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FC4200-UM-251-03-9370

TROUBLE SHOOTING

9. TROUBLE SHOOTING

If your plotter is not operating properly, try the solution(s) described in the following tables before contacting
your sales representative or nearest Graphtec vendor to request a service call.

9.1 The Plotter Doesnʼt Operate After Being Turned On

Symptom

Cause

Solution

The control panelʼs POWER lamp does
not light.
The display panel is blank.
The POWER lamp lights but the plotter
doesnʼt operate.

The plotter isnʼt being supplied
with power.

Check that the power cord is properly
plugged into the plotterʼs AC inlet and
the electrical outlet.

The plotter has broken down.

Replace the power supply unit.
Replace the main board.

The control panelʼs POWER lamp
lights, but the plotter doesnʼt operate.
The control panelʼs PAUSE lamp is
ﬂashing.
The display panel is blank.

The ROM and RAM are defective. Replace the main board.

The control panelʼs POWER lamp
lights, but the plotter doesnʼt operate.
The “Sum-ck-ROM ERROR!!” message
appears on the display panel.

The ROM and RAM are defective. Replace the main board.

Summary of Contents for FC4200-50

Page 1: ...FC4200 UM 251 03 9370 CUTTING PLOTTER SERVICE MANUAL MANUAL NO FC4200 UM 251...

Page 2: ...Y OF REVISIONS NO Date issued Description of revision Page Edition 1 01 10 23 First Printing 1 to 87 01 2 05 01 20 FC4210 60 information added 1 to 101 02 3 05 03 22 The parts number for the writing p...

Page 3: ...emoving the Rear Cover 17 6 8 Removing the Operation Panel 18 6 9 Removing the Operation Tray 18 6 10 Changing Pen Blocks 19 6 11 Adjusting the Pen Block Height 21 6 12 Adjusting the X Belt Tension 22...

Page 4: ...st of the Currently Selected Conditions 52 8 2 Running the SELF TEST 53 8 3 Using the Character Dump Mode 54 9 TROUBLE SHOOTING 55 9 1 The Plotter Doesn t Operate After Being Turned On 55 9 2 The Cut...

Page 5: ...FC4200 UM 251 03 9370 v CONTENTS 12 CIRCIT DIAGRAMS 86 12 1 Wiring Diagram 86 12 2 Main Board 88 12 3 Control Panel Relay Board 98 12 4 Y Motor Relay Board 99 12 5 Pen Board 100...

Page 6: ...mounted Compatible blade type Supersteel ceramic and sapphire blades Compatible pen types Water and oil based ballpoint pens Compatible cutting media Marking lm polyvinyl uorescent re ective Paper of...

Page 7: ...blade Compatible pen types Creasing scoring tool water and oil based ballpoint pens Usatible cutting media Marking lm polyvinyl uorescent re ective Cardboard of a thickness of 0 5 mm or less Paper of...

Page 8: ...FC4200 UM 251 03 9370 3 INTRODUCTION 1 2 Options Name Part no Description Stand ST0032 Dedicated stand for the FC4200 60 and FC4210 60...

Page 9: ...FC4200 UM 251 03 9370 4 INTRODUCTION 1 3 External Dimensions The FC4200 50 Model 200 857 780 Unit mm Dimensional precision error 5 mm...

Page 10: ...FC4200 UM 251 03 9370 5 INTRODUCTION The FC4200 60 and FC4210 60 Model Excluding the Optional Stand 200 1172 964 Unit mm Dimensional precision error 5 mm...

Page 11: ...et and use the plotter s various functions 7 Centronics parallel interface Used to connect the plotter to a computer by cable via the Centronics connector compatible parallel interface 8 RS 232C seria...

Page 12: ...lotter s various functions 6 Centronics parallel interface Used to connect the plotter to a computer by cable via the Centronics connector compatible parallel interface 7 RS 232C serial interface Used...

Page 13: ...Menu mode to select Cutter Conditions 2 during Online status or to change the cutting SPEED setting after the CONDITIONS key has been pressed F3 Press the F3 key to select a function during Menu mode...

