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FC5100-UM-252-07-9370

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2. Firmware C4 2 Data File Output Utility Ver 2 08 Look in File name Print Files of Data Files plt prn Cancel type Output LPT1 No of 1 Look in is the selector of the folder The saved files in the selected folder are shown in the file window that is under the file selector File name is the selector of the file You can type in the file name into the box or click the file that is shown in the file window Files of type is for specifying the type of file The default set up is the data file with plt or prn as the extension of the file name Other settings allow you to see all files in this setting Output is the selector of the output port The default set up is when the parallel interface printer port and LPT1 appear on the output port selector When you wish to use the USB interface click the V button and then select the name of the plotter into which you are installing the plotter driver Set Up the Plotter Driver Program 1 Obtain the plotter driver OPS628 Ver 7 12 or later from your Graphtec distributor 2 See the Read file on the plotter driver OPS628 7 12 or later for detailed installation instructions CUTTING PRO FC5100 Firmware C4 3 2 Downloading the Boot Program The boot program contains the necessary code to start the system and download the program The b
3. C2 24 5 6 How to replace the Y Tension Pulley with C2 26 5 7 How to replace and adjust the X Drive Belt C2 28 5 8 How to replace the X Motor and X Motor Pulley C2 30 5 9 How to replace the X Drive C2 32 5 10 How to tighten the Grit Rollers C2 34 5 11 How to replace and adjust the X drive Shaft with the Grit Rollers C2 35 5 12 How to adjust the Y slider Assembly C2 37 5 13 How to replace and adjust the Y Rail Assembly C2 39 5 14 How to replace and adjust the Y Slider Assembly C2 42 5 15 How to replace the Pinch C2 45 5 16 How to replace the Pinch Roller Spring C2 46 5 17 How to replace and adjust the Pen Head Block C2 49 5 18 How to adjust the Pen Arm Guide C2 51 5 19 How to replace the PCA Pen C2 52 5 20 How to replace the Y Flat Flexi
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6. C1 19 4 3 1 Method et EE C1 19 4 3 2 Method a ace nse eee C1 20 4 4 Testing the Control Panel Keys C1 22 5 Special Condition Settings 40222222 111 1 C1 25 5 1 Special Condition 1 25 5 1 1 UP ARROW Key POWER C1 25 5 1 2 DOWN ARROW Key POWER 24 2222 C1 25 5 1 3 RIGHT ARROW Key POWER 2222222 1 C1 25 5 1 4 LEFT ARROW Key POWER 2 2 4 1 C1 25 5 1 5 CONDITION Key POWER 42422 42 1 C1 25 5 2 Setting the Pen Up Condition C1 26 5 3 Setting the Parallel Interface C1 28 5 3 1 Method e per C1 28 5 31 ge 2 e C1 30 Chapter 2 Removal and Replacement Procedures 1 Before REB C2 1 2 Safety C2 2 3 Components Not to be Removed C2 3 3 1 Right side plate and Left side
7. 2259 gt 0 0 5100 100 all_ Pull force is 2 25kg 0 2kg o 5100 1334 all_ Pull force is 2 25kg 0 2kg 5100 152 Pullforceis2 25kg 0 2kg Tips For details see Chapter 2 5 7 How to replace and adjust the Drive Belt section 2 4 Pinch Roller Pressure Pull the pinch roller using a force gauge read the pressure force when the pinch roller lifts up from the grit roller When measuring the pinch roller pressure move the right pinch roller to the right edge of the grit roller and move the left pinch roller to the grit roller that is located at the far left Model Specification FC5100 75 The pinch roller pressure is 6 5kg 0 5kg 6 0kg to 7 0kg force The pressure difference between the right and left pinch roller is less than 0 4kg FC5100 100 The pinch roller pressure is 6 5kg 0 5kg 6 0kg to 7 0kg force The pressure difference between the right and left pinch roller is less than 0 4kg The center pinch roller pressure is less than 5 2kg 0 5kg 5100 130 The pinch roller pressure is 6 5kg 0 5kg 6 0kg to 7 0kg force The pressure difference between the right and left pinch roller is less than 0 4kg The center pinch roller pressure is less than 5 2kg 0 5kg FC5100 150 The pinch roller pressure is 6 5kg 0 5kg 6 0kg to 7 0kg force The pressure difference between the right and left pinch roller is less than 0 4kg The center pinch roller pressure is less than 5 2kg
