GRAPHTEC CE5000-40CRP User manual

CE5000-UM-251-09-9370
CE 5000 Series
SERVICE MANUAL
MANUAL NO. CE5000-UM-251
CUTTING PLOTTER

CE5000-UM-251-9370 ii
HISTORY OF REVISIONS
No. Date issued Description of revision Page Edition
1 06.07.06 First Printing All 01
2 06.09.13 Information for the 9e60p was added. 10-1,10-12 02
3 06.09.13 Part list for the steel stand ST0068 was added. 10-9 02
4 06.09.13 Part number for the main board of the CE5000-40 was corrected. 4-1,10-1 02
5 06.09.26 Procedure of upgrading the system firmware was corrected. 7-13 03
6 06.09.26 Section numbers were corrected. 11-10 to 11-12 03
7 06.11.07 Procedure of adjusting the pen force was corrected. 7-4 04
8 06.11.16 Footer of page was wrong. 4-1 05
9 06.11.16 Cutting Mat 40 of part number was updated. 4-1,10-3 05
10 06.11.16 Cutting Mat 120 of part number was updated. 4-1,10-3 05
11 07.02.28 Part number for the cutter pen holder was corrected. 10-6 06
12 07.02.28 The cutter pen holder and the pen holder thumb screw L10
were deleted from recommended parts list.
4-1 06
13 07.05.18 CE5000-120AP information added. All 07
14 07.10.19
Remark of the Main Board of CE5000-120AP was corrected. 4-1 08
15 08.03.04 Discription for the roll stocker was corrected. 10-15 09

CE5000-UM-251-9370 iii
CONTENTS
1. INTRODUCTION ..................................................................1-1
1.1 Main Specifications ................................................................................................... 1-1
1.2 External Dimensions .................................................................................................. 1-3
2. PARTS NAMES and FUNCTIONS ..........................................2-1
2.1 Parts Names and Functions ....................................................................................... 2-1
2.2 Assembling the Stand ................................................................................................2-5
2.3 Attaching the Basket (CE5000-60/120: Optional) .................................................... 2-12
3. OPERATIONS .................................................................... 3-1
3.1 Control Panel ............................................................................................................3-1
3.2 Menu List ..................................................................................................................3-2
3.3 Description of Special Functions A .............................................................................3-5
3.4 Description of Special Functions B .............................................................................3-8
4. RECOMMENDED PARTS LIST ............................................. 4-1
5. LIST OF TOOLS ................................................................. 5-1
5.1 Tools .........................................................................................................................5-1
5.2 Greasing And Gluing Points ........................................................................................5-1
5.3 Subparts List .............................................................................................................5-1
6. DISASSEMBLY AND REASSEMBLY ..................................... 6-1
6.1 Exterior Parts ............................................................................................................6-1
6.1.1 How to Replace the Right Side Cover ........................................................................................ 6-1
6.1.2 How to Replace the Left Side Cover .......................................................................................... 6-1
6.1.3 How to Replace the Center Cover (CE5000-40/60) ................................................................... 6-2
6.1.4 How to Replace the Center Cover (CE5000-120/120AP) ...........................................................6-3
6.1.5 How to Replace the Front Guide (CE5000-40/60) ......................................................................6-4
6.1.6 How to Replace the Front Guide (CE5000-120/120AP) ..............................................................6-5
6.1.7 How to Replace the Rear Guide .................................................................................................6-8
6.2 Mechanical Parts .................................................................................................... 6-10
6.2.1 How to Replace the Front and Rear Media Sensors .................................................................. 6-10