Page 14: ...the automatic detection of registration marks is enabled press this key to initiate automatic detection COPY key Used to repeat the cutting operation de ned by the data in the plotter s buffer CONDIT...

Page 15: ...0 60 Page Main Menu Submenu MARK INTERFACE STEP SIZE GP GL mode only ORIGIN POINT HP GL mode only ROTATE OPTION1 L UNIT FILM FUNCTION PEN WIDTH UP SPEED OPTION2 CLEAR PEN U D SELECT PEN RS 232C COMMAN...

Page 16: ...ADJ TEST OPTION2 CLEAR PEN U D SELECT PEN NEXT PAGE NEXT PAGE NEXT PAGE F1 F2 F2 F4 F3 F1 F4 F4 F4 F4 SPEED LEVEL CUT MARK T3 SENS STEP DIST ADJ ADJ SENS OFFSET SENS OPT MODE TYPE SIZE EXPAND MARK PA...

Page 17: ...ts they will damage the casing s nish If the writing panel becomes dirty wipe it using a dry cloth In case of stubborn stains use a cloth that has been moistened in a neutral detergent diluted with wa...

Page 18: ...13 LIST OF TOOLS 5 LIST OF TOOLS Colex gauges 20g 50g 100g 200g 500g Push pull gauges 1kg 2kg 10kg Ceramic Pen Cutter Pen Plunger Steal Scale Up to 30mm Personal Computer Centronics Interface Cable Ga...

Page 19: ...m Before performing any work turn off the power switch and unplug the power cord to ensure electrical safety 6 1 2 Con rmation Before and After Operations Before and after any operation perform the fo...

Page 20: ...ide in addition to the Rail Cover To replace the Rail Cover reverse the above procedure M3L6 binding head screws M3L6 binding head screws 6 3 Removing the Front and Rear Y End Covers Unfasten the M3L8...

Page 21: ...n left back side on the main unit s rear side followed by Corner Covers A and B To replace the Corner Cover reverse the above procedure Corner Cover B Corner Cover 50L M4L8 binding head screw M3L10 ta...

Page 22: ...at the top and two TP screws at the bottom followed by the Interface Cover To replace the Interface Cover reverse the above procedure M4L6 binding head screw 6 7 Removing the Rear Cover Remove Corner...

Page 23: ...peration Panel To replace the Operation Panel reverse the above procedure M3L6 binding head screw 6 9 Removing the Operation Tray Remove the two screws securing the Corner Cover 50L left side at the c...

Page 24: ...PLACEMENT PROCEDURES 6 10 Changing Pen Blocks Remove the Y Rail Cover Unfasten the two screws securing the Carriage Cover and then remove the Carriage Cover FC4200 50 FC4200 60 Unfasten the screws FC4...

Page 25: ...tach a Pen Block reverse the above procedure after adjusting the Pen Block tting height The Pen Block height must be adjusted to within 10 mm 10 5 mm for FC4210 60 from the Writing Panel to the bottom...

Page 26: ...EMENT PROCEDURES 6 11 Adjusting the Pen Block Height The Pen Block height needs be adjusted when attaching a Pen Block Position the Pen Block within 10 mm 10 5 mm for FC4210 60 from the Writing Panel...

Page 27: ...in unit Press the belt downward at the middle part of the X Rail where a screw hole is opened and at the position where the belt is in contact with the X Rail adjust the X belt tension to the followin...

Page 28: ...pper Press the rail side belt at the middle part of the Y Rail and at the position where the belt is in contact with the Y Rail adjust the Y belt tension to the following values FC4200 50 600 20 gf FC...

Page 29: ...51 03 9370 24 REPLACEMENT PROCEDURES 6 14 Adjusting the X and Y Motor Synchro Belt Tension For both X and Y motors of the FC4200 50 60 and FC4210 60 adjust the synchro belt tension to 2 0 0 2 kgf X mo...

Page 30: ...5 Setting the Origin Position FC4200 50 Adjust the drawing origin to a position 7 5 mm 24 mm from the printing lines of the electrostatic adhesion panel To set the origin or home position follow the p...

