLY AND ADJUSTMENT
(3) Perform the adjustment below.
• Loosen the M2 setscrews.
• Turn the offset pins to adjust the 692ZZ bearings to the position where there is no gap.
• Secure with the M2 set-screws.
M2 set screw
Guide shaft
Offset pin
692ZZ bearing
(4) Checking the guide shaft and bearing adjustment.
• Raise or lower the guide shaft of the slide arm and confirm that the 692ZZ bearing rotates smoothly.
• If there is still play, there may be play between the guide shaft and 692ZZ bearing of the slide arm.
Replace the pen block assembly.
FC2240-UM-251-9370 7-17
7. DISASSEMBLY AND ADJUSTMENT
7.10 Using the Mechanical Adjustment Jigs
(1) Pen block height adjustment jig (standard accessory)
FC2240-UM-251-9370 7-18
7. DISASSEMBLY AND ADJUSTMENT
7.11 Replacing the Y Bar
7.11.1 Preparations
(1) Before replacing the Y bar, place a sheet of paper on the writing panel and secure it with cellophane tape.
(2) Move the Y bar to the center of the paper and lower the pen to manually draw a line down the length of the bar.
* This line will serve as a guideline for determining perpendicularity after the Y bar is remounted.
7.11.2 Replacing the Y Bar
Make sure that the plotter is turned off.
(1) Remove the pen block which is attached to the Y bar.
(2) Remove the Y bar.
(3) Attach a new Y bar.
• Temporarily attach the Y bar along the line drawn in Step (2) of subsection 7.11.1, “Preparations.”
• Adjust the Y bar height from the front frame and rear frame to 31.5 mm.
• Adjust the Y bar frame clearance from the control panel frame to 2 mm.
(4) Mount the pen block, which was removed in Step (1) above, onto the new Y bar.
• After using the pen block adjustment jig to adjust the height of the pen block, secure the pen block in place.
NOTE: When the Y bar is moved manually from side to side while the plotter is turned off, be sure to detach the three connectors which connect the control box to the plotter’s main unit. Failure to remove these connectors may cause the gears to slip or not mesh properly.
FC2240-UM-251-9370 7-19
7. DISASSEMBLY AND ADJUSTMENT
7.11.3 Checking the Sliding of the Y Bar Frame (Manual Check)
(1) Adjust the clearance 2 mm at the front of the Y bar frame to confirm that the frame clearance is approximately identical at the front and rear of the writing panel. While moving the Y bar in the X-axis direction, make sure that no abnormal sound is generated as a result of the Y bar making contact with the Y bar frame.
(2) Other adjustments of the Y bar frame
• Loosen the screw located on the bottom plate of the control panel, then pull the control panel assembly toward you to increase the clearance.
• When the front and back clearances of the Y bar frame are identical, readjust the height of the Y bar.
• After adjustment, gently slide the Y bar within its movable range to confirm that no abnormal sound is generated.
NOTE: Before moving the Y bar by hand, be sure to detach the three connectors which connect the control box to the plotter’s main unit.
• Next, re-connect the three connectors, turn on the plotter, and use the POSITION keys to check the operation of the Y bar within the effective plotting area.
FC2240-UM-251-9370 7-20
7. DISASSEMBLY AND ADJUSTMENT
7.12 Adjusting the Perpendicularity Precision
7.12.1 Checking the Deviation in the Perpendicularity
(1) Load a thin sheet of paper on the writing panel and attach a plotter pen (0.2 mm ceramic pen) to the
No.1 pen holder.
(2) Manually move the pen to plot the pattern shown in the figure below.
(3) Turn the sheet over and load it so that points (A) and (B) on the other side are parallel to the X axis.
(4) After positioning the pen on point (D), draw a line to point (C). Check if there is any deviation between the lines between points (D) and (C) on the front and back of the sheet.
(5) If the deviation exceeds 0.25 mm, loosen the screws at the top and bottom of the Y bar and adjust the vertical orientation of the Y bar by moving it toward the pertinent side.
FC2240-UM-251-9370 7-21
7. DISASSEMBLY AND ADJUSTMENT
(6) Repeat Steps (1) to (4) above to confirm the precision of the perpendicularity.
(7) If the perpendicularity cannot be satisfactorily adjusted by performing the preceding Steps (1) to (6), repeat adjustment after loosening the two 3 mm setscrews indicated by the (E) arrows.
(8) You will be able to adjust the perpendicularity precision by performing the electrical adjustnet for fine adjustment. (See section 8.12 Adjusting the Distance and the Perpendicularity Accuracy.)
FC2240-UM-251-9370 7-22
7. DISASSEMBLY AND ADJUSTMENT
7.13 Replacing the Electrostatic Adhesion Plate
(This operation requires three persons.)
7.13.1 Peeling Off the Electrostatic Adhesion Plate
(1) Turn off the power and remove the high-voltage power supply cable connectors (P34 and J34) at the rear of the writing panel.
(2) Remove the Y bar. (See section 7.3, “Adjusting the Y slider”.)
(3) Cut into the electrostatic adhesion plate at intervals (50-100 mm) that will make it easy to peel off the electrostatic adhesion plate. If this scratches the aluminum plate underneath, polish away the unevenness with #1500 sandpaper.
(4) Peel off the electrostatic adhesion plate, using force if necessary. Using pliers or the like makes it easy.
(5) Remove any remaining double-sided tape and glue. Sprinkle on ECT-1 toner cleaning fluid (available from Graphtec) and leave for 1 or 2 minutes. Scrape off with some sort of scraper (e.g. spatula).
(6) When everything has been removed from the aluminum plate, wipe it off with ethyl alcohol.
7.13.2 Preliminary Preparations for Pasting On New Plate
(1) Wipe off the front and rear surfaces of the electrostatic adhesion plate with ethyl alcohol to remove any dirt and dust.
(2) Prepare pieces of double-sided tape of various widths* and paste them on to the rear surface of the electrostatic adhesion plate following the procedure below.
• Using narrow double-sided tape, make a border around three sides of the electrostatic adhesion plate
(leaving one of the longer sides untaped).
(Leave 1 mm open between the tape and the edge of the electrostatic adhesion plate.)
NOTE: Never let the tape overlap!
FC2240-UM-251-9370 7-23
7. DISASSEMBLY AND ADJUSTMENT
* “Pieces of double-sided tape of various widths” means tape of 120, 20, 10, 5 mm width at the production stage. If it is difficult to prepare pieces of tape of these widths, use double-sided tape as close to these widths as possible.
• Tape on lengthwise strips of wide double-sided tape at intervals of 5 mm.
NOTE: Never let the tape overlap!
Tape on the double-sided tape in such a way that the gap is as negligible as possible at the highvoltage power supply cable installation section.
• Finally, use a combination of wide and narrow double-sided tape so that there is no untaped interval greater than 5 mm.
NOTE: Never let the tape overlap!
FC2240-UM-251-9370 7-24
7. DISASSEMBLY AND ADJUSTMENT
7.13.3 Attaching the Electrostatic Adhesion Plate
(1) Temporarily fasten the side cover, line up the holes for the high-voltage power supply cable on the writing panel and the electrostatic adhesion plate and position according to the following conditions.
• Use the origin side (front X rail side and left side cover side) as the reference.
• Position about 2 mm from the origin side as in the figure below.
• Since there are slight differences in the size of electrostatic adhesion plates, the dimensions are not specified with great precision.
• “A” in the diagram above is not 2 mm.
• Be careful not to let any dirt or dust get under the electrostatic adhesion plate during positioning.
(2) Secure the origin side with strong tape.
(3) Peel off and fold back the backing sheet of the double-sided tape at the high-voltage power supply cable side for about 100 mm and paste on without letting in any dirt, dust, or air.
(4) Peel off the strong tape used for securing in Step (1) above, and while one person holds the origin side and checks for and points out any unevenness, the other two persons peel off the double-sided tape backing sheet and paste on by sliding their hands along.
• If dust or dirt gets in, remove it with tweezers or your fingernail tips.
• If air gets in, drive out the air at 5 mm intervals by kneading softly.
(5) When the entire surface has been spread out, attach it by sliding your hand across it again and pressing it.
FC2240-UM-251-9370 7-25
FC2240-UM-251-9370 7-26
7. DISASSEMBLY AND ADJUSTMENT
8. ELECTRICAL ADJUSTMENTS
8. ELECTRICAL ADJUSTMENTS
8.1 Flowchart of the Adjustment Sequence
Flowchart of the Adjustment Sequence for the FC2240 series.
8.3 Setting the Power Unit’s Supply Voltage
8.4 Checking the Power Unit’s Supply Voltage
8.6 Setting the DIP Switches
8.8 Clearing the Non-Volatile RAM
8.9 Adjusting the Home Position
8.10 Adjusting the Pen Height
8.11 Adjusting the Pen Force
8.12 Adjusting the Distance Accuracy and the perpendicularity
8.13 Adjusting the Pen Interval
8.14 DIP Switch Factory Settings
8.15 Factory Preset Settings
End of Adjustment
FC2240-UM-251-9370 8-1
8.2 Location of the Boards
8.2.1 Main Board (PR306101)
8. ELECTRICAL ADJUSTMENTS
FC2240-UM-251-9370 8-2
8.2.1 Main Relay Board (PN5042-01)
JP6
8. ELECTRICAL ADJUSTMENTS
Jumper switch setting of JP6.
8.2.2 X Flex. Board (PR223226)
JP1
Jumper switch setting of JP1.
FC2240-UM-251-9370 8-3
8. ELECTRICAL ADJUSTMENTS
8.3 Setting the Power Unit’s Supply Voltage (PS089B)
(1) Check that the plotter’s POWER switch is off.
(2) Remove the upper chassis of the Control Unit.
(3) Connect the power unit’s cable to the required connector.
Voltage series
100 V
200 V
Corresponding area
JAP 110T/K WGl117UL
CEE SEV BS AS
Connector
CN2
CN3
FC2240-UM-251-9370 8-4
8. ELECTRICAL ADJUSTMENTS
8.4 Checking the Power Unit’s Supply Voltage
8.4.1 Checking the Voltage Levels
(1) Use a multimeter to check the voltage levels of TP1 to TP5.
TP1
TP2
TP3
TP4
TP5
Voltage
+5V
+12V
+32V
-12V
+24V
(2) If voltage levels cannot be measured at TPI to TP5, use the following method to check the voltage levels.
