GRAPHTEC FC9000-75 User manual

CUTTING PLOTTER
SERVICE MANUAL
FC9000-75/100/140/160
FC9000-UM-251-01-9370

FC9000-UM-251-9370 I
HISTORY OF REVISIONS
No. Date issued Description of revision Page Edition
119.9.13 First Printing All 01

FC9000-UM-251-9370 II

FC9000-UM-251-9370 III
CONTENTS
1 INTRODUCTION .........................................................................1-1
1.1 Main Specifications ...............................................................................................................1-1
1.2 External Dimensions ............................................................................................................ 1-2
1.3 Option & Supply Parts.......................................................................................................... 1-3
2 Setup ......................................................................................... 2-1
2.1 Confirming the standard accessory.....................................................................................2-1
2.2 Assembling the stand and basket to the Plotter................................................................ 2-2
3 PARTS NAMES and FUNCTIONS ............................................ 3-1
3.1 Parts Names and Functions................................................................................................. 3-1
3.2 Attaching a Tool .................................................................................................................... 3-3
3.3 Replacing the Cross-Cutter Blade....................................................................................... 3-6
4 OPERATIONS ............................................................................ 4-1
4.1 Control Panel......................................................................................................................... 4-1
4.2 Reading the Screen (LCD) .................................................................................................... 4-3
5 RECOMMENDED PARTS LIST................................................. 5-1
6 LIST OF TOOLS ........................................................................ 6-1
6.1 Tools....................................................................................................................................... 6-1
6.2 Greasing And Gluing Points ................................................................................................ 6-1
7 DISASSEMBLY AND REASSEMBLY ........................................7-1
7.1 Exterior Parts .........................................................................................................................7-1
7.1.1 Replacing the Right Side Cover ............................................................................................................7-1
7.1.2 Replacing the Left Side Cover...............................................................................................................7-2
7.1.3 Replacing the Control Panel Assembly................................................................................................7-3
7.1.4 Replacing the Center Cover...................................................................................................................7- 4
7.1.5 Replacing the Front Guide .....................................................................................................................7-5
7.1.6 Replacing the Rear Guide ......................................................................................................................7- 6
7.1.7 Replacing the Rear Writing Panel .........................................................................................................7-7
7.1.8 Replacing the Front Writing Panel Assembly ......................................................................................7-8

FC9000-UM-251-9370 IV
7.1.9 Replacing the Fan Cover........................................................................................................................7-9
7.1.10 Replacing the Pen Block Cover...........................................................................................................7-10
7.1.11 Replacing the Push Roller ................................................................................................................... 7-11
7.1.12 Replacing the Cutting Mat ...................................................................................................................7-12
7.2 Internal Parts ........................................................................................................................7-13
7.2.1 Replacing the Rear Media Sensor.......................................................................................................7-13
7.2.2 Replacing the Front Media Sensor......................................................................................................7-13
7.2.3 Replacing the Registration Mark Sensor............................................................................................7-14
7.2.4 Replacing the Control Panel Board.....................................................................................................7-16
7.2.5 Replacing the LCD................................................................................................................................7-17
7.2.6 Replacing the Pen Block......................................................................................................................7-18
7.2.7 Replacing the Y-belt .............................................................................................................................7-20
7.2.8 Replacing the Push Roller Sensor Board...........................................................................................7-23
7.2.9 Replacing the Y-relay Board ................................................................................................................7-24
7.2.10 Replacing the Cam Sensor board .......................................................................................................7-25
7.2.11 Replacing the Y-motor..........................................................................................................................7-26
7.2.12 Replacing the X-motor .........................................................................................................................7-29
7.2.13 Replacing the Main Board....................................................................................................................7-31
7.2.14 Replacing the Fan.................................................................................................................................7-32
7.2.15 Replacing the Drive Roller Shaft Assembly .......................................................................................7-33
7.2.16 Replacing the Y Flexible Cable............................................................................................................7-36
7.2.17 Replacing the Push Roller assembly..................................................................................................7-38
7.2.18 Replacing the Push Roller base ..........................................................................................................7- 41
7.2.19 Replacing Power Supply Board.......................................................................................................... 7- 43
7.3 Belt Tension Adjustments .................................................................................................. 7- 44
7.3.1 Y-Belt Tension Adjustment ................................................................................................................. 7- 44
7.3.2 Y-Drive Belt Tension Adjustment ........................................................................................................7- 47
7.3.3 X-Drive Belt Tension Adjustment ....................................................................................................... 7- 48
7.4 Confirming the cable wiring............................................................................................... 7- 49
8 Electrical Adjustment............................................................... 8-1
8.1 List of Items Requiring Readjustment ................................................................................ 8-1
8.2 Flowchart of the Adjustment Sequence.............................................................................. 8-2
8.2.1 When the main board was replaced (Normal procedure) .................................................................. 8-2