Page 31: ...ROCEDURES 6 16 Setting the Origin Position FC4200 60 Adjust the drawing origin to a position 87 mm 20 mm from the left edge of the XR rail To set the origin or home position follow the procedure in Se...

Page 32: ...RES 6 17 Setting the Origin Position FC4210 60 Adjust the drawing origin to a position 13 mm 20 mm from the bottom left edge of the writing panel To set the origin or home position follow the procedur...

Page 33: ...FC4200 UM 251 03 9370 28 REPLACEMENT PROCEDURES 6 18 About the Position of the Register Sensor Height Adjust the sensor height from the sensor edge to the writing panel to 5 mm...

Page 34: ...mm Pasting X Paste the measure at the position at which the 0 on the measure is set 7 5 mm from the honeycomb edge along the X axis and the measure is vertically aligned with the honeycomb edge Y Pas...

Page 35: ...re at the position at which the 0 on the measure is 5 mm from the left edge of the X Rail along the X axis and the measure is vertically aligned with the honeycomb edge Y Paste the measure at the posi...

Page 36: ...e at the position at which the 0 on the measure is 13 mm from the left edge of the honeycomb edge the X axis and the measure is vertically aligned with the honeycomb edge Y Paste the measure at the po...

Page 37: ...CEMENT PROCEDURES 6 22 Pen Sense Rubber Pasting Position FC4200 50 60 only Paste 1 Pen Sense Rubber at the position shown below 3 2 2 5 25 2 5 The pasting position is accepted if the pen is within the...

Page 38: ...23 Replacing the Main Board Open the main control box Main Board Disconnect all cables from the main board Remove the all screws securing the main board To replace the main board reverse the above pro...

Page 39: ...0 50 6 7 8 2 Adjustment mode 1 ON OFF 2 3 4 5 FC4200 60 FC4210 60 6 7 8 1 ON OFF 2 3 4 5 FC4200 50 6 7 8 3 NOVRAM clear 1 ON OFF 2 3 4 5 FC4200 60 FC4210 60 6 7 8 1 ON OFF 2 3 4 5 FC4200 50 6 7 8 4 Em...

Page 40: ...or and ex cable connectors before performing the write 2 Set the DIP switch to Normal mode or Adjustment mode 3 Hold down both the Right and Left POSITION keys while turning on the power When you hear...

Page 41: ...splay the following FORCE SPEED OFFSET QUALITY F1 F3 F4 F2 PROGRAM RECEIVING KB COMPLETE Number of bytes transferred As the rmware data is successfully transferred the number of transferred bytes show...

Page 42: ...ower supply J10 are connected to the main board Set the DIP switch as shown below and switch on power 1 ON OFF 2 3 4 5 FC4200 60 FC4210 60 6 7 8 1 ON OFF 2 3 4 5 FC4200 50 6 7 8 1 The LCD displays the...

Page 43: ...mode and switch on power 2 The LCD displays the following FORCE SPEED OFFSET QUALITY F1 F3 F4 F2 SET SUFFIX STD V Firmware version 3 Press the F4 key to change the suf x display Adjust to the one spec...

Page 44: ...e LCD displays the follow ing FORCE SPEED OFFSET QUALITY F1 F3 F4 F2 0 0 MAX 3 Place white paper for adjustment use on the panel making sure that no part of it is raised above the sur face Move the ma...

Page 45: ...Use the F1 through F4 keys to adjust pen pressure until the pressure is within 24 1 g After adjustment press the Enter key to go to the next step Target pen pressure F1 key Increases pen pressure by...

Page 46: ...nge height adjustment value 5 Press the F3 key to prompt the plotter to perform a pen exchange and pen placement operations Adjust the Y and H values until the plotter can execute pen exchange and pen...

Page 47: ...SET QUALITY F1 F3 F4 F2 MOVE HOME POINT PRESS ENTER KEY 4 Attach a pen type magni er to the cutter holder and move to the home position using the position key After con rming the position press the En...