• Disconnect the main board’s J101 connector.
• Next, use the multimeter to measure the voltage levels of the J101 connector pins.
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Pin 10
Voltage
+5V
+12V
+32V
GND
GND
+5V
+12V
+32V
GND
GND
1
2
2
2
2
6
7
8
9
10
(3) If the measured voltage levels do not conform to the above tables, the power unit is probably defective.
8.4.2 The Protective Circuit
The protective circuit is activated in either of the following cases.
32 V power 5 V power
Protection against
8 A or more 6 A or more excessive current
Protection against 115% of the rated
---------excessive voltage voltage (32 V)
+12V power
6 A or more
----------
-12V power
3A or more
----------
When the protective circuit is activated, all of the plotter’s supply voltages are switched off.
If the protective circuit is activated, turn off the plotter. After the plotter is left as is for three to five minutes, it will automatically recover.
FC2240-UM-251-9370 8-5
8. ELECTRICAL ADJUSTMENTS
8.5 Explanation of the Values of the Main Board
Default factory settings
The default factory settings are recorded in the location shown below.
Main Board
The default factory settings are recorded here.
Power
Supply
Board
The contents of an example are shown below.
PEN1 88, 424, 732
PEN2 89, 424, 772, 1030, 1533
X=+10 Y=0 D=860.00
Explanation of the values
PEN1
PEN2
X
24g
24g
Distance adjustment values
Y D
Pen force values
210g
210g
400g
400g
-
700g
-
1000g
You can input the same values when you have replaced the main board without making any adjustments except the pen height, home position and pen interval adjustments.
If you have changed any values by making adjustments, record those values for the next maintenance check.
FC2240-UM-251-9370 8-6
8.6 Setting the DIP Switches
Settings for the DIP Switch on the Main Board
DIP Switch Factory Settings (Normal mode)
ON
OFF
1 2 3 4 5 6 7 8
NOVRAM CLEAR Function mode
Set bits 2, 3, 5, 6 and 7 to ON
ON
OFF
1 2 3 4 5 6 7 8
• Initialize the main board by clearing the non-volatile RAM
• Execute this function before starting any electrical adjustment
Electrical Adjustments
Set bits 4, 5, and 6 to OFF
ON
OFF
1 2 3 4 5 6 7 8
• Pen height adjustment
• Pen force adjustment
• Distance adjustment
• Home position adjustment
Keyboard and Sensor Test Mode
Set all bits to OFF
ON
OFF
1 2 3 4 5 6 7 8
8. ELECTRICAL ADJUSTMENTS
FC2240-UM-251-9370 8-7
8. ELECTRICAL ADJUSTMENTS
8.7 Updating the System Firmware
To update the system firmware you need to have the following files. In addition, you need to use a computer and USB cable or Centronics cable.
Firmware :FC2240
SEND.EXE :Utility to transfer files using Windows
OPS662 :USB Driver software for the FC2240 (when using USB to update the firmware)
(1) Check that the power supply and control panel unit are connected to the main board.
Connect a personal computer to the Centronics terminal or the USB terminal.
Caution:
If you are writing to a new board for the first time, remove the motor and flex cable connectors before performing the write function.
(2) Set the DIP switch to “Normal mode” or “Electrical Adjustment mode.”
(3) Hold down both the “Right” and “Left” POSITION keys while turning on the power. When you hear a short buzzer tone, release the keys. The LCD should display the following:
UPDATE FIRMWARE ?
YES NO
(3) Press the [F2] key, and the LCD will display the following:
SELECT I/F USB
CENTRO1 CENTRO2
Select the interface used to connect the plotter with your computer.
If you are going to select the Centronics interface, normally press the [F2] key (CENTRO1).
If CENTRO1 is not working properly, select CENTRO2.
The LCD screen changes to display the following:
PLEASE SEND PROGRAM!
PLOTTER (USB) or
PLEASE SEND PROGRAM!
PLOTTER (GET-ACK)
(4) Transfer firmware data from the personal computer.
Send firmware to the plotter from the computer.
Drag and drop the firmware file onto the SEND.EXE icon when using Windows.
The LCD screen changes to display the following:
PROGRAM RECEIVING
** KB COMPLETE
Number of bytes transferred
FC2240-UM-251-9370 8-8
8. ELECTRICAL ADJUSTMENTS
As the firmware data is successfully transferred, the number of transferred bytes shown on the LCD increases. When the transfer is completed, the display automatically changes to “FLASH MEMORY
CLEAR” and “FLASH MEMORY WRITE,” and the system begins writing to flash memory.
Note:
If you are writing to a new board, the system will automatically perform a NOVRAM clear operation following the write function.
(5) Turn off the plotter when the message below appears.
COMPLETED
POWER OFF THEN ON!
FC2240-UM-251-9370 8-9
8. ELECTRICAL ADJUSTMENTS
8.8 Clearing the Non-Volatile RAM
NOTE: Be sure to clear the non-volatile RAM after replacing the main board or before starting any electrical adjustment.
(1) After setting the SW1 DIP switch as shown below, turn on the plotter.
Set bits 2, 3, 5, 6 and 7 to ON
ON
OFF
1 2 3 4 5 6 7 8
(2) The messages below consecutively appear on the LCD panel.
NOVRAM INIT.
0% CLEAR
NOVRAM INIT.
100% CLEAR
(3) After the “ NOVRAM INIT. 100% CLEAR ” message is displayed, a menu for model selection appears on the LCD panel.
SET FC TYPE
FC2240-60-*2
(4) Select your plotter model using the the and keys, and then press the ENTER key to register your plotter model setting.
FC2240-180-*2
FC2240-120-*2
FC2240-60-*2
(5) The message below appears to select the moving coil type for each pen holder.
SET No.1 MC
MCx1 MAX=40 [500g]
Select MCx1 using the and keys for the No.1 pen, and then press the ENTER key to register your plotter.
(6) The message below appears.
SET No.2 MC
MCx2 MAX=40 [1000g]
Select MCx2 using the and keys for the No.2 pen, and then press the ENTER key to register your plotter.
FC2240-UM-251-9370 8-10
8. ELECTRICAL ADJUSTMENTS
(7) The message below appears. Press the F2 or F4 key to switch through the standards. Select the standard that matches the version displayed when the plotter was shipped, and then press the ENTER key to register your plotter standard setting.
SET SUFFIX
STD [V 1.00]
(8) After the “ COMPLETED ” message is displayed as shown below, turn off the plotter and then return the
DIP switch to its normal settings.
COMPLETED
POWER OFF THEN ON !
NOTE: Clearing the non-volatile RAM initializes the pen height adjustment, distance accuracy adjustment, and other settings to their respective default values.
FC2240-UM-251-9370 8-11
8. ELECTRICAL ADJUSTMENTS
8.9 Adjusting the Home Position
(1) Set the SW1 DIP switch as shown below and then turn on the plotter.
Set bits 4, 5, and 6 to OFF
ON
OFF
1 2 3 4 5 6 7 8
(2) Press the [NEXT] key until the LCD displays the following:
HOME ADJ.
PRESS ENTER KEY!!
(3) Press the [Enter] key. The plotter starts reading the home position. The LCD screen changes to display the following:
MOVE HOME POINT
PRESS ENTER KEY!!
(4) Attach a pen-type magnifier to the No.1 pen holder, and then move it to the desired home position using the POSITION keys. After confirming the position, press the [Enter] key.
(5) The plotter starts reading the home position again and then returns to the new home position specified in step (3). If the position is correct, press the [ENTER] key to finish.
(6) Turn off the plotter and then return the DIP switch to its normal settings, or press [NEXT] key to proceed to the next adjustment.
(This adjustment does not affect the plotter’s pen exchange adjustment.)
FC2240-UM-251-9370 8-12
8. ELECTRICAL ADJUSTMENTS
8.10 Adjusting the Pen Height
Note: • Before starting the pen height adjustment, make sure that there is no pen or cutter attached to the pen holder.
• To avoid malfunction of the pen holder, do not touch the pen holder during adjustment.
• Make sure that the pen holder is not in contact with the pen block cover.
(1) Set the SW1 DIP switch as shown below and then turn on the plotter.
Set Bits 4, 5, and 6 to OFF
ON
OFF
1 2 3 4 5 6 7 8
(2) A menu for electrical adjustment appears on the LCD panel.
(3) Press the [NEXT] key until the LCD displays the following:
PEN HEIGHT
PRESS ENTER KEY!!
(4) Press the [Enter] key. The LCD screen changes to display the following:
<AUTO ADJ
<DEFAULT POWER>
(5) Press the [F1] (AUTO ADJ) key.
After the message below appears, the plotter automatically adjusts the pen height for the No.1 and No.2 pens.
The beeper sounds twice after adjustment for the No.1 pen has been completed, and then the plotter automatically adjusts the pen height for the No.2 pen.
No.1 PEN HEIGHT
C0 A=000 O=300 G=500
No.2 PEN HEIGHT
C0 A=000 O=300 G=500
(6) When adjustment is completed, turn off the plotter and then return the DIP switch to its default settings or press the [NEXT] key to proceed to the next adjustment.
(7) Be sure to perform this adjustment whenever the pen block has been replaced.
FC2240-UM-251-9370 8-13
8. ELECTRICAL ADJUSTMENTS
8.11 Adjusting the Pen Force
Required jigs and tools
• Colex gauges (500 g, 300 g, 50 g)
• Push/Pull gauge (1 kg)
• Cutter plunger
(1) Check that the carriage cover is in place. Fit a cutter plunger from which the blade has been removed into the cutter holder.
(2) Set the SW1 DIP switch as shown below and then turn on the plotter.
Set Bits 4, 5, and 6 to OFF
ON
OFF
1 2 3 4 5 6 7 8
(3) A menu for electrical adjustment appears on the LCD panel.
(4) Press the [NEXT] key until the LCD displays the following:
PEN PRESS ADJUST
PRESS ENTER KEY!!
(5) Press the [Enter] key. The LCD screen changes to display the following:
PEN PRESS SETTING
No.1 -> 24 [g]
(6) Press the [Enter] key. When the LCD screen changes to display the following, measure the pen pressure with a Colex gauge. Use the [F1] through [F4] keys to adjust the pen pressure until the pressure is within
24 ± 1 g. After adjustment, press the [Enter] key to go to the next step. If you have only replaced the main board, input the adjustment values that were recorded.
