GRAPHTEC FC2240 User manual

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

FC2240-UM-251-9370 i
HISTORY OF REVISIONS
No. Date issued Description of revision Page Edition
1 05.11.24 First Printing All 01
2 06.04.24 Part number for the Y flexible cable corrected. 10-10 02
3 06.05.26 Part number for the control panel switch corrected. 5-1, 10-5 03
4 06.05.26 Part number for the main relay board corrected. 5-1, 10-5 03
5 06.09.07 Part number for the control panel switch corrected. 5-1 04

FC2240-UM-251-9370 ii
CONTENTS
1. INTRODUCTION .............................................................1-1
1.1 Model Names and Basic Specifications .........................................................1-1
1.2 Standard Accessories ......................................................................................1-1
1.3 Main Specifications ..........................................................................................1-2
1.4 External Dimensions ........................................................................................1-3
1.5 Stand Assembly Procedure .............................................................................1-6
1.6 Mounting Procedure .........................................................................................1-7
1.7 Removing the Y Bar Retaining Brackets ........................................................1-8
1.8 Selecting the Vacuum Pump ............................................................................1-9
1.9 Installation Location .......................................................................................1-10
2. Description of Parts ......................................................2-1
2.1 Plotter Nomenclature .......................................................................................2-1
2.2 Control Panel ....................................................................................................2-2
2.3 Types of Cutter Blades and Their Features ....................................................2-4
2.4 Cutter Pen Nomenclature .................................................................................2-5
3 Basic Operation .............................................................3-1
3.1 Replacing the Cutter Blade ..............................................................................3-1
3.2 Adjusting the Blade Length .............................................................................3-3
3.3 Mounting the Cutter Pen ..................................................................................3-4
3.4 Adjusting the Pen Carriage Height .................................................................3-5
3.5 Turning On the Plotter and Initialization .........................................................3-6
3.6 Loading the Medium .........................................................................................3-7
3.7 PAUSE Menu Configuration .............................................................................3-8
3.8 Setting the Cutting Conditions ........................................................................3-9
3.9 Running a Cutting Test ..................................................................................3-12
3.10 Achieving Optimum Cutting Results ............................................................3-13
3.11 Listing the Cutting Conditions ......................................................................3-14
3.12 Using the Character Dump Mode ..................................................................3-16
3.13 Running the Self Test .....................................................................................3-17

FC2240-UM-251-9370 iii
4. Daily Maintenance and Storage ...................................4-1
5. RECOMMENDED PARTS LIST .....................................5-1
6. LIST OF TOOLS .............................................................6-1
6.1 Tools ..................................................................................................................6-1
7. DISASSEMBLY AND ADJUSTMENT ............................7-1
7.1 Adjusting the X-Axis Drive ...............................................................................7-1
7.1.1 Removing the X Motor Cover ................................................................................................................. 7-1
7.1.2 Adjusting the X Drive Belt Tension ........................................................................................................ 7-1
7.1.3 Adjusting the Belt Tension of the Front X Slider .................................................................................. 7-2
7.1.4 Adjusting the Belt Tension of the Rear X Slider ................................................................................... 7-2
7.1.5 Checking the Belt Tension of the Front and Rear X Sliders ................................................................ 7-3
7.2 Adjusting the Y-Axis Drive ...............................................................................7-4
7.2.1 Removing the Y Motor Cover ................................................................................................................. 7-4
7.2.2 Removing the Y Motor ............................................................................................................................. 7-4
7.2.3 Adjusting the Y Drive Belt Tension ........................................................................................................ 7-6
7.3 Adjusting the Y Slider ......................................................................................7-7
7.3.1 Removing the Y Bar ................................................................................................................................. 7-7
7.3.2 Adjusting the Y Slider Belt Tension ....................................................................................................... 7-8
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
7.7 Adjusting the Position of Sensor Dog Y .......................................................7-13
7.8 Mounting the Y Slider on the Y Flexible Printed Circuit Cable ...................7-14
7.9 Pen Block ........................................................................................................7-15
7.9.1 Removing the Pen Block Cover ........................................................................................................... 7-15
7.9.2 Removing the Pen Block ...................................................................................................................... 7-15
7.9.3 Adjusting the Pen Block ....................................................................................................................... 7-16
7.10 Using the Mechanical Adjustment Jigs ........................................................7-18
7.11 Replacing the Y Bar ........................................................................................7-19
7.11.1 Preparations ........................................................................................................................................... 7-19
7.11.2 Replacing the Y Bar ............................................................................................................................... 7-19
7.11.3 Checking the Sliding of the Y Bar Frame (Manual Check) ................................................................. 7-20
7.12 Adjusting the Perpendicularity Precision ....................................................7-21
7.12.1 Checking the Deviation in the Perpendicularity ................................................................................. 7-21