Page 48: ...measure the lengths of X and Y reference lines and diagonal lines 4 Select F4 to switch to a distance adjustment value input screen FORCE SPEED OFFSET QUALITY F1 F3 F4 F2 DISTANCE ADJUST X 10 Y 10 En...

Page 49: ...FC4200 UM 251 03 9370 44 ELECTRICAL SECTION 7 When the adjustment is complete press the Next Page key to nish...

Page 50: ...til the LCD displays the following FORCE SPEED OFFSET QUALITY F1 F3 F4 F2 MARK ADJUST PRESS ENTER KEY 4 Press the Enter key The LCD display changes to display the following FORCE SPEED OFFSET QUALITY...

Page 51: ...performs carriage pen check operations This is a two step operation after retracting to the 1st position the plotter performs a pen down operation at the 2nd position 4 Press the TEST key to prompt th...

Page 52: ...computer The LCD displays the following FORCE SPEED OFFSET QUALITY F1 F3 F4 F2 GAIN SET X 65 Y 60 4 Adjust the gain until MAX ERROR is equal to or less than 7 F1 Increases the X gain F3 Increases the...

Page 53: ...ition in the electrical box shown below Power supply Inlet SW Record position Main board The contents of an example record are shown below 88 308 562 Pen pressure adjusted values 84 305 559 2nd Pen pr...

Page 54: ...justment Pen exchange adjustment Home position adjustment Gain adjustment Distance accuracy adjustment Main board Note 1 Pen relay board X home sensor Mark sensor Pen block XY motor XY timing belt rep...

Page 55: ...arts on the Main Board TP4 DIP SW TP1 TP3 TP2 TP5 Centronics Checking Voltage Levels The output voltage levels Main Board Pin No Output valtage Permissible range TP1 34V 33 5V to 34 5V TP2 12V 11 5V t...

Page 56: ...Supply Voltage 1 Check that the plotter s POWER switch is off 2 Open the chassis of the Main Control Box Power Unit 3 Connect the power unit s cable to the required connector Voltage series Correspon...

Page 57: ...eck them all at once Setting Procedure 1 Load a medium of A4 size or larger in the plotter 2 Press the PAUSE key then press the NEXT PAGE key until the menu below appears FORCE SPEED OFFSET QUALITY F1...

Page 58: ...dure 1 Load a medium of A3 size or larger in the plotter 2 Press the PAUSE key then press the NEXT PAGE key until the menu below appears FORCE SPEED OFFSET QUALITY F1 F3 F4 F2 OPTION1 OPTION2 3 Press...

Page 59: ...rocedure 1 Load a medium of A4 size or larger in the plotter FORCE SPEED OFFSET QUALITY F1 F3 F4 F2 OPTION1 OPTION2 2 Press the PAUSE key then press the NEXT PAGE key until the menu below appears FORC...

Page 60: ...t the plotter doesn t operate The plotter isn t being supplied with power Check that the power cord is properly plugged into the plotter s AC inlet and the electrical outlet The plotter has broken dow...

Page 61: ...or smoother curves The OFFSET ANGLE setting is too low Raise the OFFSET ANGLE setting The medium s corners peel off The medium peels off when cutting small characters The cutter s blade is extended to...

Page 62: ...ify the AREA setting Computer output to the plotter speci es an image that exceeds the effective area Rewrite your data to specify a smaller image Cutting conditions cannot be retained or changed The...

Page 63: ...nsor passes Firmly secure the medium so that it will not come loose Use a medium without any wrinkles creases or folds The medium is not white Use a white medium The registration marks are not printed...

Page 64: ...ge s movement After removing the obstacle turn the plotter off then back on again An external load was applied to the pen carriage during operation After removing the obstacle turn the plotter off the...

Page 65: ...s interface conditions ERROR 4 Parameter Over ow The numeric parameter of an input command exceeds its permissible range Con gure your software application menu to permit Graphtec plotter control Re s...

Page 66: ...character set that the plotter will recognize ERROR 6 Position over ow A command was issued with coordinate data that exceeds the effective cutting plotting area Issue the command with its coordinate...