Target pen pressure
+1 24g -1
+10 ***** -10
Correction value
[F1] key: Increases pen pressure by a small amount.
[F2] key: Increases pen pressure by a large amount.
[F3] key: Reduces pen pressure by a small amount.
[F4] key: Reduces pen pressure by a large amount.
(7) Next, when the LCD display changes to the 210 g setup screen, adjust the pen pressure to within 210 ±
10 g in the same way as described above.
(8) Next, on the 400 g setup screen, adjust the pen pressure to within 400 ± 20 g.
(9) The adjustment menus for the No.2 pen will be displayed after you have finished the adjustments for the
No.1 pen.
Adjust the pen pressure for the No.2 pen in the same way as you did for the No.1 pen.
FC2240-UM-251-9370 8-14
8. ELECTRICAL ADJUSTMENTS
(10) Proceed to the adjustments for the 24 g to the 1000 g.
(11) When the adjustments have been completed for the No.2 pen, the LCD display returns to the 24 g screen for the No.1 pen. At this screen, either press the [NEXT] key to proceed to the next adjustment, or turn off the plotter to exit the adjustment menu and then return the DIP switch to its normal settings.
NOTE: After you have changed the numeric value on the LCD, press the F3 key (PEN U/D) to raise and lower the cutter before measuring the pen force again.
When the measured pen force is the specified value, press the ENTER key. The next specified pen force appears on the LCD panel.
Repeat the above procedure in the following sequence.
24
210
400
700
1000
No.1 pen pressure No.2 pen pressure
24 g ± 1 g 24 g ± 1 g
210 g ± 10 g
400 g ± 20 g
N/A
N/A
210 g ± 10 g
400 g ± 20 g
700 g ± 30 g
1000 g ± 50 g
FC2240-UM-251-9370 8-15
8. ELECTRICAL ADJUSTMENTS
8.12 Adjusting the Distance and the Perpendicularity Accuracy
This adjustment will set the distance and the perpendicularity accuracy.
If you replace the main board or clear the Non-Volatile RAM, use the following procedure to input the recorded adjustment values.
How to adjust the distance accuracy
(1) Mount a ceramic pen (0.2 mm tip size) in the No.1 pen holder.
(2) Load a sheet of A1 or A2 size paper in the plotter.
(3) Set the DIP switch to the adjustment mode as shown below.
Electrical Adjustments
Set bits 4, 5, and 6 to OFF
ON
OFF
1 2 3 4 5 6 7 8
(4) Turn on the power to the plotter.
(5) Press the [NEXT] key until the following menu is displayed.
DIST. ADJ. (0.01mm)
PRESS ENTER KEY !!
(6) Press the [Enter] key to display the menu shown below.
SEl SIZE 300x300
200x200 500x700
(7) Press the [F4] key to select the 500x700 mm adjustment pattern.
(8) Press the [Enter] key to display the menu shown below.
<ORIGINAL CLEAR>
<ADJ.DRAW INPUT>
F1 key (ORIGINAL)
F2 key (ADJ. DRAW)
:Draw the test pattern without distance adjustment.
:Draw the test pattern with distance adjustment.
F3 key (CLEAR)
F4 key (INPUT)
:Clear the distance adjustment value.
:Move to the distance adjustment value setting menu.
(9) Press the [F1] key to start the test. The plotter immediately plots the test pattern, and the following menu appears.
DIST. ADJ. (0.01mm)
X =+10 Y =-10
X=500 mm
Y=700 mm
FC2240-UM-251-9370 8-16
8. ELECTRICAL ADJUSTMENTS
(10) Remove the paper and measure the X-axis distance, Y-axis distance and the diagonal distance. If you have replaced the main board only, use the recorded values.
(11) Input the axis adjustment values using the F1 to F4 keys.
Press the [F1] or [F2] key to change the X-axis adjustment value.
Press the [F3] or [F4] key to change the Y-axis adjustment value.
The formula of the input value is as follows:
Input value for X-axis = (500 mm - measured distance) x 10
Input value for Y-axis = (700 mm - measured distance) x 10
For example:
If you measured 499.7 mm for the X-axis, input 3 for the adjustment value.
Press the [F1] key to select the +0.1-mm step unit.
(12) Press the ENTER key to display the menu shown below.
+0.1 X-Y LENG -0.1
+0.01 L=860.23 -0.01
[F1] key (+0.1) :Increase the diagonal distance value in 0.1-mm steps.
[F2] key (+0.01) :Increase the diagonal distance value in 0.01-mm steps.
[F3] key (-0.1) :Decrease the diagonal distance value in 0.1-mm steps.
[F4] key (-0.01) :Decrease the diagonal distance value in 0.01-mm steps.
(13) Input the diagonal adjustment values using the [F1] to [F4] keys.
The displayed L value is the diagonal distance.
If the measured value is within the displayed L value of the specification range (±0.1 mm) or if you have input the recorded value, press the [ENTER] key to store the setting.
(14) The following menu appears.
<ORIGINAL CLEAR>
<ADJ.DRAW INPUT>
(15) If you have changed the diagonal distance value, confirm the axis distance.
Load a new sheet of paper and press the [F2] key to draw the adjusted test pattern.
Measure each distance. If the measured values are within the specification range, press the [ENTER] key to store the setting.
Specification range for the X distance = 500 mm ±0.2 mm.
Specification range for the Y distance = 700 mm ±0.2 mm.
Specification range for the diagonal distance = within 0.1 mm from the displayed L value.
If the measured value is outside the specification range, adjust again from step (6).
(16) When the adjustment is complete, turn off the power to the plotter.
(17) Return the DIP switch to its default settings (see subsection 8.6 “Setting the DIP Switches”).
FC2240-UM-251-9370 8-17
8. ELECTRICAL ADJUSTMENTS
8.13 Adjusting the Pen Interval
This enables adjustment of the distance between the origins for Pen 1 and Pen 2.
Note: Pens are used to draw lines for this adjustment. As described below, mount pens in the Pen 1 and Pen
2 positions, then specify their conditions.
Procedure
(1) Press the PAUSE key to select PAUSE mode.
(2) Press the NEXT key.
The LCD panel displays the screen below.
PEN ADJ. PEN U/D
BUFFER CLR. VIEW
(3) Press the [F1] key (PEN ADJ.) to display the menu below.
INTERVAL ADJUST
X= 0 Y= 0
(4) Mount pens in the Pen 1 and Pen 2 positions.
(5) When the TEST key is pressed, the lines shown below are drawn.
(6) Adjust the deviation of Pen 1 based on the lines drawn by Pen 2.
To adjust the X-axis deviation, press the [F2] key and then use the and keys to adjust the numeric value.
To adjust the Y-axis deviation, press the [F4] key and then use the and keys to adjust the numeric value.
The X= and Y= values can be specified in a range of -80 to +80 in 1-unit steps.,
The numeric value of 1 corresponds to 0.05 mm. To correct a deviation of 0.3 mm, for example, input 6.
(7) Press the ENTER key to register your INTERVAL ADJUST setting.
(8) Press the PAUSE key to cancel PAUSE mode, and the turn off the plotter.
Note: Your INTERVAL ADJUST setting is retained in the plotter’s internal memory even while the plotter is turned off.
FC2240-UM-251-9370 8-18
8. ELECTRICAL ADJUSTMENTS
8.14 DIP Switch Factory Settings
Setting for the main board DIP switch
ON
OFF
1 2 3 4 5 6 7 8
8.15 Factory Preset Settings
Perform the following procedure after completing all of the previous adjustments.
(1) While holding down the control panel’s POSITION key, turn on the plotter.
(2) After the following messages appear on the LCD panel, turn off the plotter.
NOVRAM CLEAR START
NOVRAM CLEAR END
(3) After turning the plotter back on and waiting until it has been initialized, check that the plotter’s conditions are set as follows.
CONDITION 1 CONDITION 5
12 COND1 PEN
20 READY 3
CONDITION 2
14 COND2 09U 0
20 READY 3
CONDITION 3
17 COND3 15U 0
20 READY 3
CONDITION 4
50 COND5 15U 0
5 READY 3
CONDITION 6
30 COND6 15U 0
10 READY 3
CONDITION 7
30 COND7 15U 0
10 READY 3
12 COND4 PEN
20 READY 3
CONDITION 8
30 COND8 15U 0
5 READY 1
FC2240-UM-251-9370 8-19
Set the HP-GL command mode.
(1) Press the PAUSE key to select PAUSE mode.
(2) Press the NEXT key.
(3) Press the NEXT key again.
I/F FUNCTION
FILM 2PEN
(4) Press the [F1] key to select INTERFACE.
RS-232C
STEPSIZE COMMAND
(5) Press the [F4] key to select COMMAND.
COMMAND
GP-GL HP-GL
(6) Press the [F4] key to select HP-GL.
(7) Press the ENTER key to register your setting.
8. ELECTRICAL ADJUSTMENTS
FC2240-UM-251-9370 8-20
8. ELECTRICAL ADJUSTMENTS
8.16 Testing the Control Panel Keys and Home Sensors
Run this test if a control panel key or home sensor has malfunctioned.
(1) Set the SW1 DIP switch as shown below and then turn on the plotter.
Set all bits to OFF
ON
OFF
1 2 3 4 5 6 7 8
(2) The menu below appears, so press the panel key corresponding to each bit and check that its value properly changes to the corresponding character or 0.
KEY & SNS TEST MODE
OPCERLUD00TN4321XY
Press each key on the control panel; the status will change as shown below.
Key
RIGHT ARROW
DOWN ARROW
UP ARROW
LEFT ARROW
F1
F2
F3
F4
NEXT
TEST
ENTER
CONDITIONS
COPY
ORIGIN
X home sensor
Y home sensor
Normal status : 0
Status of LCD
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
0 0 0 0 R 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 D 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 U 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 L 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 4 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 N 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 T 0 0 0 0 0 0 0
0 0 0 E 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 C 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 P 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
O 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 X 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Y
Key Test
While the key is pressed : corresponding character
The PAUSE key can be checked by observing its lamp.
Sensor Test
The status of each sensor is displayed on the LCD panel.