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9. 2 2 Station 2 Holder amp Station Parts List 711 339302001 2 397120250 622102071 Loam S SSS 4 622192001 wmSping2forzpenode 4 s 622192060 Pentor o 6 053203420 622192081 Arm Spring 1 for 2 pen station 762219702 PenHoderAssy4200 10 792219703 PenHoderAssya20 5 7 Light Pointer Assy Light Pointer Assy Parts List 1 621179841 Light Pointer Bracket 1 2 792217714 Light Pointer Assy for STD 1 For export model 792217715 Light Pointer Assy for Japan model For Japan model 304440005 Light Pointer Spacer D3x2 L4 0 0 7 CUTTING PRO FC5100 Parts List C5 9 5 8 Y Slider FC5100 75 Y Slider FC5100 75 Parts List 2 2230020 5pmecuma omo 4 290 vSidrag Foony s emos Y Bett Fring Pe f 2 Fc9to ony e emusso vSewoBmoeS o 7 777247680 mehRorSemo oOo 1 3 s 692117530 cabe CA s6040 058T s CUTTING PRO FC5100 Parts List C5 10 5 9 Slider 5100 100 130 150 Y Slider FC5100 100 130 150 Parts List 2 392280020 0000 4 O s 621183420 Belt Fixing Paes 2 _ 5 e 6211
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11. zemwrr derPuyAe fwrrCsmois ________ 1 Fcswoso 52 392265010 Idler Pulley Bottom Spacer for FC5100 75 FC5100 75 EE 3 MEE 1 EIBCI e 5 500051095 Power ewe sere 311000400 Idler Pulley Bearing for FC5100 75 100 130 FRABZZ 22 00 B 311060620 Drive Pulley Bearing 2 260677 CUTTING PRO FC5100 Parts List C5 6 5 4 Frame FC5100 100 130 150 Frame FC5100 100 130 150 Parts List 4 5 1 621200820 7 soosos mwrewowzugo CUTTING PRO FC5100 Parts List C5 7 5 5 Pen Block Pen Block Parts List No Part No Description QTY Remarks 1 310068320 Roller 683ZZMC3PS2S 2 2 622192012 Cutter Holder A 1 3 622192022 Cutter Holder 1 4 621113591 Thumb Screw L10 1 5 621174031 Carriage Cover FC51 1 6 617363390 Guide Shaft 1 7 691700521 Pen Encoder Sensor FPC FPC601103A 1 8 380205551 Spring E555 1 Standard model 380205351 Spring E535 1 2 pen amp Auto Regi model 9 305320007 MC Coil PL326B 1 10 617363351 Pen Encoder Strip 1 11 621113530 Guide Roller Base 1 12 392030025 Bush D3L2 5 2 13 500050122 Pen Encoder Sensor 1 CUTTING PRO FC5100 Parts List C5 8 5 6 2 Pen Holder amp Station 2 Pr Cut this part
12. 62180350 cutimgMatAsyferFCSio0 100 1 FCSt00 100 Cutting mat wih bess 621190350 Cutting Mat Assy for Fst00 130 1 FCSt00 30 Cutina 621200350 Cutting Mat Assy for FC5100 150 1 FC5100 150 Cutting mat with base 62180301 Vacuum Base Reinforcement 100 1 21190302 Vacuum Base 71 SCS 00 00 Vacuum Base Reinforcement 150 1 19 621170332 Vacuum Base 75 1 FC5100 75 EE 2 3 emen vacuum Base 80 621200830 vacuum Base 180 1 20 502210002 SewowPs sLA M X XSemw Em 621170070 FrontSensorBracket 1 22 621170321 Rear Guide FC5100 75 6219032 Rear Guide 621183200 belt forFC5100 100 200sawrsaauwe 1 621193200 belt for 5100 130 250S2M1602LWC 1 For FC5100 130 ee a mm 621180342 Flexible Cable Guide 100 Gees Y Fiexbie Cabe Gude in 621200361 Y Fiexbie Cable Guide 150 1 25 692117540 Y Flexible Cable CA 56040 054T 1 Y Flexible Cable for FC5100 75 5 2 2 692117550 Cable CA 56040 055T _1_ Flexible 5000430 sso Y Fiexbie caooroo4 1 Cable 8100180 CUTTING PRO FC5100 Parts List C5 5 621170032 Bracket Em 309100082 Spring Bush 095000040 Shaft Spri
13. C2 3 24 2 3 Pen Head C tmd i et C2 3 4 Common Removal and Replacement Procedures C2 4 4 1 How to remove and install the Right Side C2 4 4 2 How to remove and install the Left Side C2 6 4 3 How to remove and install the Top Cover Assembly C2 8 4 4 How to remove and install the Pen Head C2 9 4 5 How to remove and install the Rear C2 10 4 6 How to remove and install the Front C2 12 4 7 How to replace the PCA Main Board C2 13 5 Replacing and Adjusting Procedures C2 15 5 1 How to replace and adjust the Lever and Lever Cap C2 15 5 2 How to replace and adjust the Y slider C2 16 5 3 How to replace and adjust the Y drive C2 19 5 4 How to replace the Y drive Motor and Y motor Pulley C2 22 5 5 How to replace the Y drive Pulley Assembly