CE5000-UM-251-9370 iv
6.2.2 How to Replace the Push Roller .............................................................................................. 6-11
6.2.3 How to Replace the Push Roller Arm ....................................................................................... 6-12
6.2.4 How to Replace the Cam Sensor Board ................................................................................... 6-14
6.2.5 How to Replace the Pen Block ................................................................................................ 6-15
6.2.6 How to Replace the Push Roller Sensor ................................................................................... 6-17
6.2.7 How to Replace the Y-relay Board ........................................................................................... 6-18
6.2.8 How to Replace the Cutting Mat .............................................................................................. 6-19
6.2.9 How to Replace the Control Panel Relay Board, LCD and Membrane Switch Panel .................... 6-20
6.2.10 How to Replace the Y-belt .......................................................................................................6-22
6.2.11 How to Replace the Y-motor ................................................................................................... 6-24
6.2.12 How to Replace the X-motor ...................................................................................................6-26
6.2.13 How to Replace the Y-flexible Cable ........................................................................................ 6-28
6.2.14 How to Replace the Vacuum Fan ............................................................................................. 6-31
6.2.15 How to Replace the Main Board ..............................................................................................6-32
6.2.16 How to Replace the Power Supply ...........................................................................................6-33
6.2.17 How to Replace the Drive Roller ..............................................................................................6-34
7. ELECTRICAL ADJUSTMENTS ...............................................7-1
7.1 DIP Switch Settings ................................................................................................... 7-1
7.2 List of Items Requiring Readjustment ......................................................................... 7-1
7.3 Explanation of the Values of the Main Board Settings ................................................. 7-2
7.4 Clearing the Non-Volatile RAM ................................................................................... 7-3
7.5 Adjusting the Pen Force .............................................................................................7-4
7.6 Adjusting the Distance Accuracy ................................................................................7-6
7.7 Inputting the Servo Gain ............................................................................................7-8
7.8 Setting the Auto-Registration Mark Sensor Option ...................................................... 7-9
7.9 Adjusting the Offset of the Auto-Registration Mark Sensor ....................................... 7-10
7.10 Upgrading the System Firmware .............................................................................. 7-13
7.11 Adjusting the Pen Exchange Y Direction Value (CE5000-120AP) ............................... 7-14
7.12 Adjusting the Pen Exchange Height Value (CE5000-120AP) ...................................... 7-15
7.13 Adjusting the Spacing Between Pen 1 and Pen 2 (CE5000-120AP) ...................................... 7-16

CE5000-UM-251-9370 v
8 SERVICE MODES ................................................................8-1
8.1 Sensor Test Mode ...................................................................................................... 8-1
8.2 Control Panel Membrane Switch Test Mode ................................................................8-2
8.3 Clear Setup Mode ......................................................................................................8-3
9. TROUBLESHOOTING .......................................................... 9-1
9.1 The Plotter is Turned On But Doesn’t Operate .............................................................9-1
9.2 Media Loading Operations .........................................................................................9-2
9.3 Cutting Operations ....................................................................................................9-3
10. PARTS LIST ......................................................................10-1
10.1 Outer Casing ........................................................................................................... 10-1
10.2 Main Frame for CE5000-40/60 ...............................................................................10-3
10.3 Main Frame CE5000-120/120AP .............................................................................10-5
10.4 Pen Block ................................................................................................................ 10-7
10.5 Wiring Harness ........................................................................................................10-9
10.6 Stand (CE5000-60, CE5000-120, CE5000-120AP) ................... 10-10
10.7 Option Basket ........................................................................................................ 10-15
10.8 Other Parts ........................................................................................................... 10-15
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS ..................... 11-1
11.1 Block Diagrams ....................................................................................................... 11-1
11.1.1 Block Diagram for CE5000-120 .............................................................................................. 11-1
11.1.2 Block Diagram for CE5000-40/60 .......................................................................................... 11-2
11.2 Circuit Diagrams ..................................................................................................... 11-3
11.2.1 Main Board Top Section (PN5043-01A) ................................................................................... 11-3
11.2.2 Main Board Connector Block Section (PN5043-01A) ............................................................... 11-4
11.2.3 Main Board CPU Block Section (PN5043-01A) ......................................................................... 11-5
11.2.4 Main Board Motor Drive Section (PN5043-01A) ....................................................................... 11-6
11.2.5 Main Board FPGA Section (PN5043-01A) ................................................................................ 11-7
11.2.6 Main Board Interface Section (PN5043-01A) ........................................................................... 11-8
11.2.7 Main Board Memory Block Section (PN5043-01A) .................................................................. 11-9
11.2.8 Relay and Sensor Board Section ............................................................................................11-10
11.2.9 Control Panel Membrane Switch Panel Section ......................................................................11-11

CE5000-UM-251-9370 vi
11.2.10 120-Relay Board Section .......................................................................................................11-12
11.2.11 120-Pen Encoder Flexible Cable Section (PN5043-10) ...........................................................11-12