KEY & SNS TEST MODE
0000000000000000XY
Display
2nd bit
1st bit
Sensor name
X home sensor
Y home sensor
Operation when the High/Low level changes
When the dog blocks the sensor
Same as the above
X
Y
If a sensor is not operating properly, check its wiring, its connector contact, and the position of the sensor dog. If everything checks out all right, either the sensor or main board may be defective.
In this case, initialize the NOV-RAM and then run the sensor test again.
As a temporary measure for dealing with a defective sensor, turn off the plotter, set Bit 6 of the DIP switch to OFF, and then turn the plotter back on.
FC2240-UM-251-9370 8-21
8. ELECTRICAL ADJUSTMENTS
CAUTION:
When the plotter is turned back on, the pen position becomes the plot area’s origin ( 0, 0 ) and the plotter is not initialized.
Unless the plot area is set, the cutting mat may be damaged and a position error may be caused by the pen block striking the side plate.
(3) If a panel key’s corresponding bit does not properly change status, check the following.
• Fault in D1 or D2 on the PR223281 Key Relay Board; or they may be attached in reverse
• Improperly connected CA2232112 cable. Reconnect the cable and then run this test again
• Initialize the non-volatile RAM
• Defective main board
FC2240-UM-251-9370 8-22
8. ELECTRICAL ADJUSTMENTS
8.17 List of Items Requiring Readjustment
If you replaced any of the units listed in the table below or altered their sensor positions, be sure to readjust the corresponding items.
Unit name
Item
NOV-RAM clear and model selection
Firmware upgrade
Pen height adjustment
Pen force adjustment
Distance adjustment
Home position adjustment
Pen interval adjustment
Belt tension adjustment
Main board
M
N
M
M
M
M
M
No mark: Adjustment unnecessary
Main relay board
M
X home sensor
Y home sensor
Pen block X,Y motor
M
M
X,Y Motor drive belt
M
M M
M
M
M
M
M: Must always be adjusted N: To be adjusted as necessary
Note: The main board must have the latest version of firmware unless otherwise specified.
FC2240-UM-251-9370 8-23
9. TROUBLESHOOTING
9 TROUBLESHOOTING
9.1 Troubleshooting Flowcharts
9.1.1 Checking for Faulty Rotation of the Blade
Cutting cannot be properly performed if the blade mounted in the holder does not rotate smoothly or if there is play between the holder and blade because their diameters do not match.
Use the flowchart below to check for faulty rotation of the blade.
Rotate the blade with your finger.
Does the cutter blade rotate smoothly?
Yes
No
No
Apply the grease.
Check the cutter plunger.
PPA31-CB09/15B
PPA31-CB15
Is the spring attached to the blade?
Yes
Is there grease on the blade?
Is the spring properly attached?
No
Mount the spring so that it will not come off the blade.
No
Yes Yes
Is there play?
Yes
Yes
Has the grease deteriorated? (become heavier?)
No
Replace the blade.
No
Is the
CB09 blade in
PPA31-CB15/B?
Yes
No
Mount the CB15 blade.
If the cutter blade still does not rotate smoothly, the cutter plunger is faulty.
Replace it.
Replace the blade.
Normal.
FC2240-UM-251-9370
Is there still play?
No
Yes
Faulty cutter plunger.
Replace it
9-1
9.1.2 The Cutting Media Cannot be Satisfactorily Cut
Part 1
The starting and end points of the cutting don’t match.
The cut corners are rounded or too pointed.
9. TROUBLESHOOTING
Does the cutter blade rotate smoothly?
No See section 9.1.1
“Checking for Faulty
Rotation of the Blade”.
Yes
Attach a pen and draw in plotter mode.
Does the problem occur in plotter mode?
Yes
No
Check the cutter setting conditions.
• Cutter offset for the blade type.
• Blade length, speed, cutting force to match the media.
Is there play or a strange sound in the mechanical section?
Yes
Possible software problem
No
Check the tightening and adjustments of the mechanical section.
• Driver section pulley and setscrew looseness.
• Slider section roller pressure inadequacy.
• Motor rotation defect (wornout bearing in motor).
• Rollers at front of X rail and X slider touching.
FC2240-UM-251-9370 9-2
9. TROUBLESHOOTING
Part 2
The medium curls up at the corners.
Is the blade length too long?
No
Yes Set the blade length to the thickness of the media
+0.1 mm
Is the blade chipped or worn?
No
Yes
Replace with a new blade
Is the cutting speed high?
25 or more?
No
Yes
Lower the cutting speed to
24 or lower.
Is the acceleration high?
4 or more?
No
Yes
Lower the acceleration to 3 or less.
Check with cutter loupe
Does the cutter blade rotate smoothly?
No
Yes See section 9.1.1
“Checking for Faulty
Rotation of the Blade”.
Is there play in the mechanical section?
No
Yes
Perform the necessary adjustments.
Problems with the media
• Extremely soft
• Weak adhesion to backing sheet
• Other problems.
FC2240-UM-251-9370 9-3
Part 3
The blade skips over certain parts of the medium.
The blade skips during cutting.
FC2240-UM-251-9370
Is the blade length too long?
No
Is the blade chipped or worn?
No
Is the cutting speed high?
25 or more?
No
Is the acceleration high?
4 or more?
No
Is the cutting force low?
9 or lower?
No
Yes Set the blade length to the thickness of the media
+0.1 mm.
Yes
Replace with a new blade.
Yes
Lower the cutting speed to
24 or lower.
Yes
Yes
Lower the acceleration to 3 or less.
Raise the cutting force to
10 or more.
Is there play in the mechanical section?
No
Yes
Is there unevenness in the writing panel?
No
Yes
Perform the necessary adjustments.
Replace the writing panel.
Is the pen block installation height correct?
No
There is a problem with the medium. It is too hard.
Yes
Adjust the height using the
10.5 mm height adjustment plate (standard accessory).
9-4
9. TROUBLESHOOTING
Part 4
The cut shape differs from the specified shape.
Is drawing in plotter mode normal?
Yes
No Incorrect command selection
Specify the commands that match the plotter.
Is the interface setting correct?
Yes
Lower the cutting speed to
24 or lower.
No
Set the interface on the control panel.
9. TROUBLESHOOTING
FC2240-UM-251-9370 9-5
Part 5
Line waver.
Is the acceleration 4 or more?
No
Yes Some lines waver, so lower the acceleration.
Is the X belt tension too low?
No
Yes
Adjust the belt tension.
Is the synchro belt loose?
No
Replace the belt.
Yes
Adjust the belt tension.
Replace the X and Y motors.
9. TROUBLESHOOTING
FC2240-UM-251-9370 9-6
Part 6
9. TROUBLESHOOTING
Although cutter blade initial control operation [L] was performed, the starting point is out of place.
Does the cutter blade rotate smoothly?
Yes
No
Example
See section 9.1.1,
“Checking for Faulty
Rotation of the Blade”.
Does the blade tip come out when the pen is rotated?
No
Yes
Check the state of the spring and grease deterioration.
Is there unevenness or air in the cutting media?
No
Adjust the offset force
(cutter offset force).
Yes
When the pen is raised, the blade tip touches the cutting media and rotates.
Eliminate unevenness in the cutting media.
Remove any air from the cutting media.
Be particularly careful when the cutting media is being secured by magnets. With this method, the cutting media may float up.
FC2240-UM-251-9370 9-7
9.1.3 Initialization is Abnormal
Turn on the plotter
Does the pen block move normally in the -X and
+Y directions?
Yes
No
Does it stop when moving in the
+Y direction?
No
Yes
Faulty Y home sensor
Does it stop when moving in the
-X direction?
No
Does the
“READY” message appear and do all control panel keys operate properly?
Yes
Normal
Yes
No
Faulty X home sensor
Faulty keyboard
Faulty cable
Faulty main board
9. TROUBLESHOOTING
FC2240-UM-251-9370
Is there any movement in the X or Y direction?
Yes
No
Faulty X motor or Y motor
Is movement erratic in the X or Y direction?
No
Power board check
Is the voltage level at all pins correct?
Yes
Replace main board
Yes
No
Faulty Y encoder or X encoder
Faulty power board
9-8
9.1.4 Pen UP/DOWN Operations are Abnormal
Be sure to turn off the plotter before performing the following checking procedures.
Part 1
Use your finger to gently move the pen holder up and down.
9. TROUBLESHOOTING
Is there play or does it get stuck?
Yes
No
Electrical adjustment.
Is the guide shaft bearing pressure faulty?
Yes
Loosen the M2 set-screw and adjust the bearing to eliminate play in the guide shaft section.
No Play in the slide shaft or its bearing.
Replace the pen block assembly.
FC2240-UM-251-9370 9-9
9. TROUBLESHOOTING
Part 2
Use your finger to gently move the pen holder up and down.
Is there play or does it get stuck?
No
Yes
Repair the pen block or adjust the pen servos of the replacement main board.
Turn on the plotter.
Manually move the pen holder up and down.
Is the MC
(-) pin of the driver board generating the correct voltage?
No
Yes
Readjust the main board’s pen servos.
Is the specified voltage being correctly generated at the pen adjustment board?
Yes
No
Check for a damaged line in the X or
Y FPC cable.
Check that the cables are securely connected to the proper connectors.
Check for a damaged line in the moving coil.
Faulty main board.
FC2240-UM-251-9370 9-10
9. TROUBLESHOOTING
9.1.5 The X-axis Backlash is Excessive
Is there play in the pen block section?
Yes
No
Does the slide arm rattle?
No
Do the guide shaft and its bearing rattle?
No
No Does the Y slider rattle?
Yes
No
Check the installation on the pen block.
Yes
Remove the Y bar and adjust the Y slider roller pressure.
Do the slide shaft and its bearing rattle?
Yes
Replace the pen block assembly.
No
Loosen the M2 screw and turn the offset pin for adjustment.
Check the M2 setscrew holding the pen holder and the thumb screw, and tighten if necessary.
Does the Y bar rattle?
No
Check the screw and pressure roller.
Check the X belt and X synchro belt tension and adjust if necessary.
Check the setscrews for all the pulleys and tighten if necessary.
No
Are there strange sounds from the X motor?
Yes
No
The X motor is worn out.
Replace it.
Check the motor pulley setscrew and tighten if necessary.
FC2240-UM-251-9370 9-11
9. TROUBLESHOOTING
9.1.6 The Y-axis Backlash is Excessive
(1) Adjust the perpendicularity of the Y bar (see section 7.12, “Adjusting the Perpendicularity Precision”).