14. Make sure there are no loose mounting screws the pulleys motors grit rollers pen head mechanism or Y slider Check the tension of the X drive belt Y drive belt and or the Y slider belt Check movement friction of the Y slider and or the grit rollers Check the pen head and make sure there is no play on the pen arm mechanism Check the servo gain Poor line quality There may be play in the driving mechanism There may be friction in the driving mechanism 1 a RON Make sure there are no loose mounting screws on the pulleys motors grit rollers pen head mechanism or Y slider Check the tension of the X drive belt Y drive belt and or the Y slider belt Check movement friction of the Y slider and or the grit rollers Check the pen head and make sure there is no play on the pen arm mechanism Check the servo gain CUTTING PRO FC5100 Diagnosing Problems C1 7 Too large difference on the phase There may be play in the driving mechanism There may be friction in the driving mechanism 1 sure there are no loose mounting screws the pulleys motors grit rollers pen head mechanism or Y slider Check the tension of the X drive belt Y drive belt and or the Y slider belt Check movement friction of the Y slider and or the grit rollers 2 3 4 Check the pen head and make sure there is no play on the pen arm mechanism 5 Check the servo gain Too large difference on the perpendic
15. RAM CH CONDITION 2 EADY CONDITION 2 EADY HL ECKING BACKGROUND SETTINGS gt OPTION 1 gt OPTION 2 gt CUTTING PRO FC5100 Diagnosing Problems 7 Press the F4 OFFSET key to select TEST INITIAL DOWN FORCE gt DISTANCE ADJUST gt TEST gt 8 Press the F1 FORCE key to select the special function Then press the F1 FORCE key and the ENTER key at the CONDITION 115 gt SELF TEST gt same time The Test menu will then appear DATA DUMP gt 9 Press the F1 FORCE key to select MECHA The following menu appears the plotter immediately starts ECHA CHECK PAT the test pattern plotting NOTE If you want to cancel the test pattern plot turn off the power to the plotter 10 When plotting is complete the pen will stop Turn off the power to the plotter Checks Inspect the check patterns For more information see the Inspecting the Check Pattern section Adjustments Make the necessary adjustment only if you have a check pattern failure CUTTING PRO FC5100 Diagnosing Problems C1 3 Inspecting the Check Pattern Overshoot Check the deviation on each corner Measure the maximum deviation Ae using a glass scale and loupe Specification FC5100 75 Aeis below 0 12mm 0 12mm gt FC5100 100 Ae is below 0 12mm 0 12mm gt FC5100 130 Ae is below 0
16. 699 2d 4 10128uu07 GOONS Nad AS ZSN3S d SN3S 20135 SNS 3 AIMO S SABIO dii a 9 JOONI 5 QOONZ dW 20542 UBH 2 uag 2 135 SNS youd wus 8 2655 3d3 4019euu07 WS Nad s 4 OW Nad CUTTING PRO FC5100 ELECTRICAL C6 15 Pinch Roller Sensor Board Ui VCC PR 1 apo Pu OUTER 4 PINCH ROLLER SENSz E OPT Sensor GP1A53HR Pinch Roller v Sensor Mark Sensor Connector FFC Spin To Pen Board mo miM 51004 0600 MARK SENSOR BOARD PR611101 2 21 55 105 tmm pitch SNS1 1 1 1 1 1 i KR1228 1 1 i 1 CUTTING PRO FC5100 HISTORY OF REVISIONS Description of revision 2005 03 03 Part number for the pinch roller R assy corrected 5 1 C5 11 06 2005 03 03 Part number for the pinch roller L assy corrected C5 1 C5 11 06 2005 04 07 Part number for the key pad corrected C5 1 C5 2
