GRAPHTEC FC7000-75 User manual

CUTTING PLOTTER
SERVICE MANUAL
FC7000-75/100/130/160
FC7000MK2-60/75/100/130/160
FC7000-UM-251-10-9370

FC7000-UM-251-9370 I
HISTORY OF REVISIONS
No. Date issued Description of revision Page Edition
1 05.06.21 First Printing All 01
2 05.08.29 The cutting mats are added for the recommended parts list. 4-1 02
3 05.08.29 Part number for the right and left media stocker bracket corrected. 10-13 02
4 05.08.31 List of item requiring readjustment corrected. 7-1 02
5 05.11.24 Part number for the bracket bottom corrected. 10-3 03
6 05.11.24 Part number for the media sensor bracket corrected. 10-7 03
7 05.11.24 Part number for the labels added. 10-12 03
8 05.12.13 Part number for the model labels corrected. 10-12 04
9 05.12.13 Part number for the X motor belt corrected. 10-7 04
10 05.12.13 Part number for the pinch roller corrected. 10-10 04
11 06.02.26 The distance adjustment pattern size changed. 7-18 05
12 06.07.04 Part number for the Y drive pulley 38 assy corrected. 10-9 06
13 06.07.04 Part number for the idler pulley assy corrected. 10-9 06
14 06.08.08 Item number for the pinch roller sensor dog corrected. 10-10 07
15 06.10.19 Part number for the idler pulley assy corrected. 10-7 08
16 07.07.11 Information of the FC7000MK added. All 09
17 07.07.13
Information of the new main board for FC7000 added. 4-1,7-1,7-31 09
18 07.10.19
Information of the sensor dog position added. 6-28 10
19 07.10.19 Correction of procedure. 7-14 10
20 07.10.19 Part number for the X motor corrected. 4-1,4-2,10-7,10-9 10
21 07.10.19 Part number for the Y motor corrected. 4-1,4-2,10-7,10-9 10
22 07.10.19 Part number for the Y drive pulley corrected. 10-9 10

FC7000-UM-251-9370 II
CONTENTS
1. INTRODUCTION ..................................................................1-1
1.1 Main Specifications ................................................................................................... 1-1
1.1.1 Main Specifications (FC7000 Series) ......................................................................................... 1-1
1.1.2 Main Specifications (FC7000MK2 Series) .................................................................................. 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 Plotter ..............................................................................................2-3
2.3 Attaching the FC7000 Basket (Option) .......................................................................2-8
2.4 Attaching a Cutter Pen ..............................................................................................2-9
2.5 Replacing the Cross-Cutter Unit ............................................................................... 2-12
3. OPERATIONS .................................................................... 3-1
3.1 Control Panel ............................................................................................................3-1
3.2 Menu List ..................................................................................................................3-3
3.3 Description of Background Settings ...........................................................................3-5
3.4 Setting the Background Settings ................................................................................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
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 ..........................................................................................6-2
6.1.3 How to Replace the Center Cover .............................................................................................6-3
6.1.4 How to Replace the Front Guide ................................................................................................6-4
6.1.5 How to Replace the Rear Guide .................................................................................................6-5
6.1.6 How to Replace the Rear Writing Panel .....................................................................................6-6
6.1.7 How to Replace the Front Writing Panel Assembly ..................................................................... 6-7

