GRAPHTEC FC4200-50 User manual

FC4200-UM-251-03-9370
CUTTING PLOTTER
SERVICE MANUAL
MANUAL NO. FC4200-UM-251
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-
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CONTENTS
FC4200-UM-251-03-9370 ii
HISTORY 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 panel of the FC4200-50 is corrected. 75 03

FC4200-UM-251-03-9370 iii
CONTENTS
CONTENTS
1. INTRODUCTION ........................................................................................................................... 1
1.1 Specifications ........................................................................................................................................1
1.2 Options ..................................................................................................................................................3
1.3 External Dimensions ............................................................................................................................. 4
2. NAMES OF THE MAIN PARTS ..................................................................................................... 6
2.1 Plotter Nomenclature .............................................................................................................................6
2.2 Control Panel .........................................................................................................................................8
3. The Tree Structure of Menus ....................................................................................................... 10
4. DAILY MAINTENANCE AND STORAGE .................................................................................... 12
5. LIST OF TOOLS .......................................................................................................................... 13
6. REPLACEMENT PROCEDURES ............................................................................................... 14
6.1 Precautions ......................................................................................................................................... 14
6.2 Removing the Y Rail Cover .................................................................................................................15
6.3 Removing the Front and Rear Y End Covers ......................................................................................15
6.4 Removing the Corner Cover ................................................................................................................16
6.5 Removing the Right Side Cover ..........................................................................................................16
6.6 Removing the Interface Cover .............................................................................................................17
6.7 Removing 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
6.13 Adjusting Y Belt Tension ....................................................................................................................23
6.14 Adjusting the X and Y Motor Synchro Belt Tension ...........................................................................24
6.15 Setting the Origin Position (FC4200-50) ........................................................................................... 25
6.16 Setting the Origin Position (FC4200-60) ........................................................................................... 26
6.17 Setting the Origin Position (FC4210-60) ........................................................................................... 27
6.18 About the Position of the Register Sensor Height .............................................................................28
6.19 Measure Seal Pasting Position (FC4200-50) ....................................................................................29
6.20 Measure Seal Pasting Position (FC4200-60) ....................................................................................30
6.21 Measure Seal Pasting Position (FC4210-60) ....................................................................................31
6.22 Pen Sense Rubber Pasting Position (FC4200-50 / -60 only) ............................................................32
6.23 Replacing the Main Board .................................................................................................................33

CONTENTS
FC4200-UM-251-03-9370 iv
7. ELECTRICAL SECTION ............................................................................................................. 34
7.1 List of DIP Switches ............................................................................................................................ 34
7.2 Writing to Flash Memory ..................................................................................................................... 35
7.3 Clearing Non-Volatile RAM ..................................................................................................................37
7.4 Setting Suffix .......................................................................................................................................38
7.5 Adjusting the Mark Sensor Level ......................................................................................................... 39
7.6 Adjusting the Pen Pressure .................................................................................................................40
7.7 Adjusting Pen Exchange (FC4200-50 / 60 only) ................................................................................. 41
7.8 Adjusting the Home Position ............................................................................................................... 42
7.9 Adjusting the Distance Accuracy .........................................................................................................43
7.10 Adjusting the Mark Sensor Mechanical Position ............................................................................... 45
7.11 Verifying the Carriage Check Position (FC4200-50 / 60 only) ...........................................................46
7.12 Adjusting the Gain .............................................................................................................................47
7.13 Recording Adjustment Data ...............................................................................................................48
7.14 List of Readjustment Items ................................................................................................................49
7.15 Location of Parts on the Main Board .................................................................................................50
7.16 Setting the Power Unitʼs Supply Voltage ...........................................................................................51
8. TEST MODES ............................................................................................................................. 52
8.1 Printing a List 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 Doesnʼt Operate After Being Turned On ...........................................................................55
9.2 The Cut Results Are Unsatisfactory ....................................................................................................56
9.3 The Coordinate Axes Cannot Be Correctly Aligned .............................................................................58
9.4 General Error Messages .....................................................................................................................59
9.5 Error Messages in GP-GL Command Mode ....................................................................................... 60
9.6 Error Messages in HP-GL Command Mode ........................................................................................61
10. SPECIFYING THE PEN CONDITIONS ..................................................................................... 62
10.1 The Cutter Penʼs Conditions ............................................................................................................. 62
10.2 Selecting a Set of Cutting Conditions ................................................................................................ 64
10.3 Specifying the Cutting Conditions ..................................................................................................... 65
10.4 Running a Cutting Test ......................................................................................................................70
11. PART LIST ................................................................................................................................. 72
11.1 Recommended List of Parts ..............................................................................................................72
11.2 External Casing .................................................................................................................................73
11.3 Main Frame, X Slide Section, and X Drive Section ...........................................................................75
11.4 Y Bar, Y Slide Section, Y Drive Section, and Pen Block Section .......................................................78
11.5 Electrical Section ...............................................................................................................................83
11.6 Accessories, and Others ....................................................................................................................85
11.7 Option Stand for FC4200-60 and FC4210-60 (ST0032) ...................................................................85