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18. 2 model AMAA AW CUBA DOU 00000 12345678 12345678 12345678 12345678 FC5100 75 FC5100 100 FC5100 130 FC5100 150 Checks B Not required Adjustments B Not required CUTTING PRO FC5100 Parameter Settings C3 17 9 Adjusting the Plot Area This adjustment will set the position of the plot area with respect to the pinch rollers Run this test if you replace the Pen board or Main board Run this test if you move the position of the Pen board Tools Phillips screwdriver for an screw Ceramic pen 0 2mm tip size A4 size ANSI A size or larger size paper Preparation Requirements 1 Tips Remove the right side cover from the plotter For details of step 1 see Chapter 2 Section 4 1 How to Remove and Replace the Right Side Cover Adjustment Set Up Requirements 1 Attach the pen to the penholder Load the paper into the plotter Move the pen carriage near the right pinch roller manually so that it is inside of the pinch roller Set SW1 to the system parameter setting mode as illustrated below Production adjustment mode for the standard model and Auto registration model Set DIP switches No 4 and 5 6 to OFF Other DIP switch settings depend on the type of model Cem Production adjustment mode for 2 pen model Set the distance parameters to exchange Pen 1 and Pen 2 Set DIP switch No 4 to ON and 5 6 to OFF Other DIP switch settings
19. 7 CUTTING PRO ____ 100 SERVICE MANUAL GRAPHTEC CORP CONTENTS Chapter 1 Diagnosing Problems 1 Test Modes for Production Inspection C1 1 1 1 Mechanical Check Pattern 1 1 1 2 1 8 1 3 Printing the Skew Test Patterns C1 10 2 Mechanical Adjustment cisiiisinnnsnnascstinnnensiccccancacestanencsosseuneeerwstecenns C1 12 2 1 Y Slider Belt 4 4 4 2 1 C1 12 2 2 Y Drive Belt Vem si RM C1 12 2 3 X Drive Belt Tension AEn C1 12 2 4 Pinch Roller Press re gece usce Ged 1 12 2 5 Pen Head Position M C1 13 2 6 Pen ATM isise SERTE C1 13 3 Running the Aging Patterns eee C1 14 4 Test Methods for Hardware Problems C1 16 41 Eee ER DCUIM C1 16 4 1 1 Checking the Power C1 16 4 1 2 THE Protective wec 1 16 4 2 Testing the SSMS ONS dence sae eet eee 1 17 4 3 Temporary Use of the Plotter without the Sensor
20. CUTTING PRO FC5100 Removal and Replacement Procedures C2 37 5 12 How to adjust the Y slider Assembly Overview If the plotter exhibits poor cutting plotting results one possibility may be that the Y slider assembly and Y rail have become loosely connected Adjust the Y slider assembly accordingly Tools Phillips screwdriver for an screw Hex Nut driver size 5 5mm Hex L key Wrench size 1 5mm for an Socket Set screw Cutter Pliers As required Force Gauge range 300g and 1kg Steel Rule Scale or Caliper metric scale at least 30mm or longer Screw Locker Adhesive type 14018 As required Silicon Grease type G501 As required Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the left side cover from the plotter See Chapter 2 Section 4 2 How to Remove and Install the Left Side Cover for more information 3 Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information 4 Remove the pen head cover from the plotter See Chapter 2 Section 4 4 How to Remove and Install the Pen Head Cover for more information 5 Remove the pen head block from the Y slider plate See Chapter 2 Section
21. Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information Remove the six 6 M3 Binder head screws that hold the control panel to the top cover 4 Pull the control panel out from the top cover assembly 5 Starting from the left side of the control panel lift up the sheet switch that is taped to the control panel and the LCD unit 6 Slowly pull off the sheet switch from the control panel Remove the Teflon tape from the flexible printed circuit cable FPC running from the sheet Switch CAUTION Gently separate the sheet switch from the LCD unit area If the sheet switch is pulled too hard damage may result to the LCD or the LCD panel may come off If the panel is separated from the LCD unit it is not repairable Storage Procedure Carefully place the control panel and the top cover onto a flat surface to prevent damaging the components Reinstallation Procedure 1 Check that sheet switch area on the control panel is free from glue and dirt Clean off any dirt or glue with a cloth moistened in ethyl alcohol Insert the FPC running from the sheet switch into the hole on the control panel do not use the hole on the side of the control panel Center the sheet switch in the rece