(2) Adjust the Y belt tension.
FC2240-UM-251-9370 9-12
9. TROUBLESHOOTING
9.2 The Plotter is Turned On But Doesn’t Operate
Symptom
• The control panel’s POWER
Cause
• The plotter is not being
Solution
Check that the power cord is securely lamp does not light.
• Nothing appears on the display panel.
• The control panel’s POWER lamp lights but the plotter does not operate.
• The control panel’s PAUSE lamp flickers.
supplied with power.
• The plotter is defective.
• The system firmware is defective.
• Nothing appears on the display panel.
• The POWER LED lamp lights • The System firmware is and the LCD displays a sum defective.
check error.
connected to the plotter’s AC line inlet and the electrical output.
Check the main board and connectors.
Reinstall the system firmware or replace the main board.
Reinstall the system firmware or replace the main board.
Sum-Ck ROM RAM ERR!!
FC2240-UM-251-9370 9-13
9. TROUBLESHOOTING
9.3 Error Messages
Error Display Cause
Cutting conditions
OVER CURRENT
POWER OFF THEN ON do not suit the
POSITION ALARM cutting medium.
Movement of the
POWER OFF THEN ON pen carriage is
• The beeper sounds being obstructed.
Excessive load is
• The PROMPT lamp flickers causing the current
Verification item
Cutting conditions the X or Y slider?
(1) Have the Y bar retaining brackets
Solution
Lower the cutting SPEED and/or the cutting FORCE.
Is there anything blocking Turn off the plotter, remove the obstacle, then turn the plotter back on.
No .....Remove the Y bar retaining brackets.
to the motor to exceed the rated value.
been removed?
Yes ....Verify item (2)
(2) Does the X or Y slider No .....Check and adjust the move smoothly?
X or Y belt tension and X or Y motor belt tension.
SPEED ALARM
POWER OFF THEN ON
• The beeper sounds
• The PROMPT lamp flickers
FC2240-UM-251-9370
Home sensor or sensor plate adjustment.
(3) Is the X or Y flexible cable securely connected?
Yes ....Verify item (3).
No .....Connect it securely.
Yes ....Replace the X or
Y flexible cable if
(4) Is the X or Y home sensor plate position defective.
No .....Check and adjust the
X or Y home sensor correct?
plate position.
(5) Is the X or Y home sensor position correct?
Yes ....Verify item (5).
No .....Check and adjust the X-home sensor position.
Yes ....Replace the X-home sensor if defective.
No .....Replace the X-motor if defective.
Motor (6) Does the X-motor turn smoothly?
The internal speed control is faulty.
Yes ....Replace the main
(1) Is the main servo axes gain adjustment board if defective.
No .....Adjust the main servo axes gain.
correct? Yes ....Verify item (2)
(2) Does the X or Y slider No .....Check and adjust the move smoothly?
X or Y belt tension and X or Y motor belt
(3) Is the X or Y flexible cable securely connected?
tension.
Yes ....Verify item (3).
No .....Connect it securely.
Yes ....Replace the X or
Y flexible cable if defective.
9-14
9. TROUBLESHOOTING
9.4 Error Messages in GP-GL Command Mode
Error Display Cause Verification item Solution
The plotter received (1) Did the plotter receive No .....Verify item (2)
ERROR 1
COMMAND ERROR an unrecognizable command.
an unrecognizable command?
(2) Is there any noise on
Yes ....Send correct data to plotter.
No .....Verify item (3) the line?
Yes ....Check the interface
ERROR 4
PARAMETER OVERFLOW
ERROR 5
I/O ERROR
• The software configuration regarding the output device has been
(3) Has the correct cable or move the plotter to another location.
No .....Set the correct model model name been set for the plotter?
name.
Configure your software application menu to permit
Graphtec plotter control.
The numeric parameter of an input command exceeds its permissible range.
An error related to the changed.
• The plotter’s interface conditions have been changed.
receipt of data occurred within the interface.
Re-specify the software application’s interface conditions.
Configure your software application menu to permit
Graphtec plotter control.
Re-specify the software application’s interface conditions.
Set the correct model name if it was incorrect.
FC2240-UM-251-9370 9-15
9. TROUBLESHOOTING
9.5 Error Messages in HP-GL Emulation Mode
If any of the following command errors occur, they are nearly always caused by one of the reasons below:
(1) The software configuration regarding the output device has been changed; or
(2) The plotter’s interface conditions have been changed
When a command error occurs in HP-GL TM emulation mode, therefore, first check the two corresponding points below:
(1) Configure the software to drive your plotter, and ensure that the software’s interface conditions are correctly set; and
(2) Ensure that the plotter’s interface conditions are set to match those of the software.
Error Display
ERROR 1 Instruction not recognized
ERROR 2 Wrong number of parameters
ERROR 3 Out of range parameters
ERROR 5 Unknown character set
Cause
An unrecognizable instruction was executed.
Execute a recognizable command.
A command was executed with the wrong number of parameters.
A command containing an unusable parameter was specified.
An unrecognizable character set was specified.
Verification item Solution
(1) Did the plotter receive No .....Verify item (2) an unrecognizable Yes ....Send correct data command?
(2) Is there any noise on to plotter.
No .....Verify item (3) the line?
Yes ....Check the interface cable or move the plotter to another
(3) Has the correct model name been set location.
No .....Set the correct model name.
for the plotter?
Configure your software application menu to permit
Graphtec plotter control.
Re-specify the software application’s interface
Execute the command conditions.
Configure your software with the correct number of application menu to permit parameters.
Graphtec plotter control.
Execute the command with its parameters specified within their permissible ranges.
Specify a recognizable character set.
Re-specify the software application’s interface conditions.
Set the correct model name if it was incorrect.
FC2240-UM-251-9370 9-16
Error Display
ERROR 6
Position overflow
ERROR 7
Buffer overflow
ERROR 10 Invalid
I/O output request
ERROR 11 Invalid byte following ESC
ERROR 12 Invalid byte I/O Control
ERROR 13 Out of range I/O parameter
ERROR 14 Too many
I/O parameters
ERROR 15 Error in
I/O transmission
ERROR 16 I/O buffer overflow
9. TROUBLESHOOTING
Cause
A command was executed with
Verification item
Execute the command with its coordinate data
Solution
Configure your software application menu to permit coordinate data that exceeds the effective specified within the effective cutting/plotting
Graphtec plotter control.
Re-specify the software cutting/plotting area
The data being area.
Decrease the application’s interface conditions.
input exceeded the capacity of the plotter’s downloadable downloadable characters,
Set the correct model polygons.
name if it was incorrect.
character buffer, polygon buffer, etc.
During execution of an output command, another output
Check the flow of your programmed data.
command was executed.
The ESC character was followed by an
Check the ESC commands in your invalid byte.
A device control program.
Check the device control command containing commands in your an invalid byte was program.
received.
A parameter outside of the permissible numeric range was
Check the program.
specified.
Too many parameters Check the number of were received.
command parameters.
During data transfer, Check the settings of the a framing error, parity interface conditions.
error, or overrun error occurred.
The I/O buffer received data at a
Check the settings of the handshaking mode and other interface conditions.
faster pace than it could process, indicating that handshaking is not successful.
FC2240-UM-251-9370 9-17
9. TROUBLESHOOTING
9.6 The Cutting Results are Unsatisfactory
Problem
The cut corners are rounded or
Cause Solution
The cutter OFFSET is incompatible Adjust the cutter OFFSET value: too pointed.
with the blade type being used.
* If too low, corners become rounded.
The cut line starts out crooked.
The blade mounted in the holder does not rotate smoothly.
* If too high, corners are too pointed.
For CB15 holders (red blade adjustment knob), grease the blade and holder.
Remove any foreign matter inside the pen holder.
Raise the Offset Cut Pressure setting
(the Offset Cut Pressure is separate
The Offset Cut Pressure is too low.
With the CB15B cutter pen (green from the cutting FORCE).
Replace the blade with a new one blade adjustment knob) and the
CB09 cutter pen (blue blade that has a spring.
adjustment knob), the spring has come loose from the blade.
With the CB15 cutter pen (red blade adjustment knob), the blade
Grease the blade and holder (B).
The blade skips and does not completely cut lines that should be has fallen out.
The blade is extended too far.
Adjust the blade length.
solid.
The cutting SPEED is too high.
Lower the SPEED setting.
Solid lines are not cut at a constant depth.
Coarse resolution of curved lines. The software’s resolution setting is Adjust the software’s resolution
The film curls up at the corners.
The film curls up when cutting small characters.
too low.
setting.
The blade offset angle is too low. Raise the blade offset angle.
The blade is extended too far.
Adjust the blade length.
The cutter OFFSET is incompatible Adjust the cutter OFFSET value: with the blade type being used.
* If too low, corners become rounded.
The blade is cutting into the backing sheet.
The blade falls out of the cutter plunger.
* If too high, corners are too pointed.
The cutting SPEED is too high.
Lower the SPEED setting.
The blade is dull.
Replace the blade.
The QUALITY setting is too high. Lower the QUALITY setting.
The blade is extended too far.
Adjust the blade length.
The cutting FORCE is too high.
Lower the FORCE setting.
The blade is too small for the Use a blade that fits securely in the holder.
Insufficient grease.
holder.
For CB15 holders (red blade adjustment knob), grease the cutter blade and holder.
FC2240-UM-251-9370 9-18
9. TROUBLESHOOTING
Problem
Film can be cut but is hard to
Cause
The retack sheet is not sticky
Solution
Switch to a retack sheet that is more weed afterward.
enough.
sticky.
Cut film cannot be picked up using
Film gets entangled during cutting. Reduce the blade length and/or lower a retack sheet.
the cutting FORCE.
Weeding of cut film was postponed Promptly weed cut film.
Abnormal noise generated by the cutter pen during cutting.
The film is discolored where the blade has passed.
The cutting results differ from the specified size.
too long.
Film is stuck in the tip of the cutter Adjust the blade length and cutting plunger.
FORCE setting.
The programmable resolution
(STEP SIZE) has been set differently at the plotter and the software application.
Set both the plotter and software to the same resolution.
Check whether scaling has been specified.