FC2240-UM-251-9370 iv
7.13 Replacing the Electrostatic Adhesion Plate .................................................7-23
7.13.1 Peeling Off the Electrostatic Adhesion Plate ...................................................................................... 7-23
7.13.2 Preliminary Preparations for Pasting On New Plate .......................................................................... 7-23
7.13.3 Attaching the Electrostatic Adhesion Plate ........................................................................................ 7-25
8. ELECTRICAL ADJUSTMENTS ......................................8-1
8.1 Flowchart of the Adjustment Sequence ........................................................8-1
8.2 Location of the Boards .....................................................................................8-2
8.2.1 Main Relay Board (PN5042-01) ............................................................................................................... 8-3
8.2.2 X Flex. Board (PR223226) ....................................................................................................................... 8-3
8.3 Setting the Power Unit’s Supply Voltage (PS089B) .......................................8-4
8.4 Checking the Power Unit’s Supply Voltage ....................................................8-5
8.4.1 Checking the Voltage Levels .................................................................................................................. 8-5
8.4.2 The Protective Circuit ............................................................................................................................. 8-5
8.5 Explanation of the Values of the Main Board .................................................8-6
8.6 Setting the DIP Switches ..................................................................................8-7
8.7 Updating the System Firmware .......................................................................8-8
8.8 Clearing the Non-Volatile RAM ......................................................................8-10
8.9 Adjusting the Home Position .........................................................................8-12
8.10 Adjusting the Pen Height ...............................................................................8-13
8.11 Adjusting the Pen Force ................................................................................8-14
8.12 Adjusting the Distance and the Perpendicularity Accuracy .......................8-16
8.13 Adjusting the Pen Interval .............................................................................8-18
8.14 DIP Switch Factory Settings ..........................................................................8-19
8.15 Factory Preset Settings ..................................................................................8-19
8.16 Testing the Control Panel Keys and Home Sensors ...................................8-21
8.17 List of Items Requiring Readjustment ..........................................................8-23
9 TROUBLESHOOTING ....................................................9-1
9.1 Troubleshooting Flowcharts ............................................................................9-1
9.1.1 Checking for Faulty Rotation of the Blade ............................................................................................ 9-1
9.1.2 The Cutting Media Cannot be Satisfactorily Cut .................................................................................. 9-2
9.1.3 Initialization is Abnormal ........................................................................................................................ 9-8
9.1.4 Pen UP/DOWN Operations are Abnormal .............................................................................................. 9-9
9.1.5 The X-axis Backlash is Excessive ........................................................................................................9-11
9.1.6 The Y-axis Backlash is Excessive ........................................................................................................ 9-12

FC2240-UM-251-9370 v
9.2 The Plotter is Turned On But Doesn’t Operate ............................................9-13
9.3 Error Messages ...............................................................................................9-14
9.4 Error Messages in GP-GL Command Mode .................................................9-15
9.5 Error Messages in HP-GL Emulation Mode ..................................................9-16
9.6 The Cutting Results are Unsatisfactory .......................................................9-18
10. PARTS LISTS ...............................................................10-1
10.1 Mainframe ........................................................................................................10-1
10.2 Stand ................................................................................................................10-3
10.3 Control Panel ..................................................................................................10-4
10.4 Control Unit .....................................................................................................10-5
10.5 X Drive Unit .....................................................................................................10-6
10.6 Y Drive Section ...............................................................................................10-9
10.7 Standard Accessories ..................................................................................10-12
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS ........ 11-1
11.1 Wiring Connection ..........................................................................................11-1
11.2 Key Relay Board (PR223281) .........................................................................11-3
11.3 Main Relay Board (PN5042-01A) ...................................................................11-4
11.4 X Relay Board (PR223203) .............................................................................11-6
11.5 X Flex. Board (PR223224A) ............................................................................11-7
11.6 X-Y Relay Board (PN5042-02A) ......................................................................11-8
11.7 Pen Flex. Board (PR223226A) ........................................................................11-9
11.8 2-Pen Relay Board (PR223229A) .................................................................11-10
11.9 2-Pen Board (PR223227A) ............................................................................ 11-11
11.10 High Voltage Board (PR31001C) ..................................................................11-12
11.11 Main Board (PR306101) ...............................................................................11-13
11.12 Miscellaneous ...............................................................................................11-25