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23. 5 3 1 Method 1 The Parallel Interface Condition is set by the hardware setup Tools Phillips screwdriver for an M3 screw Preparation Requirements 1 Tips Set 1 Note Remove the right side cover from the plotter For details of step 1 see Chapter 2 Section 4 1 Up Requirements Set SW1 to the system parameter setting mode as illustrated below ment Turn on the power to the plotter First the Initial menu appears and then the Item Selection V 1 00 HL menu appears RAM CHECKING Press the F4 OFFSET key to select PARALLEL FORCE PEN UP PARALLEL Press the UP ARROW key or the DOWN ARROW key to change the setting Press the ENTER key to store the setting Setting the parameter to 1 or 2 will change the timing of the BUSY signal When you have a problem on the parallel interface change the setting of the parameter and then use the parallel interface The item selection menu appears FORCE PEN UP PARALLEL CUTTING PRO FC5100 Diagnosing Problems C1 29 6 If you wish to continue the settings press the necessary key to select other parameters If you wish to finish the parameter setting or when all of the parameters are set turn off the power to the plotter Return the SW1 setting to normal mode as illustrated below Normal mode Factory shipment Standard model MARAN
24. Serial RS232C Interface Selection menu then appears Graphtec Cutter Servo Gain Adjust Program Version 2 00 Computer s Serial RS232C Interface Port Selection Press 1 Key to select the COM 1 port Press 2 Key to select the COM 2 port Press Key to EXIT this Program Select the RS232C Interface Port to use the Servo Gain Adjustment 2 The Serial RS232C Interface Port Test menu appears Graphtec Cutter Servo Gain Adjust Program Version 2 00 Serial RS232C Interface Port Test Connect the Serial RS232C cable and set condition on the plotter RS232C Interface 9600 BAUD 8 BIT NONE PARITY HARDWIRE Command Others COMMAND GP GL STEP SIZE 0 1mm Press any Key to start the Serial RS232C Interface Port test When testing is complete the Model Selection menu appears Press any key on the keyboard to start the test 3 The Model Selection menu appears Select FC4100 75 100 130 Graphtec Cutter Servo Gain Adjust Program Version 2 00 Graphtec Cutter Model Selection Press 3 Key to select the FC4100 75 100 130 Press 4 Key to select the FC3100 60 FC2100 60A Press 5 Key to select the FC3100 100 120 Press 6 Key to select the Others Press 0 Key to RETURN to the Interface Port Selection menu Press Key to EXIT this Program CUTTING PRO FC5100 Parameter Settings C3 27 4 The Action Item Selection menu appears Graphtec Cutter Servo Gain Adjust Program Version
25. Use the UP ARROW key or the DOWN ARROW key to change the force setting The number on the LCD will increase or decrease Press the F1 FORCE key to raise the pen press the F1 FORCE key again to lower the pen Measure the actual force again NOTE Before measuring the force make sure to raise and then lower the pen Adjust the 10g pen force If the measured value is within range of specification 17g 19g press the ENTER key to store the setting The next specified pen force appears Adjust the 40g pen force If the measured value is in range of specification 360 44g press the ENTER key to store the setting The next specified pen force appears Adjust the 120g pen force If the measured value is in range of specification 108g 132g press the ENTER key to store the setting The next specified pen force appears Adjust the 265g pen force If the measured value is in range of specification 239g 291g press the ENTER key to store the setting The next specified pen force appears Adjust the 430g pen force If the measured value is in range of specification 440g 480g press the ENTER key to store the setting The adjustment item selection menu appears Tips When adjusting the pen force it is important to do it quickly Delaying the pen force adjustment changes the temperature of the actuator and causes artificially lower readings When this happens the actual pen force may be higher than the specification This is especi