Page 67: ...ons by Media Type Medium Thickness mm Blade used FORCE SPEED QUALITY Film for outdoor signs 0 05 to 0 08 CB09UA 10 to 14 30 or less 2 to 3 Decorative film 0 08 to 0 1 CB09UA 14 to 17 30 or less 2 to 3...

Page 68: ...a coarser nish but shortens the overall cutting plotting time Lowering the SPEED and QUALITY settings results in a ner nish but lengthens the overall cutting plotting time Precautions on Cutting Rubbe...

Page 69: ...set of cutting conditions you must rst select the destination COND No By selecting a different COND No you can easily switch between pre de ned cutting conditions for four types of media Procedure 1 P...

Page 70: ...peci ed In addition ne adjustment of the pre registered OFFSET value for each blade type is possible within a 5 range Setting Procedure 1 Press a function key from F1 to F4 to select the COND No of th...

Page 71: ...ions to be edited 2 Press the CONDITIONS key to display the menu below for specifying the cutting conditions FORCE SPEED OFFSET QUALITY F1 F3 F4 F2 12 COND1 09U 0 30 CHANGE PEN1 4 3 Press the F1 FORCE...

Page 72: ...edited 2 Press the CONDITIONS key to display the menu below for specifying the cutting conditions FORCE SPEED OFFSET QUALITY F1 F3 F4 F2 12 COND1 09U 0 30 CHANGE PEN1 4 3 Press the F2 SPEED key to mov...

Page 73: ...for specifying the cutting conditions FORCE SPEED OFFSET QUALITY F1 F3 F4 F2 12 COND1 09U 0 30 CHANGE PEN1 4 3 Press the F4 QUALITY key to move the blinking cursor to the lower right position as shown...

Page 74: ...K MODE2 STR 0MM END 0MM 4 Press the F1 MODE 1 or F3 MODE 2 key to move the asterisk symbol and select MODE 1 or 2 MODE 1 Overcutting is performed at the starting and end points of cutting as well as a...

Page 75: ...wish to start the cutting test Caution The cutter pen will start moving as soon as the TEST function is selected so be sure to keep your hands hair and so forth away from the plotter s moving parts 5...

Page 76: ...f the triangle s Ideally only slight traces of the cutter blade should remain on the medium s base sheet If the base sheet has been cut through either the FORCE setting is too high or the cutter blade...

Page 77: ...2190140 P4 Y Tension Pulley P4 Y Tension Pulley 622190350 Inertia Pulley Z24 Inertia Pulley Z24 500050538 4200 Fan TUDC24B4 602 772219560 4200 Control Panel Relay Board Control Panel Relay Board 77221...

Page 78: ...Operation Tray 4250 FC4200 50 1 622195561 Operation Tray 4260 FC4200 60 FC4210 60 1 7 022550130 Front Cover 50H FC4200 50 1 622195540 Front Cover 4260 FC4200 60 FC4210 60 1 8 054225030 Front Cover A2...

Page 79: ...FC4200 UM 251 03 9370 74 PART LIST External Casing...

Page 80: ...Pulley 60 X Intermediate Pulley 60 1 8 622190130 X Tension Pulley X Tension Pulley 2 9 622190151 Pulley S2M Z30 Pulley S2M Z30 2 10 370801091 X Drive Belt Belt 120S2M160V 1 11 622190401 X Slide Belt...

Page 81: ...FC4200 UM 251 03 9370 76 PART LIST Main Frame X Slide Section and X Drive Section...

Page 82: ...FC4200 UM 251 03 9370 77 PART LIST X Rear Slide Section for FC4210 60 14 15 23 24 21 22 20...

Page 83: ...Insulating Sheet B FC4200 50 FC4200 60 1 095704040 Insulating Sheet B FC4210 60 2 20 617363321 LB4YC Assembly FC4200 50 FC4200 60 1 621214000 LM6L Assembly FC4210 60 2 21 619003360 Bearing Roller Bas...