FC7000-UM-251-9370 III
6.2 Mechanical Parts ......................................................................................................6-8
6.2.1 How to Replace the Rear Media Sensor .....................................................................................6-8
6.2.2 How to Replace the Front Media Sensor ....................................................................................6-9
6.2.3 How to Replace the Pinch Roller ............................................................................................. 6-10
6.2.4 How to Replace the Control Panel Board, LCD Assembly ......................................................... 6-11
6.2.5 How to Replace the Pen Block ................................................................................................ 6-13
6.2.6 How to Replace the Y-belt ....................................................................................................... 6-15
6.2.7 How to Replace the Pinch Roller Sensor .................................................................................. 6-17
6.2.8 How to Replace the Y-relay Board ........................................................................................... 6-19
6.2.9 How to Replace the Cam Sensor .............................................................................................6-20
6.2.10 How to Replace the Y-motor ................................................................................................... 6-21
6.2.11 How to Replace the X-motor ................................................................................................... 6-22
6.2.12 How to Replace the Main Board ..............................................................................................6-23
6.2.13 How to Replace the Vacuum Fan .............................................................................................6-24
6.2.14 How to Replace the Drive Roller ..............................................................................................6-25
6.2.15 How to Replace the Cutting Mat .............................................................................................. 6-27
6.2.16 Home Dog Position .................................................................................................................6-28
6.2.17 Cross Cutter Dog Position .......................................................................................................6-28
7. ADJUSTMENTS ..................................................................7-1
7.1 List of Items Requiring Readjustment ......................................................................... 7-1
7.2 Mechanical Adjustments ............................................................................................ 7-2
7.2.1 Y-Belt Tension Adjustment ........................................................................................................ 7-2
7.2.2 Y-Drive Belt Tension Adjustment ............................................................................................... 7-3
7.2.3 X-Drive Belt Tension Adjustment ............................................................................................... 7-4
7.2.4 Pinch Roller Pressure Adjustment ............................................................................................. 7-5
7.3 Electrical Adjustments ............................................................................................... 7-7
7.3.1 Position of the DIP Switch and Connectors ................................................................................ 7-7
7.3.2 DIP Switch Settings .................................................................................................................. 7-9
7.3.3 Checking the Power Supply Board Voltage Levels .................................................................... 7-10
7.3.4 Explanation of the Values of the Main Board Settings .............................................................. 7-11
7.3.5 Clearing the Non-Volatile RAM ................................................................................................ 7-12
7.3.6 How to Enter the Adjustment Menu ......................................................................................... 7-14
7.3.7 Adjusting the Pen Force .......................................................................................................... 7-16
7.3.8 Adjusting the Distance Accuracy ............................................................................................ 7-18

FC7000-UM-251-9370 IV
7.3.9 Adjusting the Auto-Registration Mark Sensor Sensitivity .......................................................... 7-20
7.3.10 Adjusting the Offset of the Auto-Registration Mark Sensor ...................................................... 7-21
7.3.11 Adjusting the Cross Cutter Home Position ............................................................................... 7-23
7.3.12 Adjusting the Offset of the Light Pointer Position ..................................................................... 7-25
7.3.13 Confirming the 2-Pen Model (2-pen model) ............................................................................. 7-26
7.3.14 Adjusting the Pen Exchange Y Direction Value (2-pen model) .................................................. 7-27
7.3.15 Adjusting the Spacing Between Pen 1 and Pen 2 (2-pen model) ............................................................ 7-29
7.3.16 Adjusting the Servo Gain ........................................................................................................ 7-31
7.4 Upgrading the System Firmware .............................................................................. 7-32
8. SERVICE MODES ................................................................8-1
8.1 Sensor Test Mode ......................................................................................................8-1
8.2 Control Panel Switch Test Mode .................................................................................8-2
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
9.4 Error Messages .........................................................................................................9-4
9.4.1 Hardware Error Messages ........................................................................................................9-4
9.4.2 Error Messages in GP-GL Command Mode ................................................................................9-5
9.4.3 Error Messages in HP-GL Emulation Mode ................................................................................9-6
10. PARTS LIST ......................................................................10-1
10.1 Outer Casing ........................................................................................................... 10-1
10.2 Control Panel ..........................................................................................................10-3
10.3 Pen Block ................................................................................................................10-5
10.4 Main Frame ............................................................................................................. 10-7
10.5 Y Rail ......................................................................................................................10-9
10.6 Y Slider ................................................................................................................. 10-11
10.7 Wiring Harness ...................................................................................................... 10-12
10.8 Labels ................................................................................................................... 10-13
10.9 Media Stocker, Stand .................................................................... 10-14
10.10 Option Basket ........................................................................................................ 10-15