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27. 1 3 Replacing the Pen Head Assembly C3 1 1 4 Replacing the PCA Pen Board C3 2 2 Locations of the Components on the Main Board C3 3 3 Setting the DIP Switches rina nandi arra toni yx uai C3 4 4 Factory Preset Settings UU ceu do C3 6 5 Clearing the Non Volatile 4 2 2 2 1 2 1 C3 8 6 Setting the Servo Gain C3 10 7 Adjusting the Pen FOFGG C3 12 8 Adjusting the LED Pointer Offset C3 15 9 Adjusting the Plot Area rennen tat C3 17 10 Adjusting the Distance Accuracy C3 20 11 Adjusting the Servo Gain 4 2 2 C3 23 11 1 Installation and Starting the Servo Gain Adjustment C3 23 11 2 Adjusting the Servo Gain 2 1 1 C3 25 Chapter 4 Firmware 1 Installation and Starting the Data File Output Utility Program C4 1 2 Downloading the Boot Program eese C4 3 3 Downloading the Main Program C4 5 Chapt
28. 12345678 12345678 12345678 FC5100 75 FC5100 100 FC5100 130 150 Sensor test mode Set DIP Switches No and 4 5 6 7 to ON Test the sensors m Key test mode Set All DIP Switches to OFF Test the control pano keys CUTTING PRO FC5100 Parameter Settings C3 5 Production adjustment mode This is the setup mode for the system parameters Set the servo gain parameters Set the pen force parameters Set the LED pointer offset parameters Set the plot area position parameters Set the pen up condition parameter Set the parallel interface condition parameter Set the Auto Registration Mark sensor parameters Auto Registration Mark option Set the pen offset parameter 2 Pen option Production adjustment mode for the standard model and Auto registration model Set DIP switches No 4 and 5 6 to OFF Other DIP switch settings depend on the type of model CERT Production adjustment mode for 2 pen model Set the distance parameters to exchange Pen 1 and Pen 2 Set DIP switch No 4 to ON and 5 6 to OFF Other DIP switch settings depend on the type of model DTE SERVO GAIN COMPENSATION SETTING mode This is the setup mode for the system parameters 1 2 Set the servo gain compensation parameters This setting is available on the FC5100 100 and FC5100 130 only ww CUTTING PRO FC5100 Parameter Settings C3 6 4 Factory Preset Settings This step will change the user
29. 3 Have two people remove the plotter from the stand Proceed with caution taking care not to drop the plotter from the stand How to disassemble the Stand 1 Remove the basket option if it is installed on the stand 2 Remove the two 2 plugs that cover the screw access holes on the right side leg of the stand 3 Remove the two 2 M6 Socket Cap screws that hold the middle bar onto the right side leg of the stand 4 Remove the two 2 plugs that cover the screw access holes on the left side leg of the stand Remove the two 2 M6 Socket Cap screws that hold the middle bar onto the left side leg of the stand Storage Procedure m Lay the components on a flat surface to prevent damage How to assemble the Stand 1 Install the middle bar onto the right side leg of the stand using two 2 M6 x 16mm Socket Cap screws 2 Install the two 2 plugs into the screw access holes on the right side leg of the stand 3 Install the middle bar onto the left side leg of the stand using two 2 M6 x 16mm Socket Cap Screws 4 Install the two 2 plugs into the screw access holes on the left side leg of the stand Install the basket option if necessary CUTTING PRO FC5100 Removal and Replacement Procedures C2 67 How to install the Plotter 1 Lock the casters on the stand 2 Have two people mount the plotter onto the stand Align the index pins on the stand into the holes on the media bracket of the plotter The side leg mounts onto the