CE5000-UM-251-9370 1-1
1. INTRODUCTION
1. INTRODUCTION
CAUTION
DOUBLE POLE/NEUTRAL FUSING
1.1 Main Specifications
CE5000-40CRP/60/120
Item CE5000-40CRP CE5000-60 CE5000-120
CPU 32-bit CPU
Configuration Grit rolling
Drive system Digital servo
Maximum cutting area 375 mm x 50 m 603 mm x 50 m 1213 mm x 50 m
Range of guaranteed precision 356 mm x 5 m*1 584 mm x 5 m*1 1194 mm x 5 m*1
Compatible media widths Minimum: 50 mm
Maximum: 482 mm
(19 inches)
Minimum: 50 mm
Maximum: 712 mm
(28 inches)
Minimum: 85 mm
Maximum: 1346 mm
(52 inches)
Maximum media thickness 0.25 mm
Maximum cutting speed 60 cm/s (in all directions) 100 cm/s (45° direction)
Specifiable cutting speeds 1–10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60 cm/s 1–10, 15, 20, 25, 30, 35, 40, 45,
50, 55, 60, * cm/s
Cutting force 0.2 to 2.3 N
(20 gf to 300 gf) (31 levels)
0.2 to 4.4 N
(20 gf to 450 gf) (38 levels)
Minimum character size Approximately 5 mm for alphanumeric characters (varies depending on the medium, font, etc.)
Mechanical resolution 0.005 mm
Programmable resolution GP-GL: 0.1/0.05/0.025/0.01 mm; HP-GLTM *2: 0.025 mm
Repeatability precision 0.1 mm or less per 2 m*1
No. of pens mountable 1 pen
Compatible cutter type Supersteel cutter blades
Compatible pen type Water-based fiber-tip pens
Compatible cutting film Marking film (PVC, fluorescent, or reflective film) up to 0.25 mm in thickness
(excluding high-luminosity reflective film)
Interfaces RS-232C/USB (Full Speed)
Buffer capacity 2 MB
Command modes GP-GL, HP-GLTM *2 (selected on the control panel)
Display panel Liquid crystal display (16 characters x 1 row)
Rated power supply 100 to 240 V AC, 50/60 Hz
Power consumption 100 VA
Operating environment 10°C to 35°C, 35% to 75% RH
Conditions for guaranteed precision 16°C to 32°C, 35% to 70% RH
External dimensions (W x D x H) Approx.
623 x 285 x 223 mm
Approx.
851 x 585 x 1004 mm
*3
Approx.
1,487 x 744 x 1194 mm
*3
Weight Approx. 9.4 kg Approx. 25 kg
*3
Approx. 39.1 kg
*3
*1: Varies depending on the type of Graphtec-authorized film and the cutting conditions
*2: HP-GLTM is a registered trademark of Hewlett-Packard Company.
*3: Including the stand

CE5000-UM-251-9370 1-2
1. INTRODUCTION
CE5000-120AP
Item CE5000-120AP
CPU 32-bit CPU
Configuration Grit rolling
Drive system Digital servo
Maximum cutting area 1164 mm x 50 m
Maximum guaranteed cutting area 1164 mm x 3 m*1
Compatible media widths
Media widths 160 to 270, 300 to 400, 440 to 540, 580 to 680, 710 to 810, 850 to
950, 990 to 1090, 1120 to 1220 mm (the effective drawing area is the
maximum obtainable area for the corresponding medium width) Up to
1180 mm when roll media (2-inch core) is used
Maximum roll outer diameter 190 mm
Media types Fine quality paper for apparel patterns (64 to 130 g/m2)
Roll media diameter: 2-inch, 3-inch
Maximum cutting speed 60 cm/s
Specifiable cutting speeds 1 to 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60 cm/s
Cutting force 20 to 300 gf (31 levels)
Mechanical resolution 0.005 mm
Programmable resolution GP-GL: 0.1/0.5/0.025/0.01 mm, HP-GLTM *3: 0.025 mm
Repeatability precision
Mechanical precision Within 0.1 mm/3m*2
Guaranteed precision Within ±0.5 mm/3 m, up to a maximum of five consecutive pages*1
(cutter pen/plotter pen exchange precision is also included)
No. of pens mountable 2
Compatible cutter blade type Supersteel
Compatible pen type Water-based fiber-tip pens, Oil-based ballpoint pen
Interfaces RS-232C/USB 2.0 (Full speed)
Buffer capacity 2 MB
Command modes GP-GL, HP-GLTM *3 (selected on the control panel)
Display panel LCD (16 characters x 1 row)
Rated power supply 100 to 240 V AC, 50/60 Hz
Power consumption 100 VA
Operating environment 10°C to 35°C, 35% to 75% RH
Conditions for guaranteed precision 16°C to 32°C, 35% to 70% RH
External dimensions (W x D x H) Approx. 1,487 x 656 x 1189 mm
Weight 43 kg
*1: When the following Graphtec-specified conditions have been met:
• Graphtec-specified paper must be used for cutting/plotting.
• “PAPER LOAD: 2” must be specified for the PAPER LOAD setting and “UNTIL: 180 seconds” for the PAPER READY
TIME setting.
• After five pages have been cut/plotted consecutively, the paper must be reloaded.
• If expansion or contraction of the paper due to temperature and/or humidity changes has occurred during a cutting
or plotting operation, the following margins of error are added to the repeatability precision value:
0.1 mm/°C, 0.3 mm/10% RH.
*2: The precision specification is the precision that was obtained when Graphtec’s mylar film was used to measure the
mechanical precision. Please note that as only fine quality pattern paper can be used with this device, the precision
may differ slightly.
*3: HP-GLTM is a registered trademark of Hewlett-Packard Company.