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

FC4200-UM-251-03-9370 1
INTRODUCTION
1. INTRODUCTION
This plotter incorporates a digital servo drive to perform cutting and plotting operations at high speed and
high precision.
Besides being used to cut marking film and other media, this plotter can also be used as a pen plotter.
1.1 Specifications
Specifications for the FC4200-50 and the FC4200-60
FC4200-50 FC4200-60
CPU 32-bit CPU
Configuration Flatbed cutting plotter
Drive system Fully-digital servo drive
Max. cutting area 590 × 430 mm 910 × 610 mm
Compatible media width 500 mm 666 mm
Max. cutting speed 65 cm/s
Specifiable cutting speeds 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60,65 cm/s
Cutting force 10 to 600 gf
Min. character size about 5 mm for alphanumerics (varies with the medium and font used)
Mechanical step size 0.005 mm
Programmable step size GP-GL: 0.1, 0.05, 0.025, 0.01 mm; HP-GL™: 0.025 mm*1
Repeatability precision*20.1 mm or less
Distance precision*2[Travelling distance × ±0.2% or less] or ±0.1 mm, whichever is larger
Perpendicular precision 0.3/430 mm or les 0.4/610 mm or less
Registration mark reading precision*3within 0.3 mm
Max. no. of pens 2 pens can be concurrently mounted
Compatible blade type Supersteel, ceramic, and sapphire blades
Compatible pen types Water- and oil-based ballpoint pens
Compatible cutting media Marking film (polyvinyl, fluorescent, reflective)
Paper of 0.5-mm thickness or less (pattern paper, oilboard)*4
Compressed polystyrene sheets of 0.8-mm thickness or less*5
Sandblasting rubber of 1.5-mm thickness or less*5
High-luminance reflective film*6
Interfaces RS-232-C serial and Centronics-compatible parallel interfaces (automatic
selection)
Buffer capacity 2 Mbytes
Resident command sets GP-GL and HP-GL™ (selected at the control panel)
LCD display 20 characters x 2 lines
Rated power 100 to 120 VAC, 50/60 Hz; 220 to 240 VAC, 50 Hz (specify when ordering)
Power consumption 120 VA or less
Operating environment 10 to 35°C, 35 to 75% R.H. (non-condensing)
External dimensions (WxDxH) approx. 857 x 780 x 200 mm approx. 1172 x 964 x 200 mm
Weight (without stand) approx. 19 kg approx. 26 kg
*1 HP-GL is a registered trademark of Hewlett-Packard Company.
*2 The figure varies with the type of Graphtec-designated medium used and the currently selected cutting conditions.
*3 Based on the precision when using the pen provided and high-grade paper to read this plotterʼs resident pattern.
*4 For use with the CB15U or CB15U-K30 cutter blade.
*5 For use with the CB15U-K30 cutter blade.
*6 For use with the CB15UA cutter blade.

FC4200-UM-251-03-9370 2
INTRODUCTION
Specifications for the FC4210-60
FC4210-60
CPU 32-bit CPU
Configuration Flatbed cutting plotter
Drive system Fully-digital servo drive
Max. cutting area 860 × 600 mm
Compatible media width 666 mm
Max. cutting speed 65 cm/s
Specifiable cutting speeds 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60,65 cm/s
Cutting force 0.098 to 5.88 N (10 to 600 gf)
Minmum character size about 5 mm for alphanumeric characters (varies depending on the medium
and fonts used)
Mechanical resolution 0.005 mm
Programmable resolution GP-GL: 0.1, 0.05, 0.025, 0.01 mm; HP-GL™: 0.025 mm*1
Repeatability precision*20.1 mm or less
Distance precision*2Travelling distance × ±0.2% or less or ±0.1 mm, whichever is larger
Perpendicular precision 0.4/610 mm or less
Registration mark reading precision*3within 0.2 mm
Maximum number of tools 2
Compatible blade type Supersteel blade
Compatible pen types Creasing/scoring tool, water- and oil-based ballpoint pens
Usatible cutting media Marking film (polyvinyl, fluorescent, reflective)
Cardboard of a thickness of 0.5 mm or less
Paper of 0.5mm thickness or less (pattern paper, oilboard)*4
F, G grade microflute
Clear sheet for packaging
Interfaces RS-232-C serial and Centronics (automatic selected)
Buffer capacity 2 MB
Resident command sets GP-GL and HP-GL™ (selected at the control panel)
LCD display 20 characters x 2 lines
Rated power-supply voltage 100 to 120 VAC, 50/60 Hz; 220 to 240 VAC, 50 Hz (specify when ordering)
Power consumption 120 VA or less
Operating environment 10 to 35°C, 35 to 75% R.H. (no condensation allowed)
External dimensions (WxDxH) approx. 1172 x 964 x 200 mm
Weight (without stand) approx. 27 kg
*1 HP-GL is a registered trademark of Hewlett-Packard Company.
*2 Depends on Graphtec-designated medium used and the currently selected cutting conditions.
*3 As determined by reading the plotter using the pen (included with the plotter) and high-grade paper.
*4 For use with the CB15U or CB15U-K30 cutter blade.