FC9000-UM-251-9370 V
8.2.2 When the main board was replaced (The adjustment values could not copy.) ............................... 8-3
8.2.3 When the pen block was replaced ....................................................................................................... 8-4
8.2.4 When the X or Y motor was replaced .................................................................................................. 8-4
8.2.5 When the Rear or Front X Media sensor was replaced...................................................................... 8-4
8.2.6 When the registration mark sensor was replaced.............................................................................. 8-4
8.2.7 When the cam sensor board was replaced......................................................................................... 8-5
8.2.8 When the optional 2nd pen was installed ........................................................................................... 8-5
8.2.9 When the optional 2nd pen of holder or station was replaced ......................................................... 8-5
8.2.10 When the optional push roller was installed....................................................................................... 8-5
8.2.11 When the gird roller was replaced ....................................................................................................... 8-5
8.3 DIP Switch Settings .............................................................................................................. 8-6
8.4 Explanation of the Values of the Main Board Settings...................................................... 8-8
8.5 Confirming the version of firmware .................................................................................... 8-9
8.6 Upgrading the System Firmware ........................................................................................8-10
8.7 Clearing the NOV-RAM ........................................................................................................8-12
8.8 Selecting Display Language & Length Unit.......................................................................8-14
8.9 Copying the Adjustment value form the SUB-NVRAM.....................................................8-15
8.10 How to Enter the Adjustment Menu ...................................................................................8-16
8.11 Adjusting the Pen Force......................................................................................................8-18
8.11.1 Inputting the pen force from the recorded value...............................................................................8-18
8.11.2 Adjusting the pen force from the measured force ........................................................................... 8-20
8.12 Adjusting the friction.......................................................................................................... 8-23
8.13 Adjusting the Distance Accuracy...................................................................................... 8-25
8.13.1 Inputting the distance accuracy from the recorded value............................................................... 8-25
8.13.2 Adjusting the distance accuracy from the measured distance....................................................... 8-27
8.14 Adjusting the Registration Mark Sensor Sensitivity ....................................................... 8-30
8.15 Adjusting the Offset of Registration Mark Sensor........................................................... 8-33
8.15.1 Inputting the registration mark sensor offset position from the recorded values........................ 8-33
8.15.2 Adjusting the registration mark sensor offset position from the measured values ..................... 8-36
8.16 Adjusting the Cross Cutter Home Position ...................................................................... 8-40
8.16.1 Inputting the Cross Cutter Home Position from the recorded values............................................ 8-40
8.16.2 Adjusting the Cross Cutter Home Position from the measured values ......................................... 8-42

FC9000-UM-251-9370 VI
8.17 Adjusting the X Media Sensor Position ............................................................................ 8-45
8.17.1 Inputting the X Media Sensor Position from the recorded value.................................................... 8-45
8.17.2 Adjusting the X Media Sensor Position............................................................................................. 8-48
8.18 Adjusting the 2nd Pen Exchange position ....................................................................... 8-50
8.18.1 Inputting the 2nd Pen Exchange position from the recorded value............................................... 8-50
8.18.2 Adjusting the 2nd Pen Exchange position........................................................................................ 8-52
8.19 Adjusting the Spacing Between Tool 1 and Tool 2 .......................................................... 8-55
8.19.1 Inputting the Spacing Between Tool 1 and Tool 2 from the recorded value .................................. 8-55
8.19.2 Adjusting the Spacing Between Tool 1 and Tool 2 ........................................................................... 8-57
8.20 Setting the Number of Push Rollers.................................................................................. 8-62
8.21 Back up the adjustment value to the SUB-NVRAM ......................................................... 8-64
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 ............................................................................................................... 9-5
9.4 Print & Cut Operation ........................................................................................................... 9-7
9.5 USB connection ...................................................................................................................9-11
9.6 Error Messages ....................................................................................................................9-12
9.6.1 Hardware Error Messages ...................................................................................................................9-12
9.6.2 Error Messages in GP-GL Command Mode .......................................................................................9-17
9.6.3 Error Messages in HP-GL Emulation Mode ..........................................................................................20
9.6.4 Error Messages on ARMS.......................................................................................................................22
9.6.5 Other Error Messages .............................................................................................................................28
9.6.6 Warning Messages ..................................................................................................................................31
9.7 Service mode...........................................................................................................................33
9.7.1 Sensor & Panel Switch Test Mode .........................................................................................................33
9.7.2 Printing the Setting of the Plotter ..........................................................................................................35
9.7.3 Printing the Test Pattern .........................................................................................................................36
9.7.4 Confirm the Cutting Data ........................................................................................................................37
9.7.5 Self Diagnostic Test.................................................................................................................................38
9.7.6 Registration Mark Sensor Test ...............................................................................................................40
9.7.7 Clear Setup Mode ....................................................................................................................................42