FC7000-UM-251-9370 V
10.11 Other Parts ........................................................................................................... 10-15
11. BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS ..................... 11-1
11.1 Block Diagrams ....................................................................................................... 11-1
11.1.1 Block Diagrams FC7000 ......................................................................................................... 11-1
11.1.2 Block Diagrams FC7000MK2 .................................................................................................. 11-2
11.2 Circuit Diagrams ..................................................................................................... 11-3
11.2.1 Main Board Top Section .......................................................................................................... 11-3
11.2.2 Main Board (CONNECTOR 1 BLOCK) ....................................................................................... 11-4
11.2.3 Main Board (CONNECTOR BLOCK) .......................................................................................... 11-5
11.2.4 Main Board (CPU BLOCK) ....................................................................................................... 11-6
11.2.5 Main Board (DC DRIVER) ........................................................................................................ 11-7
11.2.6 Main Board (I/F BLOCK) ......................................................................................................... 11-8
11.2.7 Main Board (GRC SERVO BLOCK) ............................................................................................ 11-9
11.2.8 Main Board (MEMORY BLOCK) ...............................................................................................11-10
11.2.9 Main Board (USB BLOCK) .......................................................................................................11-11
11.2.10 Control Board ........................................................................................................................11-12
11.2.11 Relay Board, Pinch Roller Sensor Board, RMS Board ..............................................................11-13
11.3 Circuit Diagrams (FC7000MK2 Main Board) ............................................................11-14
11.3.1 Main Board (CPU) ..................................................................................................................11-14
11.3.2 Main Board (CPU) ..................................................................................................................11-15
11.3.3 Main Board (FPGA) ................................................................................................................11-16
11.3.4 Main Board (I/F) ....................................................................................................................11-17
11.3.5 Main Board (Motor Drive) ......................................................................................................11-18
11.3.6 Main Board (Memory) ............................................................................................................11-19
11.3.7 Main Board (Power Supply) ................................................................................................... 11-20

FC7000-UM-251-9370 1-1
1. INTRODUCTION
1. INTRODUCTION
1.1 Main Specifications
1.1.1 Main Specifications (FC7000 Series)
FC7000-75 FC7000-100 FC7000-130 FC7000-160
CPU 32-bit
Configuration Grit-rolling plotter
Drive Digital servo
Max. cutting area
(expanded mode)
50m x 762 mm 50m x 1067 mm 50m x 1372 mm 50m x 1626 mm
Guaranteed precision cutting area
*1
10m x 742 mm 10m x 1047 mm 10m x 1352 mm 10m x 1606 mm
Mountable media width Max. 920 mm, Min.
50 mm
Max. 1224 mm, Min.
50 mm
Max. 1529 mm, Min.
50 mm
Max. 1834 mm, Min.
50 mm
Max. cutting speed (Axial) 148.5cm/sec (45 ips)
Specifiable speeds 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 70, 80, 90, 100, 105 cm/sec
Cutting pressure 48 steps, 0.196-5.88N (20-600gf)
Min. character size 3mm (0.125 in.) alphanumeric Helvetica med. Font
Mechanical resolution 0.005mm
Programmable resolution GP-GL: 0.01/0.05/0.025/0.01mm, HP-GL: 0.025mm *2
Repeatable accuracy *1 Max. 0.1 mm/2-m unit (excluding media shrinkage)
Number of cutters/pens 1 (2 for the optional 2-pen models) *3
Pen types Water-based fiber-tip, oil-based ballpoint, ceramic, and disposable ink pens
Pouncing tool type Pouncing tool: PPA33-TP12, 1.2-mm pin diameter) *4
Compatible media Mono-vinyl chloride media, fluorescent media, and media for illuminated displays,
high reflective media, up to 0.25mm thick, Sandblast rubber up to 1mm thick*5
Compatible paper for pouncing Regular paper from 0.06 to 0.13 mm thick
Standard interfaces RS-232C/USB (Auto switching)
Buffer memory 2 MB
Resident command sets GP-GL/HP-GL(Control panel switching)
LCD Panel 20x4 - Supports 7 languages: with amber backlight
Power supply 100-240VAC/50-60 Hz (Auto switching)
Power consumption 140VA max.
Operating environment Temperature: +10˚C to +35˚C
Humidity: 35% to 75% (non-condensing)
Guaranteed accuracy environment Temperature: +16 ˚C to +32 ˚C
Humidity: 35% to 70%(non-condensing)
External dimensions without stand 1260 x 402 x 477mm 1560 x1210 x 715mm 1860 x 1210 x 715mm 2120 x 1210 x 715mm
Weight 29 kg 43 kg
(including stand)
51 kg
(including stand)
59 kg
(including stand)
*1 When the optional basket and Graphtec-specified media are used.
*2 HP-GL is a registered trademark of Hewlett-Packard Company.
*3 The 2-pen unit is a factory-installed option. It cannot be retrofitted.
*4 The PPA32-TP12 pouncing pen cannot be used.
*5 The CB15UA cutter blade and a reinforced backing sheet must be used when cutting high-intensity reflective film.
1.1.2 Main Specifications (FC7000MK2 Series)