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

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

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

FC4200-UM-251-03-9370 6
NAMES OF THE MAIN PARTS
2. NAMES OF THE MAIN PARTS
2.1 Plotter Nomenclature
FC4200-50 / FC4200-60
(1) Pen carriage : Drives the cutter/pen to the left/right.
(2) Pen holder : Holds the cutter/pen and drives it up/down.
(3) Pen station : Holds a pen for plotting.
(4) Y bar : Holds the pen carriage; moves left/right.
(5) Writing panel : Cutting/plotting is performed here.
(6) Control panel : Used to set and use the plotterʼs 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 serial interface : Used to connect the plotter to a computer by cable via the RS-232C
connector serial interface.
(9) AC line inlet : Connect one end of the power cord here and the other end to an
electri cal socket.
(10) Power switch : Controls the on/off status of the power supply to the plotter.
(11) CHART HOLD key (–50 only) : Used to hold the medium.
(8)
(7)
(10)
(9) (1)
(2)
(3)
(6) (11)
Pen holder 1
Pen holder 2
Pen station
(4)
(5)

FC4200-UM-251-03-9370 7
NAMES OF THE MAIN PARTS
FC4210-60
(1) Pen carriage : Drives the cutter/pen to the left/right.
(2) Pen holder : Holds the cutter/pen and drives it up/down.
(3) Y bar : Holds the pen carriage; moves left/right.
(4) Writing panel : Cutting/plotting is performed here.
(5) Control panel : Used to set and use the plotterʼs 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 to connect the plotter to a computer by cable via the RS-232C
connector serial interface.
(8) AC line inlet : Connect one end of the power cord here and the other end to an
electri cal socket.
(9) Power switch : Controls the on/off status of the power supply to the plotter.
(6)
(7)
(1)
(3)
(4)
(2)
(5)
Pen holder 1 Pen holder 2
(8)
(9)

FC4200-UM-251-03-9370 8
NAMES OF THE MAIN PARTS
2.2 Control Panel
POWER
PROMPT
FORCE
SPEED
OFFSET
QUALITY
F1 F3
F4
F2
Indicator Lamps
POWER
POWER
The POWER lamp remains lit (green) while the plotter is on.
PROMPT
The PROMPT lamp lights (red) when the plotter receives data that will cause the pen carriage
to move outside the effective cutting area.
Function Keys
The four function keys F1 through F4 are used to select a menu or to select a function on a displayed menu.
F1
Press the F1 key to select a function during Menu mode, to select Cutter Conditions 1 during
Online status, or to change the cutting FORCE setting after the CONDITIONS key has been
pressed.
F2
Press the F2 key to select a function during 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, to select Cutter Conditions 3 during
Online status, or to change the cutter OFFSET setting after the CONDITIONS key has been
pressed.
F4
Press the F4 key to select a function during Menu mode, to select Cutter Conditions 4 during
Online status, or to change the cutting QUALITY setting after the CONDITIONS key has been
pressed.
POSITION Keys
These POSITION keys function differently according to the plotter ʼs operat-
ing status. They are used to change a setting on a displayed menu during
Menu mode, but are used to move the pen carriage at all other times.
When a key is first initially pressed, the pen carriage moves slowly. When you con-
tinue to hold down the key, the pen carriage starts moving more quickly.