FC2240-UM-251-9370 vi

FC2240-UM-251-9370 1-1
1. INTRODUCTION
1. INTRODUCTION
1.1 Model Names and Basic Specifications
Model No. of pens Media hold down method Cutting area
FC2240-60VC 2 Vacuum suction 610 (X) x 920 (Y) mm
FC2240-120MG 2 Magnetic
1200 (X) x 920 (Y) mmFC2240-120ES 2 Electrostatic adhesion
FC2240-120VC 2 Vacuum suction
FC2240-180ES 2 Electrostatic adhesion 1740 (X) x 920 (Y) mm
FC2240-180VC 2 Vacuum suction
1.2 Standard Accessories
Item Description Q’ty
Power cable 1
Cutter pen set PPA31-CB15B, CB15U-2SP, CB15U-K30-5SP 1 set
Water based fiber-tip pen KF552-BK 1
Sheet holder plates For MG models only (2 large, 2 medium, 4 small) 1 set
Hexagon wrench For M4 bolts 1
Height adjustment plates 10 mm, 4 mm height 1 of each
Paper alignment seals 1 pack
Durable flexible hose For VC models only, 1.5 m to 5 m (can expand/contract)
Connection bore diameter: Ø38mm (-60), Ø58mm (-120/180) 1
Hose band For VC models only 2
Vacuum pump installation base For VC models only 1
CD-ROM User’s manual, Driver, other software 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 1-2
1. INTRODUCTION
1.3 Main Specifications
FC2240-60VC FC2240-120VC/MG/ES FC2240-180VC/ES
Configuration Flatbed
Effective cutting area 610 x 920 mm 1200 x 920 mm 1740 x 920 mm
Media hold-down method VC models: Vacuum suction, MG models: Magnetic,
ES models: Electrostatic adhesion
Maximum cutting speed 400 mm/sec (40-step range)
Cutting force High force mode: 9.8 N (1 kgf) max : 40-step range 2 to 80
Standard force mode: 4.9 N (500 gf) max : 40-step range 1 to 40
Minimum character size About 10 mm square (varies with the character font and cutting media)
Mechanical resolution 0.0025 mm
Programmable resolution GP-GL mode: 0.1/0.05/0.025/0.01 mm, HP-GLTM mode: 0.025 mm
Distance accuracy Within 0.1% of the distance moved (plotter mode)
Perpendicularity Within 0.5 mm/900 mm (plotter mode)
Repeatability Within 0.1 mm (plotter mode)
Number of pens/cutters 2
Cutter and pen types Cutter blades: Supersteel
Pens: water-based fibertip, oil-based ballpoint, disposable ink pen*1
Cutting media Marking film (vinyl, fluorescent, reflective), Stiff paper/card up to 0.5 mm
thick, Sandblast rubber sheets up to 1 mm thick, High-intensity reflective
film. Polystyrene foam sheets
Interfaces RS-232C, Centronics, USB 2.0 (full speed); auto-switching
Buffer memory 2 MB
Command sets GP-GL and HP-GLTM emulation
LCD panel 20 characters x 2 lines
Power supply 100-120 VAC, 50/60 Hz, 1.2 A max
220-240 VAC, 50/60 Hz, 0.7 A max
Operating environment 10 to 35˚C, 35 to 75% RH (non-condensing)
Guaranteed precision
operating environment
16 to +32˚C, 35% to 70% RH (non-condensing)
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) Approx. 58 kg Approx. 69 kg Approx. 74 kg
Option Vacuum pump (Blower) [VC models only]
*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.