FC7000-UM-251-9370 1-2
1. INTRODUCTION
FC7000MK2-60 FC7000MK2-75 FC7000MK2-100 FC7000MK2-130 FC7000MK2-160
CPU 32-bit
Configuration Grit-rolling plotter
Drive Digital servo
Max. cutting area
(expanded mode)
50m x 610 mm 50m x 762 mm 50m x 1067
mm
50m x 1372
mm
50m x 1626
mm
Guaranteed precision cutting area
*1
15m x 590 mm 15m x 742 mm 15m x 1047
mm
15m x 1352
mm
15m x 1606
mm
Mountable media width Max. 866 mm,
Min. 50 mm
Max. 920 mm,
Min. 50 mm
Max. 1224 mm,
Min. 50 mm
Max. 1529 mm,
Min. 50 mm
Max. 1834 mm,
Min. 50 mm
Max. cutting speed (Axial) 148.5cm/sec (45 ips)
Specifiable speeds 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 70, 80, 90, 100, 105 cm/sec
Cutting pressure 48 steps, 0.196-5.88N (20-600gf)
Min. character size 3mm (0.125 in.) alphanumeric Helvetica med. Font
Mechanical resolution 0.005mm
Programmable resolution GP-GL: 0.01/0.05/0.025/0.01mm, HP-GL: 0.025mm *2
Repeatable accuracy *1 Max. 0.1 mm/2-m unit (excluding media shrinkage)
Number of cutters/pens 1 (2 for the optional 2-pen models) *3
Pen types Water-based fiber-tip, oil-based ballpoint and disposable ink pens
Pouncing tool type Pouncing tool: PPA33-TP12, 1.2-mm pin diameter) *4
Compatible media Mono-vinyl chloride media, fluorescent media, and media for illuminated displays,
high reflective media, up to 0.25mm thick, Sandblast rubber up to 1mm thick*5
Compatible paper for pouncing Regular paper from 0.06 to 0.13 mm thick
Standard interfaces RS-232C/USB (Auto switching)
Buffer memory 2 MB
Resident command sets GP-GL/HP-GL(Control panel switching)
LCD Panel 20x4 - Supports 7 languages: with amber backlight
Power supply 100-240VAC/50-60 Hz (Auto switching)
Power consumption 160VA max.
Operating environment Temperature: +10˚C to +35˚C
Humidity: 35% to 75% (non-condensing)
Guaranteed accuracy environment Temperature: +16 ˚C to +32 ˚C
Humidity: 35% to 70%(non-condensing)
External dimensions without stand 1110 x 402 x
477mm
1260 x 402 x
477mm
1560 x1210 x
715mm
1860 x 1210 x
715mm
2120 x 1210 x
715mm
Weight 22 kg 29 kg 43 kg
(including stand)
51 kg
(including stand)
59 kg
(including stand)
*1 When the optional basket and Graphtec-specified media are used.
*2 HP-GL is a registered trademark of Hewlett-Packard Company.
*3 The 2-pen unit is a factory-installed option. It cannot be retrofitted.
*4 The PPA32-TP12 pouncing pen cannot be used.
*5 The CB15UA cutter blade and a reinforced backing sheet must be used when cutting high-intensity reflective film.