FC4200-UM-251-03-9370 9
NAMES OF THE MAIN PARTS
Menu Keys
PAUSE key: Press this key to enter Menu mode and light its green lamp. Press it again to
cancel Menu mode and turn off the lamp. Press this key when you wish to proceed to set a
function. If the plotter receives data after this key is pressed, it will temporarily store the data
in its data buffer.
ENTER key: Press this key to register the selected setting when specifying a function. In
Pause status, you can reset the plotter by concurrently pressing the ENTER and ORIGIN
keys.
ORIGIN key: Used to change the position of the coordinate systemʼs origin point. When
the automatic detection of registration marks is enabled, press this key to initiate automatic
detection.
COPY key: Used to repeat the cutting operation defined by the data in the plotterʼs buffer.
CONDITIONS key: Press this key to change any of the cutting conditions appearing on the
plotterʼs display panel.
TEST key: Press this key to run a test to check whether the currently selected cutting
conditions are suitable for the medium loaded.
NEXT PAGE key: Press this key during Menu mode to proceed to the next menu page.
CANCEL/VIEW key: During a cutting operation, press this key to immediately stop cutting.
While the Ready message is being shown on the plotterʼs display panel, press this key to
move the pen outside of the maximum cutting/plotting area. To return the pen to its original
position, press this key again.

FC4200-UM-251-03-9370 10
THE TREE STRUCTURE OF MENUS
3. The Tree Structure of Menus
In Menu mode for FC4200-50 and FC4200-60
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
COMMAND
AREA
MIRROR
SORT
THICK
OFST FCE
OFST ANG
STP PASS
DIST ADJ
TEST
NEXT PAGE
NEXT PAGE
NEXT PAGE
PAUSE
F1
F2
F2
F4
F3
F4

FC4200-UM-251-03-9370 11
THE TREE STRUCTURE OF MENUS
In Menu mode for FC4210-60
INTERFACE
OPTION1
FILM
FUNCTION
PEN WIDTH
UP SPEED
OFST FCE
OFST ANG
STP PASS
L UNIT
DIST 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
PAUSE
Page Main Menu Submenu
ORIGIN POINT (HP-GL mode only)
AREA
ROTATE
THICK
MIRROR
SORT
PEN NO.
PERF.
STEP SIZE
(GP-GL mode only)
RS-232C
COMMAND
�Only when the MARK mode is ON

FC4200-UM-251-03-9370 12
DAILY MAINTENANCE AND STORAGE
4. DAILY MAINTENANCE AND STORAGE
Daily Maintenance
During the course of daily plotter operation, be sure to observe the following precautions.
Never lubricate the mechanisms of the plotter.
If the plotterʼs casing becomes dirty, wipe the soiled areas using a dry cloth or a cloth that has been moist-
ened in a neutral detergent diluted with water.
Never use thinner, benzine, alcohol, or similar solvents; they will damage the casingʼs finish.
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 water.
Never use benzine, thinner, alcohol, or similar solvents to clean the panel.
Storing Your Plotter
To store the plotter when it is not being used, be sure to observe the following points:
Remove the cutter and/or plotter pen attached to the pen holder and cover its tip with the protective cap
provided.
To protect the plotter from dust and dirt, cover it with a cloth.
Avoid storing the plotter in places subject to direct sunlight or high temperatures.

FC4200-UM-251-03-9370 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
• Gain Adjustment program

FC4200-UM-251-03-9370 14
REPLACEMENT PROCEDURES
6. REPLACEMENT PROCEDURES
6.1 Precautions
6.1.1 Safety Confirmation
To prevent the plotter from malfunctioning and to ensure the safety of operators, please follow the
instructions below:
• Before turning on the power for the plotter, take care that your hands, hair, or clothing are not caught up
in the pen carriage or sliding mechanism.
• Before performing any work, turn off the power switch and unplug the power cord to ensure electrical
safety.
6.1.2 Confirmation Before and After Operations
Before and after any operation, perform the following steps:
• Mark the part attachment positions with a pencil to ensure that parts can be restored to their proper
positions.
• Confirm the order of parts assembly.
• Perform condition printing and self and cutting tests to check the plotter status before performing any
operation. Confirm whether the plotter settings have changed and whether the plotter has trouble mov-
ing smoothly.

FC4200-UM-251-03-9370 15
REPLACEMENT PROCEDURES
6.2 Removing the Y Rail Cover
Remove the M3L6 binding head screws securing the Y Rail Cover at five locations (two locations on the
pen block side and three locations on the opposite side), 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 binding head screws securing the Front and Rear Y End Covers at four locations
each, and then remove the Front and Rear Y End Covers.
To replace the Front and Rear Y End Covers, reverse the above procedure.
M3L8 binding head screws