FC9000-UM-251-9370 VII
10 PARTS LIST............................................................................. 10-1
10.1 Outer Casing.........................................................................................................................10-1
10.2 Control Panel....................................................................................................................... 10-3
10.3 Pen Block............................................................................................................................. 10-4
10.4 Main Electrical Parts........................................................................................................... 10-5
10.5 Y Drive Part.......................................................................................................................... 10-6
10.6 Y Slider Part......................................................................................................................... 10-8
10.7 X Drive Part.......................................................................................................................... 10-9
10.8 Stand, Basket .....................................................................................................................10-11
10.9 Details of Stocker Bracket.................................................................................................10-13
10.10 Details of Basket Base Bracket ........................................................................................10-14
10.11 Optional Take up roller (FC9000-140/160) ........................................................................10-15
10.12 Labels ..................................................................................................................................10-16
11 WIRING DIAGRAMS ................................................................11-1
12 Target electrical component for WEEE instruction..............12-1

FC9000-UM-251-9370 1-1
1 INTRODUCTION
1 INTRODUCTION
CAUTION
DOUBLE POLE/NEUTRAL FUSING
1.1 Main Specications
FC9000-75 FC9000-100 FC9000-140 FC9000-160
CPU 32-bit
Conguration Grit-rolling plotter
Drive Digital servo
Max. cutting area
(expanded mode)
762 mm x 50 m
1067 mm x 50 m 1372 mm x 50 m 1626 mm x 50 m
Guaranteed precision cutting area *1 742 mm x 15 m 1047 mm x 10 m
(894 mm x 15 m)
1352 mm x 10 m
(894 mm x 15 m)
1607 mm x 10 m
(894 mm x 15 m)
Mountable media width Min. 50 mm
Max. 920 mm
Min. 50 mm
Max. 1224 mm
Min. 50 mm
Max. 1529 mm
Min. 50 mm
Max. 1850 mm
Number of push rollers 2344
Max. cutting speed (Axial) 148.5cm/sec (45 degree direction)
105 cm/sec (Axis direction)
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
Max. cutting force 5.88N (600gf)
Min. character size 5 mm (0.197 in) alphanumeric Helvetica med. Font
Mechanical resolution 0.005mm
Programmable resolution GP-GL: 0.1/0.05/0.025/0.01 mm, HP-GL*2: 0.025 mm
Repeatable accuracy *1 Max. 0.1 mm/2-m unit (excluding media shrinkage)
Number of cutters/pens 1
Pen types Water-based fiber-tip pen, oil-based ballpoint pen
Compatible media Mono-vinyl chloride media, fluorescent media, and reflective media up to 0.25 mm
thick (Excluding the high reflective media)
Compatible paper for pouncing Regular paper from 0.06 to 0.13 mm thick
Interfaces USB2.0 (Full Speed)/Network (Ethernet 10BASE-T/100BASE-TX)/RS-232C*3
(Auto switching)
Buffer memory 2 MB
Resident command sets GP-GL/HP-GL*2(Control panel switching)
LCD Panel Graphic type (240 x 128 dots)
Power supply 100-240VAC/50-60 Hz
Power consumption 140 VA 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 (W x D x H)
including the basket and stand
1360 x 1151 x 1232 mm 1665 x 1151 x 1232 mm 1970 x 1150 x 1232 mm 2224 x 1150 x 1232 mm
Weight 49 kg 56 kg 64 kg 70 kg
*1 When the optional basket and Graphtec-specied media are used.
*2 HP-GL is a registered trademark of Hewlett-Packard Company.
*3 The RS-232C interface is option for the Japanese and Chinese model only.