Scaling has been specified at the
When the plotter is receiving data, software application
The programmable resolution the PROMPT lamp lights (an (STEP SIZE) has been set
Set both the plotter and software to the same resolution.
offscale error occurs).
Some parts of the film cannot be cut.
differently at the plotter and the software application.
The computer sent coordinate data that exceeds the specified
Set the effective cutting area to a larger area.
The currently selected cutting conditions are disregarded or cannot be changed.
Characters or lines are deformed during pen plotting.
The length of cutting results differ from the program (slight distance effective cutting area.
The computer sent coordinate data that exceeds the maximum effective cutting area.
The Parameter Priority setting is set to program mode.
Switch to larger film or change the coordinate data.
Change the Parameter Priority setting to manual mode.
The ENTER key was not pressed Make sure you are setting the after changing the settings.
The plotter is in Cutting mode.
The distance correction requires adjustment.
conditions correctly.
Set the blade type of the cutter
OFFSET function to PEN (0).
Adjust the distance correction.
error).
Cut characters are deformed.
The starting and end points of cutting do not match.
The Step Pass is too high.
Coordinate points are incorrectly specified.
The Offset Cut Pressure is too low.
The film is too flimsy.
Blade rotation is not smooth.
Lower the Step Pass setting.
Check the coordinate data by plotting it with a pen.
Raise the Offset Cut Pressure setting.
Switch to a stronger film.
For CB15 holder (red blade adjustment knob), grease the cutter blade and holder.
FC2240-UM-251-9370 9-19
10. PARTS LIST
10. PARTS LISTS
10.1 Mainframe
No.
Part No.
E1 772232120 X Relay Board
Description
E2 772232100 X Flex. Board
E3 773503490 High Voltage Board
E4
122927320 Y Flexible Cable 60/120
692807300 Y Flexible Cable 180
E5 122907030 X Flexible Cable
5
6
3
4
7
1
2
8
621474130 Corner Cover (Rear Right)
022900082 Electrostatic Panel 12
022900202 Electrostatic Panel 18
022900132 Magnetic Sheet 90
772293710 Vacuum Panel 60
772293030 Vacuum Panel 120
772293040 Vacuum Panel 180
022907302 Power Board Cover
621474110 Corner Cover (Front Right)
022907391 Support Bracket
022907291 Support Bracket
022907231 Frame Holder Plate
022901330 Tray 60
022900740 Tray 120
022900750 Tray 180
022907410 Main Frame
9
622301660 Main Frame 60
10 621474100 Corner Cover (Front Left)
12 792292700 2-Pen Type Block Assembly HP
13 621474120 Corner Cover (Rear Left)
14 022907253 Board Cover
15 621474140 Side Cover
16
17
022903752 X Flexible Guide 120 Right
022903721 X Flexible Guide 180 Right
022901340 X Flexible Guide 60 Left
022903721 X Flexible Guide 120 Left
022903781 X Flexible Guide 180 Left
Q’ty Remarks
1 PR223203 Assembly
1 PR223224 Assembly
1 PR31001C Assembly
1
CA2292-32 (-60/-120)
CA2232-32 (180)
1 CA2290-03
2
2
1
1
1
1
1
1
1
4 M4-18
8 M4-12
2
1
2
FC2240-60
FC2240-120
FC2240-180
FC2240-120/180
FC2240-60
1
FC2240-120ES
FC2240-180ES
FC2240-120MG
FC2240-60VC
FC2240-120VC
FC2240-180VC
1
FC2240-120
FC2240-180
FC2240-60
FC2240-120
FC2240-180
FC2240-UM-251-9370 10-1
Mainframe
10. PARTS LIST
FC2240-UM-251-9370 10-2
10.2 Stand
No.
1
2
3
4
8
Part No.
Description
621470940 Left Side Foot 60
621480920 Left Side Foot 90/EX
621470950 Right Side Foot 60
621470930 Right Side Foot F223
054221031 Rear Main Bar 60
622301800 Rear Main Bar 90
622301760 Rear Main Bar EX
054221021 Front Main Bar 60
622301790 Front Main Bar 120
622301730 Front Main Bar 180
772290670 Gas Spring Assembly 120
772232670 Gas Spring Assembly EX
621470900 Stand 60 Assembly
621480900 Stand 120 Assembly
621490900 Stand 180 Assembly
Stand
Q’ty
1
1
1
1
1
1
Remarks
FC2240-60
FC2240-120/180
FC2240-60
FC2240-120/180
FC2240-60
FC2240-120
FC2240-180
FC2240-60
FC2240-120
FC2240-180
FC2240-120ES/MG
FC2240-180ES
FC2240-60
FC2240-120
FC2240-180
10. PARTS LIST
FC2240-UM-251-9370 10-3
10.3 Control Panel
No.
Part No.
Description
E1 772232010 Key Rely Board
E2 772232020 LCD
E3 122907010 Control Cable
1
2
3
4
5
682247030 Sheet Switch
621476000 Panel Frame
022901330 Tray 60
022900742 Tray 120
022900750 Tray 180
022900572 Cable Holder
772230260 Chart Hold Switch
772230860 Panel, Blind
Control Panel
1
2
Q’ty
1 PR223281
1
1 CA2290-01
Remarks
1 PN5042-03
1
1
FC2240-60
FC2240-120
FC2240-180
1
1
ES
VC/MG
10. PARTS LIST
6
E1
E2
3
E3
4
FC2240-UM-251-9370 10-4
10.4 Control Unit
No.
1
2
3
4
5
6
Part No.
Description
508102306 Power Switch
518000033 AC Inlet
792240700 Main Board
792240701 Main Relay Board
510000051 Switching Power Supply
500050273 Fan
Control Unit
Q’ty
1 SW,2WI36/92
Remarks
1 SUP-B3G-E
1
1
1 PS089B
1 TUDC24B4
4
10. PARTS LIST
2
3
6
5
1
FC2240-UM-251-9370 10-5
10.5 X Drive Unit
No.
19
20
21
22
15
16
17
18
11
12
13
14
7
8
9
10
23
24
25
27
28
29
30
3
4
5
6
32
33
34
35
36
38
39
41
42
43
44
45
46
49
51
52
53
54
56
Part No.
Description
312208069 Bearing
022904221 Bearing Spacer
022903590 Pulley Shaft, Right
022904500 X Belt
022904510 X Belt 120
022904520 X Belt EX
022903671 Roller Lever
022900400 Roller ø27
022903533 X Slider
020003131 Roller
022903680 Roller Collar A
022903662 Flexible Plate
022903871 Lower Bracket, Right
022903911 X Roller Collar
311068820 Bearing
022902540 Drive Pulley R
022903260 Pulley
372290003 Notched Synchro Belt
022903181 Drive Shaft, Rear
022903151 Pulley
022903102 Gear Box
022903111 X-Motor Bracket
022903121 Box Fitting Plate
053206100 Motor Pulley
022903133 Intermediate Shaft
022900360 Drive Collar C
022903250 Pulley
375311001 Notched Synchro Belt
022900351 X Gear Space Board
621472200 X Motor Cover
022903242 Drive Shaft M
022903290 Coupling
022903211 Collar
022902530 Drive Pulley F
022903191 Drive Shaft, Front
022903851 Lower Bracket, Front
022903521 X Slider, Front
022903910 X Roller Collar
022903651 Belt Plate D
302200026 Shaft
022903580 Pulley Shaft, Front
022903641 Belt Plate C
022901320 X Rail, Front 60
022903500 X Rail, Front 120
022903761 X Rail, Front 180
022901310 X Rail, Rear 60
022903511 X Rail, Rear 120
022903772 X Rail, Rear 180
022903631 Belt Plate B
022903691 Roller Collar B
022904212 Spacer ø04-1.5
362200005 Rubber Foot
E1 772230250 X Limit Switch
E2
E3
772290110 X Motor
162291230 X Flexible Cable 60/120
162291240 X Flexible Cable 180
FC2240-UM-251-9370 10-6
Q’ty Remarks
4 F608ZZ
2
2
2
S2ML2350, FC2240-60
S2ML3200, FC2240-120
S2ML4200, FC2240-180
1
1
2
1
1
9
2
3
6 F688ZZ
1 S2M
1 60Z-TN
1 120TN15-15W
1
1
1
1 30Z-TN
2
1 Z22
1
1
1 99Z-TN
1 120TN15
1
1
1
2
2
1
1
1 S2M
1
1
1
5
1
1 ASB335
1
FC2240-60
FC2240-120
FC2240-180
1
2
2
2
1 SJ5008
1 PR223208
1 UGFMEDA5LGR28
1
FC2240-60/120
FC2240-180
10. PARTS LIST
No.
60
61
62
63
64
Part No.
Description
022904540 XR End
022904560 XR Pulley Bracket
022904530 XF End
022904550 XF Pulley Bracket
622301630 Belt Plate
Q’ty
1
1
1
1
2
Remarks
10. PARTS LIST
FC2240-UM-251-9370 10-7
X Drive Unit
10. PARTS LIST
FC2240-UM-251-9370 10-8
10.6 Y Drive Section
6
7
4
5
No.
1
2
3
Part No.