FC7000-UM-251-9370 1-3
1. INTRODUCTION
1.2 External Dimensions
FC7000-75, FC7000MK2-60/75
922 (FC7000MK2-60)
1072 (FC7000-75,FC7000MK2-75)
62 170
476.763
383 21
123
94
1110 (FC7000MK2-60)
1260 (FC7000-75,FC7000MK2-75)
Units: mm
Dimensional accuracy: ±5 mm
FC7000-75, FC7000MK2-60/75 with Option Stand
1110 (FC7000MK2-60)
1260 (FC7000-75, FC7000MK2-75) 209 715 90
1190 20
209
715
1014
90
Units: mm
Dimensional accuracy: ±5 mm

FC7000-100/130/160
1560 (FC7000-100)
1860 (FC7000-130)
2120 (FC7000-160) 209 715 90
1190 20
209
715
1014
90
Units: mm
Dimensional accuracy: ±5 mm

FC7000-UM-251-9370 2-1
2. PARTS NAMES and FUNCTIONS
2. PARTS NAMES and FUNCTIONS
2.1 Parts Names and Functions
Front View
Grit roller
Media sensor
Power switch
Pinch roller
Pen carriage
Cross-cutter unit
Pen holder
Pinch rollers
Control panel
Stand
Cutting groove
Cutting mat
Grit roller position guide
Pen station
Grit roller
Media sensor
Power switch: ................. Used to turn the plotter on and off.
Control panel: ................. Used to access various plotter functions.
Pinch rollers: ................... Rollers that push the media against the grit rollers.
Grit rollers: ...................... Metallic rollers with a file-like surface that feed the media back and forth.
Media sensors: ............... The front sensor is used to sense the leading edge of the media. The rear sensor is
used to sense the trailing edge of the media.
Pen carriage: .................. Moves the cutter-pen or plotting pen across the media during cutting or plotting.
Pen holder: ..................... Holds the cutter-pen or plotting pen and moves it up or down.
Pen station (installed on 2-pen models only):
The second pen is mounted here.
Stand: ............................. Used to make the plotter more portable and to free up counter space.
Grit roller position guide:
Stickers on the front of the Y rail and the rear side of the top cover that show the
position of each grit roller. Use these alignment marks as an aid in locating the
pinch rollers.
Cutting groove: ............... Used when cross-cutting is performed.
Cross-cutter unit: ............ Used to perform cross-cutting of media so that the cut length can be removed from
the roll.

FC7000-UM-251-9370 2-2
2. PARTS NAMES and FUNCTIONS
Rear View
Media set lever
AC line inlet
Media stocker
Stock rollers
USB interface connector
Serial interface connector
Media lock
Pinch roller hold-down force switching lever
Media set lever: .............. Used to raise or lower the pinch rollers during the loading or unloading of media.
Pinch roller hold-down force switching lever:
Used to switch between the two pinch roller forces (strong and weak).
AC line inlet: ................... Inlet where the power cord is connected.
Media stocker: ................ Used to carry roll media and ensure its proper rotation.
Stock rollers: ................... A media roll is placed on these rollers.
Media lock: ..................... Used to prevent the stock rollers from rotating when the media roll has been placed
on top of them. The media lock ensures that the media is pulled straight out from
the roll.
USB interface connector:
Used to connect the plotter to the computer with a USB interface cable.
Serial interface connector:
Used to connect the plotter to the computer with an RS-232 serial interface cable.