FC9000-UM-251-9370 1-2
1 INTRODUCTION
1.2 External Dimensions
H
D1
D2W
Units: mm
Dimensional accuracy: ±5 mm
FC9000-75 FC9000-100 FC9000-140 FC9000-160
External dimensions
W x D1 (D2) x H
(mm)
1360×1151(803)×1232 1665×1151(803)×1232 1970×1151(803)×1232 2224×1151(803)×1232

FC9000-UM-251-9370 1-3
1 INTRODUCTION
1.3 Option & Supply Parts
Option
Option mane Model name Description Q’ty
Take Up unit OPH-A43 For FC9000-140 1 set
OPH-A44 For FC9000-160 1 set
Flange set OPH-A52 Flange for the stock roll media 1 set
Supply Parts
Supply mane Model name Description
Cutting blade holder PHP33-CB09N-HS 1 piece: for CB09U series blade.
PHP33-CB15N-HS 1 piece: for CB15U series blade.
PHP35-CB09N-HS 1 piece: for CB09U series blade. Metal top type
PHP35-CB15N-HS 1 piece: for CB15U series blade. Metal top type
Cutting blade CB09UB-5 5 blades/pack: 0.9 mm dia. 45º angle, Supersteel
CB09UB-K60-5 5 blades/pack: 0.9 mm dia. 60º angle, for thin lm
CB15U-5 5 blades/pack: 1.5 mm dia. 45º angle, Supersteel
CB15U-K30-5 5 blades/pack: 1.5 mm dia. 30º angle, for sandblast rubber
CB15UA-5 5 blades/pack: 1.5 mm dia. 45º angle, for high intensity reective lm
CB15UA-K30-5 5 blades/pack: 1.5 mm dia. 30º angle, for high intensity reective lm
Water-based ber-tip pen holder PHP31-FIBER 1 piece: pen holder for KF700 series pen
Water-based ber-tip pen KF700-BK 10 pens/pack: pen (black)
KF700-RD 10 pens/pack: pen (red)
Oil-based ballpoint pen holder PHP34-BALL 1 piece: pen holder for KB700 pen
Oil-based ballpoint pen KB700-BK 10 pens/pack: pen (black)
Cross-cutter blade PM-CC-002 1 blade/pack: cross-cutter blade
Pouncing tool PPA33-TP12 1 set/pack: steel pin 1.2 mm dia

FC9000-UM-251-9370 2-1
2 Setup
2 Setup
2.1 Conrming the standard accessory
When the standard accessory box is opened, conrm the following standard accessory is contained.
Item Q’ty Item Q’ty
Power cable 1 pc. USB cable 1 pc.
DVD
• Various software
• User’s Manual (pdf)
1 pc. TO ENSURE SAFE AND CORRECT
USE SETUP MANUAL
Cutter Blade Manual
1 set
Cutter plunger (PHP33-CB09-HS) 1 pc. Cutter blade: CB09UB-1 1 pc.
Water-based ber pen adapter (PHP31-
FIBER)
1 set Water-based ber pen (KF700-BK [1P]) 1 pc.
Cutter blade adjustment magnier (PM-
CT-001)
1 pc. Flange Set 1 set
Software Activation Code 1 Sheet

FC9000-UM-251-9370 2-2
2 Setup
2.2 Assembling the stand and basket to the Plotter
Procedure
(1) Take out the following part of stand from the packing box.
The long parts are in the packing box of main unit.
Stand side bar x 2
Stock roller x 2
Media stocker roller L and R
Allen wrench (for M5 cap screw
M5L16 Cap screw x 16
M5L10 Cap screw x 16
Basket Cloth Arm x 4
Basket tube short x 2
Basket tube long x 1
Basket tube hanger bracket x 2
Basket Cloth x 1
Stopper x 2
Center bar x 1
Foot x 2
(2) Assemble the left and right stand sides. Insert the four M5L16 cap screws (long) to the thread of the
stand side bar by hand, and then tighten them by hand. Then fasten four M5L16 cap screws by using
the Allen wrench.

FC9000-UM-251-9370 2-3
2 Setup
(3) Insert the four M5L16 cap screws (long) to the thread of the center bar by hand (two on each side), and
then tighten them by hand. Then fasten four M5L16 cap screws by using the Allen wrench.
There is front and rear for the center bar, when instal the plotter onto stand, conrm it.
Front
Rear
Front
Rear
Confirm this groove.
(4) Conrm the front side and the rear side for the stand by shape of center bar. 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 the four M5L10 cap screws (two short screws for each side), using the Allen wrench.
(5) Attach the basket tube hanger brackets to each of the media stocker roll brackets. Fasten with the four
M5L10 cap screws (two short screws for each side), using the Allen wrench.
There is direction to attach the basket tube hanger brackets.
Attach the basket tube hanger brackets to the media stocker roll brackets as shown in the picture below.
Right
Right
Left Left
When attaching the bracket, conrm the direction of bracket.