CE5000-UM-251-9370 1-3
1. INTRODUCTION
1.2 External Dimensions
CE5000-40CRP
623 322
285
443
322
（122 ）
Units: mm
Dimensional accuracy: ±5 mm
CE5000-60
1004
585
851
Units: mm
Dimensional accuracy: ±5 mm

CE5000-UM-251-9370 1-4
1. INTRODUCTION
CE5000-120
744
1487
1194
Units: mm
Dimensional accuracy: ±5 mm
CE5000-120AP
1487
1020
1189
Units: mm
Dimensional accuracy: ±5 mm

CE5000-UM-251-9370 2-1
2. PARTS NAMES and FUNCTIONS
2. PARTS NAMES and FUNCTIONS
2.1 Parts Names and Functions
Front View
Media set lever
Pen holder
Pen carriage
Grit roller
Cutting mat
Push rollers
The above illustration is of the CE5000-120 model.
USB interface
connector
Serial (RS-232C)
interface connector
Control panel
Cutting mat : Cutting or plotting is performed on this mat.
Grit roller : Feeds the medium backward or forward
Push rollers : Push the medium against the grit roller
Pen carriage : Moves the cutter pen to the left and right
Pen holder : Holds the cutter pen and moves it up and down
Media set lever : Raises or lowers the push rollers during loading of a
medium
Control panel : Used to operate the cutting plotter and set functions
USB interface connector : Used to connect a USB cable
Serial (RS-232C) interface connector : Used to connect an RS-232C serial interface cable

CE5000-UM-251-9370 2-2
2. PARTS NAMES and FUNCTIONS
Rear View
Power switch
AC power inlet
Stock rollers
Stoppers Stand
The above illustration is of the CE5000-120 model.
AC power inlet : Connects the power cord to the cutting plotter
Power switch : Turns the power supply to the cutting plotter on or off
Stand : Supports the cutting-plotter unit
Stock rollers : Hold the roll media
Stoppers : Used to determine the position of the roll media loaded

CE5000-UM-251-9370 2-3
2. PARTS NAMES and FUNCTIONS
Front View (CE5000-120AP)
Media set lever
Control panel
Grit roller
Cutting mat
Push rollersStock shaft
Stopper
Pen station
Pen carriage
Pen holder
Cutter pen holder
USB
interface connector
Serial (RS-232C)
interface connector
Cutting mat : Cutting or plotting is performed on this mat.
Grit roller : Feeds the medium backward or forward.
Push rollers : Pushes the medium against the grit rollers.
Pen carriage : Moves the cutter pen to the left and right.
Cutter pen holder : Hold the cutter pen and moves it up and down.
Pen holder : Holds the pen and moves it up and down.
Pen station : Used to mount the pen before it is used.
Media set lever : Raises or lowers the push rollers during loading of a
medium.
Control panel : Used to operate the cutting plotter and set functions.
USB interface connector : Used to connect a USB cable.
Serial (RS-232C) interface connector : Used to connect an RS-232C serial interface cable.
Stock shaft : Used to load roll media.
Stoppers : Used to hold a roll medium in place (left and right, one
each).

CE5000-UM-251-9370 2-4
2. PARTS NAMES and FUNCTIONS
Rear View (CE5000-120AP)
Power switch
AC power inlet
Alignment shaft
Basket
Stand
AC power inlet : Connects the power cord to the cutting plotter.
Power switch : Turns the power supply to the cutting plotter on or off.
Stand : Supports the cutting-plotter unit.
Alignment shaft : Used when loading roll media.
Basket : Used to catch media after it has been cut.