Page 84: ...R1228 FC4200 50 FC4200 60 1 500050535 Mark Sensor KR1228 FC4210 60 2 40 772219530 4200 Pen Board FC4200 50 FC4200 60 1 772121520 4210 Pen Board FC4210 60 1 40 1 508000015 Y Home Sensor GP1A53HR 1 41 5...

Page 85: ...FC4200 UM 251 03 9370 80 PART LIST Y Bar Y Slide Section Y Drive Section and Pen Block Section 46 45...

Page 86: ...FC4200 UM 251 03 9370 81 PART LIST Y Slide Section for FC4210 60 43 44 8 40 10 Y Drive Section for FC4210 60 48 47 49 Pen Block Section for FC4210 60 31 42 32 37 24...

Page 87: ...FC4200 UM 251 03 9370 82 PART LIST Registration Mark Sensor Section for FC4210 60 39 17...

Page 88: ...ply PS089B 1 4 772219560 Control Panel Relay Board 4200 Control Panel Relay Board 1 5 508000025 Power Supply SW JWA2120 0033 1 6 518000033 Inlet SUP B3G E 1 7 792420100 4200 Main Board 4200 Main Board...

Page 89: ...FC4200 UM 251 03 9370 84 PART LIST Electrical Section...

Page 90: ...21219010 Adhesive sheet Adhesive sheet FC4210 60 1 8 621219020 Application Sheet Application Sheet FC4210 60 1 9 622190810 Packing Box for FC4200 50 Packing Box FC4250 1 622190800 Packing Box for FC42...

Page 91: ...CA905003 PR905005 J3 J4 J2 J4 J4 J3 X FLEX J2 J22 Y MOTOR NC J18 CENTRONICS PR905001 MAIN BOARD J9 J10 J2 J20 RS 232C J19 FC4200 50 ONLY CA905004 J5 J1 J3 J2 J4 PR905002 CA2252 11 PR06704 CA905002 PR...

Page 92: ...MC FPC601103 ENCORER MC CA905007 PR905005 PR905005 J3 J1 J4 J2 J4 J4 J3 X FLEX J2 J22 Y MOTOR NC J18 CENTRONICS PR905001 MAIN BOARD J9 J10 J2 J20 RS 232C J19 J5 J1 J3 J2 J4 PR905002 CA2252 11 PR06704...

Page 93: ...FC4200 UM 251 03 9370 88 CIRCIT DIAGRAMS 12 2 Main Board Main Board 1 10...

Page 94: ...FC4200 UM 251 03 9370 89 CIRCIT DIAGRAMS Main Board 2 10...

Page 95: ...FC4200 UM 251 03 9370 90 CIRCIT DIAGRAMS Main Board 3 10...

Page 96: ...FC4200 UM 251 03 9370 91 CIRCIT DIAGRAMS Main Board 4 10...

Page 97: ...FC4200 UM 251 03 9370 92 CIRCIT DIAGRAMS Main Board 5 10...

Page 98: ...FC4200 UM 251 03 9370 93 CIRCIT DIAGRAMS Main Board 6 10...

Page 99: ...FC4200 UM 251 03 9370 94 CIRCIT DIAGRAMS Main Board 7 10...

Page 100: ...FC4200 UM 251 03 9370 95 CIRCIT DIAGRAMS Main Board 8 10...

Page 101: ...FC4200 UM 251 03 9370 96 CIRCIT DIAGRAMS Main Board 9 10...

Page 102: ...FC4200 UM 251 03 9370 97 CIRCIT DIAGRAMS Main Board 10 10...

Page 103: ...FC4200 UM 251 03 9370 98 CIRCIT DIAGRAMS 12 3 Control Panel Relay Board...

Page 104: ...FC4200 UM 251 03 9370 99 CIRCIT DIAGRAMS 12 4 Y Motor Relay Board...

Page 105: ...FC4200 UM 251 03 9370 100 CIRCIT DIAGRAMS 12 5 Pen Board Pen Board for FC4200 50 and FC4200 60...

Page 106: ...FC4200 UM 251 03 9370 101 CIRCIT DIAGRAMS Pen Board for FC4210 60...

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