FC9000-UM-251-9370 2-4
2 Setup
(6) Attach a media stocker roll bracket to each of the left and right stand sides as shown in the picture
below. And then fasten with the four M5L16 cap screws (two long screws for each side), using the Allen
wrench.
(7) Attach the stopper to the stock roller, and then put on the stock rollers on the media stocker bracket as
shown in the picture below.
(8) Conrm the direction of basket cloth arm as shown in the picture below, and then attach the basket cloth
arm to the foot of stand.
Fasten with the eight M5L16 cap screws (eight long screws for each basket cloth arm), using the Allen
wrench.

FC9000-UM-251-9370 2-5
2 Setup
(9) Insert the basket tubes to the basket cloth as shown in the picture below.
Insert the long tube to the center of basket cloth, and insert the short tubes to the front and rear.
Short tube
Long tube
(10) Put on the center basket tube onto the basket tube hanger brackets, and then connect the front and
rear basket tube to the basket cloth arm as shown in the picture below.

FC9000-UM-251-9370 3-1
3 PARTS NAMES and FUNCTIONS
3 PARTS NAMES and FUNCTIONS
3.1 Parts Names and Functions
Front View
Power switch
Cutting groove
Cutting mat
Push roller
Grit roller
Media sensor
Cross cutter unit
Push roller
positioning guide
Tool carriage Tool holder
Media Set lever
Control panel
Media stopper
Pen station
Pen holder
(Optional)
(Optional)
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.
Tool carriage:..................... Moves the cutter-pen or plotting pen across the media during cutting or plotting.
Tool holder:........................ Holds the cutter-pen or plotting pen and moves it up or down.
Pen station, pen holder:.... Second pen is mounted here. (installed on 2-pen models only)
Grit roller position guide:.. Stickers on the front of top cover that show the position of each grit roller. Use
these alignment marks as an aid in locating the pinch rollers.
Cutting mat:........................ Cutter blade moved on this mat, preventing wears of the blade.
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.
Media Stopper:................... 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.
Media set lever:.................. Used to raise or lower the pinch rollers during the loading or unloading of media.

FC9000-UM-251-9370 3-2
3 PARTS NAMES and FUNCTIONS
Rear View
Push roller hold-down force switching lever
Media set lever
Stock rollers
Media stocker
AC line inlet
USB interface
Stopper Stand
Basket
USB memory
port
Optional RS-232C interface
for Japanese and Chinese
model
Network interface (LAN)
AC line inlet:....................... Inlet where the power cord is connected.
Push roller hold-down force switching lever:
............................................. Used to switch between the three pinch roller forces.
Media stocker:.................... Used to carry roll media and ensure its proper rotation.
Stock rollers:...................... A media roll is placed on these rollers.
USB interface connector:
............................................. Used to connect the plotter to the computer with a USB interface cable.
Network interface connector:
............................................. Used to connect the plotter to the computer with a network interface cable.
Optional RS-232C interface connector:
............................................. Used to connect the plotter to the computer with an RS-232 serial interface
cable.
This option is for the Japanese and Chinese model only.
USB memory dedicated port:
............................................. The port that is used only for the USB memory.
Stand:.................................. Stand for the plotter.
Basket:................................ Used to receive Media and removing static electricity from media.

FC9000-UM-251-9370 3-3
3 PARTS NAMES and FUNCTIONS
3.2 Attaching a Tool
Attach a tool (cutter pen, plotter pen) to the plotter.
Attaching a Tool
When mounting the tool in the tool holder, push the tool all the way into the holder until its ange contacts
the upper part of the holder and then tighten the screw rmly. To prevent injury, avoid touching the tool
immediately after the cutting plotter is turned on or whenever the tool is moving. It is explained here using
cutter pen as an example.
(1) Loosen the pen holder screw.
(2) While pushing the tool holder in the upward direction, push the tool all the way into the holder until its
ange contacts the upper part of the holder.
• When pushing the tool holder with your ngers, the blade tip may be protruding. Take care not to cut
your ngers.
For half cutting
(backward)
For cutting out
(forward)
Tool holder
Bracket to hold tool Flange