CE5000-UM-251-9370 2-5
2. PARTS NAMES and FUNCTIONS
2.2 Assembling the Stand
CE5000-60/120:Standard
Stand Construction
The stand is made up of the following parts.
Stand feet (L/R)
Hexagonal socket bolt
(M5) x 12
Coin screw x 4
CE5000-60 only
Hexagonal socket bolt
(M6) x 8
CE5000-120 only
Allen wrench (M5) Allen wrench (M6)
CE5000-120 only
CE5000-60
CE5000-120
Center bar
CE5000-60
CE5000-120
Stand side bar（L/R）
CE5000-60 CE5000-120
Stand Assembly Instructions
(1) Fasten the stand feet (L/R) to the side bars (L/R) with the hexagonal socket bolts (M5), using the Allen
wrench.
Stopper
Hexagonal
socket bolt (M5)
Hexagonal
socket bolt (M5)
Stand side bar Stand side bar
Stand foot Stand foot
Front Front
CE5000-60 CE5000-120
* There are three
bolt holes, but
the center one
is not used.
(2) Fasten the stand tops (L/R) to the stand side bars (L/R) with the hexagonal socket bolts (M5), using the
Allen wrench.
CE5000-60 CE5000-120
Hexagonal
socket bolt (M5)
Stand side bar
Stand top
Hexagonal
socket bolt (M5)
Stand side bar
Stand top

CE5000-UM-251-9370 2-6
2. PARTS NAMES and FUNCTIONS
(3) Loosely fasten the stand side bars (L/R) to the center bar with the hexagonal socket bolts (CE5000-60:
M5, CE5000-120: M6), using the Allen wrench.
Hexagonal
socket bolt
(M6)
Center bar
Stand side bar
Hexagonal
socket bolt
(M6)
Center bar
Stand side bar
CE5000-60
CE5000-120
(4) Mount the CE5000 cutting plotter on the stand by inserting the positioning pins on the stand into the
positioning holes on the underside of the cutting plotter. Fasten using the four coin screws or hexagonal
socket bolts (M6).
CE5000-60
CE5000-120
Coin screws
Stand
CE5000-60
Positioning pins
Hexagonal socket
bolts (M6)
Positioning pins
Stand
CE5000-120
(5) Tighten the hexagonal socket bolts loosely fastened in step 3.

CE5000-UM-251-9370 2-7
2. PARTS NAMES and FUNCTIONS
CE5000-120AP:Standard
Stand Construction
The stand is made up of the following parts.
Stand side bar x 2 (L/R) Center bar x 1
Alignment shaft x 1
Stopper x 2 (L/R)
Hexagonal socket bolt (M6) x 8
Allen wrench (M6) x 1
Stock shaft x 1
Basket Construction
Sheet support pipe x 2
Sheet support pipe bracket x 2 Rubber cap x 4 Hexagonal socket bolt (M6) x 4
Sheet x 1

CE5000-UM-251-9370 2-8
2. PARTS NAMES and FUNCTIONS
Stand Assembly Instructions
(1) Fasten the center bar to the stand side bars (L/R) temporarily with the hexagonal socket bolts(M6),
using the Allen wrench.
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(2) Fasten the sheet support pipe brackets to the stand tops with the hexagonal socket bolts (M6).
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CE5000-UM-251-9370 2-9
2. PARTS NAMES and FUNCTIONS
(3) Insert the sheet support pipes into the sheet support pipe brackets. Use the lower holes for the pipe that
will be at the front of the cutting plotter, and the upper holes for the pipe that will be at the rear.
Remove the tape from the ends of the pipes to expose the adhesive, and then fit the rubber caps on
firmly.
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(4) Mount the CE5000-120AP on the stand by inserting the positioning pins on the stand into the positioning
holes on the underside of the cutting plotter and then fasten with the four hexagonal bolts (M6).
Make sure that the casters with the stoppers are at the front.
Positioning pin
Hexagonal
socket bolt (M6)
Stand
CE5000AP
cutting plotter
Stoppers

CE5000-UM-251-9370 2-10
2. PARTS NAMES and FUNCTIONS
(5) Attach the media guide bracket to the underside of the front panel. Loosen the two decorative screws
that are attached to the underside of the front panel (one on each side) by two or three turns, slot the
bracket in, and then tighten the screws.
Media guide bracket
Decorative screw
Pin
(6) Attach the alignment shaft to the top of the stand. Loosen the attached bindhead screws A (M4) two or
three turns, and then insert the brackets on the end of the shaft using the elongated screw holes. Tighten
the screws to hold the brackets in place. Push the shaft in until it contacts the curved area indicated by “a”
in the figure below, and then tighten the A (M4) bindhead screws.
When the shaft has been attached, tighten the bindhead screws B (M4), and check that the shaft does
not rotate. The bindhead screws B are screws to prevent the shaft from rotating. Position the shaft as
desired (check both the rotation direction and the horizontal direction) and then tighten the screws.
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a
a
a
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

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
(7) Tighten all the hexagonal bolts that were temporarily fastened in step 1.