621473400 Y Gear Box
Description
621473411 Y Motor Bracket
022903362 Pulley
022903370 Pulley
022903331 Y Pulley Shaft
621473420 Y Motor Cover
022903351 Y Bar Plate
8
9
022903380 Shaft ø5
022903534 X Slider R
10 053206100 Motor Pulley
11
12
13
14
311068820 Bearing
311060520
379011002
375311001
Bearing
Notched Synchro Belt
Notched Synchro Belt
15 362200005 Rubber Foot
20 022904012 Y Bar
21 022904041 Y Pulley Bracket
22 022904230 Y F End
23 022904062 Y Front Bracket
24 022904071 Y Front Plate
25 022904080 Bearing Shaft
26 621473340 Y End Front Cover
27 022904500 Y Belt
28 022904221 Bearing Spacer
29 022904331 Y-Flexible Cable Reinforcement
30 311060820 Bearing
31 022904250 Y Stopper
40 022904022 Y Slider
41 621473310 Plate PUF
42 022904131 Offset Pin A
43 022904151 Offset Pin C
44 022904311 GND Plate
45 022904171 Board Bracket
46 022904182 Flexible Guard
47 022904192 Flexible Plate
48 022904202 Y Sensor Holder
49 022904212 Collar ø4-1.5
50 022904300 Roller Plate
51 022903631 Belt Holder B
52 020003131 Roller
53 022900410 Roller ø12
54 359200007 Spacer
55 022904321 Y Roller Collar
60 022902430 2-Pen MC Block
61 090113200 Long Magnetic Circuit Board A
62 010014101 Slide Shaft Assembly
63 021500621 50 Slide Arm
64 022906323 Hall IC Bracket
65 053203350 Guide Shaft
66 310069220 Bearing
67 053203350 MC Up Spring
68 340804012 O Ring,S4
69 034004591 Offset Pin
70 021500631 Cutter Holder
71 621113581 Thumb Screw L14
72 302200060 Spacer BSB315
73 621473200 2-Pen Cover
74 621473300 2-Pen Block Plate
75 022902451 2P2 Slide Arm
76 302200076 MC Up Spring E537
77 621473320 Y Slider Cover T
78 621473330 Plate PUR
FC2240-UM-251-9370 10-9
Q’ty
1
1
1 88Z-TN
1
2
1 44Z-TN
1
Remarks
1
1
2 22Z
2 F688ZZ
2 F605ZZ
1 79TN15-10.0K
1 120TN15-10.0W
1 SJ-5008
1
1
1
1
3
1
1
1 S2ML2350
1
1
2 F608ZZ
1
1
1
1
1
2
2
1
1
1
2
1
6
4
8
2 C305
4
1
1
1
2
1
1
2 A0000
2
2
4 BB692ZZMC3PS2S
1
1
1
2
1
2
2
2
2 L14
10. PARTS LIST
No.
Part No.
Description
792232701 2-Pen Block T Assembly
E1 772247520 X-Y Relay Board
E2 772247550 Y Motor
E3 772232140 2-Pen Relay Board
E4 305320007 Moving Coil
E5 110006060 MC Flexible Cable
E6 792240702 Height Sensor
E7 772230310 Y Limit Switch Assembly
E8 772232130 Pen Flex. Board
E9 162291100 Y-Flexible Cable
E10 122937391 2-Pen T Cable
E11 792232705 2-Pen T Board Assembly
E12 122936110 MC T Flexible Cable
Q’ty
1
Remarks
1 PN5042-02 Assembly
1 UGFMED-B5LGRA6
1 PR223229 Assembly
3 PL-326B
1 FPC10002
2
1 PR229008 Assembly
1 PR223226 Assembly
1 FCA2291010
1 CA2292-39
1 PR223227 Assembly
1 FPC2293110
10. PARTS LIST
FC2240-UM-251-9370 10-10
Y Drive Section
10. PARTS LIST
FC2240-UM-251-9370 10-11
10.7 Standard Accessories
6
7
4
5
No.
1
2
3
Part No.
Description
022909550 Pen Block Height Adjustment Plate
022909561 Pen Height Adjustment Plate
621479900 User’s Manual FC2240-CDM01M
621479910 Safety Manual ANCUTF-UM-AM1
621479920 Quick Manual
302200020 Hexagonal Wrench (2.5)
AC Power Cable
8
9
972100151 PPA31-CB15B
972100300 CB15U-2SP
10 972100320 CB15U-K30-5SP
11 947000051 KF550-F6
12 915052360 PL525-A2-KP
13 302200102 Flexible Hose ø50 mm
14 302200104 Hose Band
15 302200018 Magnetic Plate (2 large, 2 medium, 4 small)
772290800 Hanger Assembly
16 022908050 Hanger F
17 022908060 Hanger R
18 022908070 Roller Shaft
19 022908080 Nut R16
20 022908590 Tray Nut 18
21 022908590 Tray Nut 12
1
1
1
1
2
1
1
1
1
2
2
1
1
1
1
1
1
1
1
Q’ty Remarks
1
1
1 CD-ROM
V Type Only
V Type Only
M Type Only
10. PARTS LIST
FC2240-UM-251-9370 10-12
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
11.1 Wiring Connection
(1/2)
FC2240-UM-251-9370 11-1
(2/2)
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
HEIGHT SENSOR HEIGHT SENSOR
FC2240-UM-251-9370 11-2
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
11.2 Key Relay Board (PR223281)
1 2 3 4 5 6 7 8 9 10
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 4 3 2 1
34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
FC2240-UM-251-9370 11-3
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
11.3 Main Relay Board (PN5042-01A)
Main Relay Board 1/2
+34V +34V C .HLD G MC1(+) MC1(+) MC1(-) MC1(-) G
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 +5V GND XHOMEZ GND XENA GND XENB GND GND GND XM+ XM+ XM- XM-
1 8 2 9 3 10 4 11 5 12 6 13 7 14
2 4 6 8
1 3 5 7
MC1(+) MC1(-)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
GND GND KEY0 KEY1 KEY2 KEY3 KEY4 KEY5 KEY6 KE
2 4 6 8
1 3 5 7
2 4 6 8
1 3 5 7
2 4 6 8
1 3 5 7
2 4 6 8
1 3 5 7
2 4 6 8
1 3 5 7
FC2240-UM-251-9370
1 2 3 4 5 6
-12V GND +12V GND PLFB GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1 2 3 4 5 6 7 8
11-4
Main Relay Board 2/2
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
4
PR CL
1
.0 N.C
8
NJM072B 3
4
10
PR CL
13
FC2240-UM-251-9370 11-5
11.4 X Relay Board (PR223203)
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
+5V
P303
1
2
3
+5V
XHOMEZ
GND
IL-G-3P-S3T2-E
+5V
GND
XHOMEZ
GND
XENA
GND
XENB
GND
GND
GND
XM(+)
XM(+)
XM(-)
XM(-)
FRC5-C14L53T-OL
11
12
10
9
13
14
8
7
6
5
4
3
2
1
P31
FL1 DSS306-102M
+5V
+5V
P302
1
2
3
4
+5V
GND
XENA
XENB
IL-G-4P-S3T2-E
FL2
FL3
FBR07HA
FBR07HA
P301
1
2
XM(+)
XM(-)
IL-G-2P-S3T2-E
FC2240-UM-251-9370 11-6
11.5 X Flex. Board (PR223224A)
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
9 8 7 6 5 4 3 2 1
2 1
8 4
8 4
FC2240-UM-251-9370 11-7
0 9 8 7 6 5 4 3 2 1
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
11.6 X-Y Relay Board (PN5042-02A)
+5V YHOMEZ GND
1 2 3
+5V GND YENB YENA
1 2 3 4
YM (-) YM (+)
2 1
MC1 (+) MC1 (-) GND PLFB2 -12V +12V PLFB1 GND MC2 (+) MC2 (-)
10 9 8 7 6 5 4 3 2 1
8 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
MC1 (+) MC1 (-)
-12V +12V GND
+5V GND
YENB GND YEMA GND YM (-) YM (-) YM (+) YM (+)
FC2240-UM-251-9370 11-8
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
11.7 Pen Flex. Board (PR223226A)
MC1 (+)
MC1(-)
GND
PLFB2
-12V
+12V
PLFB1
GND
MC2(+)
MC2(-)
J61
9
10
7
8
5
6
3
4
1
2
52044-1010
P62
4
3
6
5
2
1
8
7
10
9
MC1 (+)
MC1(-)
GND
PLFB2
-12V
+12V
PLFB1
GND
MC2(+)
MC2(-)
IL-6-10P-S3L2-E
FC2240-UM-251-9370 11-9
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
11.8 2-Pen Relay Board (PR223229A)
MC1 (+)
MC1(-)
FG
-12V
+12V
SG
PLFB1
PLFB2
MC2(+)
MC2(-)
P91
9
10
7
8
5
6
3
4
1
2
IL-G-10PS3L2E
P92
7
8
5
6
3
4
1
2
9
10
MC1 (+)
MC1(-)
FG
-12V
+12V
SG
PLFB1
PLFB2
MC2(+)
MC2(-)
IL-G-10PS3L2E
FC2240-UM-251-9370 11-10
11.9 2-Pen Board (PR223227A)
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
1 2 3 4 3 2 1
3 2 1 1 2 3 4
9 10 1 2
8 4 8 4
4 8
8 4
4 8
8 4
FC2240-UM-251-9370
3 4 5 6 7 8
11-11
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
11.10 High Voltage Board (PR31001C)
1 2 3
1 2 3
FC2240-UM-251-9370 11-12
11.11 Main Board (PR306101)
Main Board, Top
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
YMP YMM MCP MCM
TMBLED TOMBO
PNENA PNENB OSDSCK B/WZ OSDSIN LOCALLED OFFSLED
PLFB PE
YMP YMM MCP MCM XMP XMM
XCOMA XCOMB YCOMA YCOMB PNCOMA PNCOMB
A[21..1] D[15..0] KROMCSZ NVRAMCSZ WRHZ WRLZ NV_BUSYZ FR_BUSYZ
XCOMA XCOMB YCOMA YCOMB
PNCOMA PNCOMB
WRLZ CS4Z CS6Z SRVINTZ LOCALINTZ
PNENA PNENB LOCALZ
TMBSEL OSDCSZ OSDSCK
RSNS ROLL INRZ
KCONT0Z KCONT1Z KCONT2Z
WRLZ IOCS1Z
RASZ CASHZ CASLZ