FC7000-UM-251-9370 2-3
2. PARTS NAMES and FUNCTIONS
2.2 Assembling the Plotter
FC7000-75 (desktop model; stand not provided but is available as an option)
When the FC7000-75 is used without a stand, the media stocker bracket is attached directly to the plotter.
The media stocker is made up of the following parts.
Stock roller x 2Media stocker bracket x 2 M4 binding-head screw x 4
ATTACHING THE MEDIA STOCKER
(1) Fasten the media stocker brackets to the left and right inside surfaces of the plotter unit, using two M4
binding-head screws for each media stocker bracket.
(2) Insert an M4 screw in the second hole from the front side of the plotter.
• Check that all of the screws used for fastening have been tightened. The media
may not be fed correctly if even one of the screws is loose.
• When installing the plotter, make sure that there are no objects in its vicinity.
Leave a clear space of at least 300 mm around the plotter.
• When the FC7000-75 is used without a stand, the maximum diameter of the roll
media that can be used is 160 mm.

FC7000-UM-251-9370 2-4
2. PARTS NAMES and FUNCTIONS
FC7000-100/130/160 (stand provided)
Assemble the stand, attach the media stocker to the stand, and then mount the plotter on the stand.
The stand and the media stocker are made up of the following parts.
Base assembly x 2 Allen wrench
(for M5 screws) x 1
Center bar x 1Stand side bar x 2 Socket head cap screw
(M5) x 20
Stock roller x 2
Media stocker bracket x 2
ASSEMBLING THE STAND
The mounting direction is different for the front loading and the rear loading models.
<Front loading>
<Rear loading>

FC7000-UM-251-9370 2-5
2. PARTS NAMES and FUNCTIONS
(1) Assemble the left and right stand sides. Fasten a base assembly to each of the stand side bars with four
socket head cap screws, using the Allen wrench.
Socket head
cap screws
Stand side bar
Base assembly
Stand side bar
• Assemble the stand so that the front and rear lengths of the base assembly are
the same for both the left and right stand sides.
(2) Loosely fasten the center bar to the left and right stand sides with four socket head cap screws (two on
each side), using the Allen wrench.
Socket head
cap screws
Socket head
cap screws
Center bar
Stand sides
(3) Attach a media stocker bracket to each of the left and right stand sides with two socket head cap screws,
using the Allen wrench. Mount the media stocker brackets so that each one protrudes directly above the
longer of the two base assembly lengths.
Base assembly
Stand sides
Media stocker bracket
Media stocker bracket
Socket head cap screws

FC7000-UM-251-9370 2-6
2. PARTS NAMES and FUNCTIONS
(4) Mount the plotter on the stand by inserting the positioning pins on the stand into the positioning holes
on the underside of the plotter. Fasten with four socket head cap screws (two on each side), using the
Allen wrench.The cutting plotter mounting direction is different for the front loading and the rear loading
models.
Socket head
cap screws
Positioning pin
Socket head
cap screws
Caster stoppers
Positioning pin hole
<Front loading>
<Rear loading>
(5) Tighten the socket head cap screws loosely fastened in Step 2.
• Check that all of the screws used for fastening have been tightened. The media
may not be fed correctly if even one of the screws is loose.
• When installing the plotter, make sure that there are no objects in its vicinity.
Leave a clear space of at least 300 mm around the plotter.

FC7000-UM-251-9370 2-7
2. PARTS NAMES and FUNCTIONS
Mounting the stock rollers
Insert the stock rollers into the slots on the media stocker brackets.
Front
Stock rollers
Stock rollers
<Front loading>
<Rear loading>

FC7000-UM-251-9370 2-8
2. PARTS NAMES and FUNCTIONS
2.3 Attaching the FC7000 Basket (Option)
The FC7000 Basket box contains one basket holder assembly (one front basket tube and one rear basket
tube inserted into two tube brackets), one cloth basket, and a screw/wrench set.
(1) Attach one of the two tube brackets on the basket holder assembly to the left side of the stand with two
socket head cap screws, using the Allen wrench.
Repeat this step with the other side.
Socket head
cap screw
Basket holder assembly
Stand
Socket head
cap screw
(2) Drape the middle section of the cloth basket over the stand’s center bar, and then snap the middle
section of the cloth basket around the center bar. Snap the front edge of the cloth basket around the
front basket tube, and then snap the rear edge of the cloth basket around the rear basket tube.
Cloth basket
Holder snap
Front
Cloth basket
Side view
Separate into front and rear baskets,
with the center bar as the center point
Center bar