WRHZ WRLZ RASZ CASHZ CASLZ CS4Z CS6Z TXD0 RTS0Z DTR0Z TXD1
RXD0 CTS0Z DSR0Z RXD1
CENINTZ KE
FC2240-UM-251-9370 11-13
Main Board, Connect 1/2
4 1 1
4 11
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
1 2 3 4 5 6 7 8 9 1
XMP XMM
2 3 2 3 4 5 6 7 8
2 3 4 5 6 7 8 9
14
7
VCC
GND
3 6 8
1 4 2 5 9
C16 10
C15 10
2 3 4
2 3 4
3 6 8 1
1
7
4
N D G
VCC
1 4 2 5
C19 10
C18 10
2 3 4 5
FC2240-UM-251-9370 11-14
Main Board, Connect 2/2
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
GND GND +5V +5V KEY0 KEY1 KEY2 KEY3 KEY4 KEY5 KEY6 KEY7 PAUSELED PROMPTLED C/HLED1 C/HLED2 PAUSEZ CHAR KEYCONTZ0 KEYCONTZ1 GND GND LCDB0 LCDB1 LCDB2 LCDB3 LCDB4 LCDB5 LCDB6 GND
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
LCDB0 LCDB1
FAN2+ FAN2-
FAN1+ FAN1-
L1 LHL08TB221K
FC2240-UM-251-9370
LOCALLEDZ OFFSLEDZ
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
GND GND KEY0 KEY1 KEY2 KEY3 KEY4 KEY5 KEY6 KEY7 PAUSELED PROMPTLED PAUSEZ KEYCONTZ0 KEYCONTZ1 GND GND LCDB0 LCDB1 LCDB2 LCDB3 LCDB4 LCDB5 LCDB6 GND
2
1
2
1
2
1
2
1
1 2 3 4 5 6 7 8 9 10
2
1
11-15
Main Board, CPU
A19
A20
A18
A21
A15
A16
A10
A11
A12
A13
A6
A7
A8
A9
A4
A5
A0
A1
A2
A3
RA14 1
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
A9 A8 A7 A6 A5 A4 A3 A2 A1
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
WRHZ WRLZ RASZ CASHZ CASLZ CS4Z CS6Z TXD0 R DTR0Z TXD1 SFREE FAN_ONZ
VCC
VCC
VSS
VSS
VSS
VSS
VSS
VSS
VSS
VSS
VSS
VSS
VCC
VCC
VCC
VCC
VCC
VCC
72
61
96
52
40
31
22
12
3
99
84
83
77
75
70
43
15
106
R14 1M
74 73
CTS0Z DSR0Z
C31 C
C32 1
C30 C
NV_BUSYZ LOCALINTZ
R61 R
C34 1
C33 1UF/50V
FC2240-UM-251-9370 11-16
Main Board, DRAM
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
D10 D1 D12 D13 D14 D15
VSS
VSS
VSS
VCC
VCC
VCC
37
22
42
1
6
21
A3 A4 A5 A6 A7 A8 A9 NC NC
20 23 24 25 26 27 28 16 15
40 41
DQ14 DQ15
U14 M5M418160CJ
FC2240-UM-251-9370
18 16 14 12 9 7 5 3
1Y1 1Y2 1Y3 1Y4 2Y1 2Y2 2Y3 2Y4
1A1 1A2 1A3 1A4 2A1 2A2 2A3 2A4
2 4 6 8 11 13 15 17
1G 2G
1 19
A1 A2 A3 A4 A5 A6 A7 A8
18 16 14 12 9 7 5 3
1Y1 1Y2 1Y3 1Y4 2Y1 2Y2 2Y3 2Y4
1A1 1A2 1A3 1A4 2A1 2A2 2A3 2A4
2 4 6 8 11 13 15 17 1 19
1G 2G
A9 A1
CASHZ CASLZ
RDDZ WRLZ
11-17
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
Main Board, Driver
D34 SFPW D36 SFPW
5 SFPW 7 SFPW
9 SFPW
R19 3 C39 1
C37 1 C38 1
GND
VS
6
2
C40 2
R20 3 C45 1
C43 1 C44 1
C46 2
GND
VS
6
2
R23 1
R26 10
4 11
FC2240-UM-251-9370 11-18
11 4
R31 30
C54 3
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
Main Board, G_Array
TP6 TP(TH)
NVRAMCSZ IOCS1Z XCOMA XCOMB YCOMA YCOMB PN
C58 C
VSS
VSS
VSS
VSS
VSS
VSS
VSS
VSS
VDD
VDD
VDD
VDD
90
79
65
54
40
29
15
4
78
53
28
3
37 38 39 41 42 43 44 56 69 70 74 75
FDDCS* CENCS* PE
IOCS1* IOCS2*
XDAL* YDAL*
D<2> D<1> D<0>
19 20 21
RD* WR*
47 46 49 50
PENSD SAMP
55 80 84 99
A5 A4 A3 A2 A1 D10 D
CS4Z CS6Z
PNENA PNENB
R35 2
FL40 E
FC2240-UM-251-9370 11-19
Main Board, IF
D7 D6 D5 D4 D3 D2 D1 D0 +5V SLC ACK STB BUSY ERROR OPEN OPEN GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND N.C. GND
9 8 7 6 5 4 3 2 18 13 10 1 11 32 14 15 12 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 33
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
DATA0
DATA1
DATA2
DATA3
DATA4
DATA5
DATA6
DATA7
RA27 1K*4
18 17 16 15 14 13 12 11
B1 B2 B3 B4 B5 B6 B7 B8
A1 A2 A3 A4 A5 A6 A7 A8
2 3 4 5 6 7 8 9
G DIR
19 1
RA30 10
8
7
6
5
4
3
2
1
9
10
11
12
13
14
15
16
VCC
VCC
VCC
GND
24
17
39
2
38 37
PA4 PA5 PA6
15 16 18 19 20 21
PB1 PB2 PB3 PB4 PB5 PB6
10 11 13 8 7 6 5
PC1 PC2 PC3 PC4 PC5 PC6 PC7
RD WR CS RESET
44 34 1 33
U21 M
A2 A3
C61 1
DTR TXD RXD CTS DSR +5V SHILED GND
4 20 2 3 5 6 9 1 7
RXD0 CTS0Z DSR0Z RXD1
6 4 22 17 2 1 24 20
R1OUT R2OUT R3OUT R4OUT T1OUT T2OUT T3OUT T4OUT
U24 MAX208E/SO
R1IN R2IN R3IN R4IN
7 3 23 16
T1IN T2IN T3IN T4IN
5 18 19 21
C1+ C1- C2+ C2- V+ V-
10 12 13 14 11 15
TXD0 R DTR0Z TXD1
C63 2 C64 2
C65 2 C66 2
1 2 3 4 5
FC2240-UM-251-9370 11-20
Main Board, IO
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
1 2 3 4 5 6 7 8 9 10
FC2240-UM-251-9370
KCONT0Z KCONT1Z KCONT2Z
ROLL RSNS
RA36 10
LCDB0 LCDB1 LCDB2 LCDB3 LCDB4 LCDB5 LCDB6
RA35 10
VCC
VCC
VCC
GND
24
17
39
2
38 37 15 16 18 19 20 21 10 11 13 8 7 6 5
PC1 PC2 PC3 PC4 PC5 PC6 PC7
44 34 1 33
U25 MSM82C55A
A2 A3
C68 1
IOCS1Z RESET
11-21
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
Main Board, Memory
46
27
37
VSS
VSS
VCC
A17 A18
17 16
U26 M
11 12 13 15 16 17 18 19
14
28
GND
VCC
A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10
10 9 8 7 6 5 4 3 25 24 21 23 2
1 26
22 27
U31 H
14
28
11 12 13 15 16 17 18 19
GND
VCC
A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A1
10 9 8 7 6 5 4 3 25 24 21 23 2 20 27
U28 IDT71256SA
14
28
11 12 13 15 16 17 18 19
GND
VCC
A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A1
10 9 8 7 6 5 4 3 25 24 21 23 2 20 27
U30 IDT71256SA
46
27
37
VSS
VSS
VCC
A17 N
17 16
15 14 13 12 11 10 9 7
Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7
A B C
1 2 3
G2A G2B
6 4 5
FC2240-UM-251-9370
46
27
37
VSS
VSS
VCC
A17 N
17 16
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
43 44 45 46 47 48
11-22
Main Board, Pen DAC
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
FC2240-UM-251-9370
U34B NJM074M
C76 1
C77 1
8 4
C78 1
C80 1
4
12
21
VDD
DGND
DB0 DB1 DB2 DB3 DB4 DB5 DB6 DB7 DB8 DB9 DB10 DB1
6 7 8 9 10 11 13 14 15 16 17 18
CSA CSB
5 20
AGND
1
U34D NJM074M
R46 2
D4 D5 D6 D7 D
C79 1
2
1
U34A NJM074M (PEN)
11
R48 4
C83 1
U34C NJM074M
R51 1
11-23
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
Main Board, USB
VBUS D- D+ GND
1 2 3 4
R57 4.7K
R52 4.7K
R56 1M
X1 H
D10 D1 D12 D13 D14 D15 A0 A1 A2 A3 A4 A5 A6
44 43 42 41 38 37 36 35 22 21 20 19 16 15 14 13 32 31 30 29 28 27 26
3 40
VCC0 VCC1
5 39
GND0 GND1
9 10
11 8
RES C
4 17
TEST1 TEST2
R60 10
R59 10
R58 10
FC2240-UM-251-9370
D14 D15
A1 A2
11-24
TP9 RC
2
1
D31 RB491D D32 RB491D
G
2
C88 1
11.12 Miscellaneous
Part No.
792807030 Cable
692807972 Cable
692807982 Cable
692807991 Cable
692807051 Cable
692807142 Cable
692807131 Cable
122907010 Cable
122907030 Cable
692236120 Cable
122927343 Cable
122927511 Cable
692236210 Cable
122937391 Cable
108901173 Cable
692236041 Cable
692236051 Cable
692247010 Cable
Description
692247020 Cable
692247030 Cable
692247040 Cable
692247050 Cable
110006060 Flexible Cable
122936100 Flexible Cable
122936110 Flexible Cable
162291100 Flexible Cable
162291240 Flexible Cable
162291230 Flexible Cable
520100241 AC Cable
520100330 UL/CSA AC Cable
500050024 CEE AC Cable
520000022 BS AC Cable
520100103 SUS AC Cable
520100098 SAA AC Cable
520000005 BS AC Cable (P)
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS
CA223303
CA223207A
CA223208A
CA223209A
CA2232503A
CA2232112B
CA2232113A
CA2290-01
Rating
CA2290-03
CA2292-32A
CA2292-34C
CA2292-51A (FC2240-180)
CA2292-41B (FC2240-60/120)
CA2293-39A
CA08917C
CA306004
CA306005
CA504201
CA504202
CA504203
CA504204
CA504205
FPC10002
FPC2293100
FPC2293110
FCA2291010
FCA2291123 (FC2240-180)
FCA2291023 (FC2240-60/120)
VM1182-1276.5M
UL/CSA Code SJT
VM0306B-0304B2M
GRCK-B0
PISEV-H05VV-F-1C
SAA Standard Cable Set 3M
Z-VCTF-OR-BS
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
Q'ty
1
1
1
1
1
2
1
1
1
1
1
1
1
FC2240-UM-251-9370 11-25

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