30. 6 11 Main Board I O Connection 3 C6 12 Main Board Power Section C6 13 P n Board 6 14 Pinch Roller Sensor Board e rectc tu C6 15 Sensor NEN o T RT C6 15 Diagnosing Problems Chapter 1 Diagnosing Problems This chapter describes how to diagnose plotter problems 1 Test Modes for Production Inspection This step will plot the inspection test patterns that are stored on the Flash ROM Tools Ceramic pen 0 2mm tip size 1 size or ANSI 0 size tracing or vellum paper Glass scale 0 1mm resolution 0 05mm resolution recommended Loupe magnification 25 and 50 1 1 Mechanical Check Pattern Printing Requirements 1 Attach the pen to the penholder and load the paper into the plotter with the longer edge in the X axis Turn on the power to the plotter First the Initial menu appears then the Media Type menu Press the F3 QUALITY key to select SHEET The initialization routine is executed to determine the paper size The Ready menu appears Set the condition as follows FORCE 12 SPEED 20 QUALITY 6 Tool PEN Press the MENU key to obtain the MENU mode The Menu Mode menu appears Press the NEXT key until the Option menu appears Press the F4 OFFSET key to select OPTION 2 1 00
31. Adjustments H 1 Adjust the Y slider Assembly On the top of the Y slider assembly there are two 2 screws on the FC5100 75 model and four 4 screws on the FC5100 100 130 models Loosen the M3 x 6mm Flanged Binder head screws and the one 1 M3 x 6mm Socket Head screw holding the Y slider bracket Tighten the one 1 M3 x 6mm Socket Head screw While pushing the Y slider roller bracket toward the Y rail tighten the M3 x 6mm flanged screw from the inside out on both sides Check the Y slider assembly assuring that it is mounted firmly to the Y rail The Y slider assembly should not be loose from the Y rail If it is loose repeat steps 1 4 until the Y slider is firm against the Y rail but still slides smoothly from left to right The spring plate adjustment sets proper pressure between both the top and bottom Y slider rollers and the Y rail It also reduces roller bearing overload or overbidding it minimizes roller drag reduces roller wear and minimizes Y slider front to back pivot See Chapter 2 Section 5 12 How to Adjust the Y slider Assembly for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 44 The Y slider belt tension adjustment sets proper belt tension Incorrect tension can cause Y axis problems such as overshoot errors and out of phase alignment problems See Chapter 2 Section 5 2 How to Replace and Adjust the Y slider Belt for more information The pen height adjustment sets the
32. B Not required Set Up Requirements Turn on the power to the plotter while pressing the DOWN ARROW key 1 2 The Initial menu appears The language selection menu appears Press the NEXT key until the media sensor menu appears If the media sensor is malfunctioning press the F4 OFFSET key to disable the sensor If the media sensor is functioning correctly press the F3 QUALITY key Press the ENTER key to store the setting If the pinch roller sensor is malfunctioning press the F4 OFFSET key to disable the sensor If the pinch roller sensor is functioning correctly press the F3 QUALITY key Press the ENTER key to store the setting Turn off the power of the plotter Then turn on the power of the plotter The initial menu appears The media type menu appears Select the media type The initialization routine is executed to determine the paper size by using the available sensor 10 The READY menu appears 1 00 C1 20 HL ER RAM CHECKING LANGUAGE English PINCH ROLLE 1 00 CONDITION 1 EADY HL ER RAM CHECKING 30 4 CB09Ux 0 CUTTING PRO FC5100 Diagnosing Problems C1 21 11 Set plot area For more information see Chapter 5 AREA in the User Manual CAUTION Exercise extreme caution when using the plott
33. Phillips screwdriver for an M3 screw Ceramic pen 0 2mm tip size A2 size paper or ANSI C size paper Scale 500mm long and 0 2mm resolution Preparation Requirements 1 Tips Remove the right side cover from the plotter For details of step 1 see Chapter 2 Section 4 1 How to Remove and Replace the Right Side Cover Adjustment Set Up Requirements 1 Attach the pen to the penholder Load the paper into the plotter with the longer edge in the X axis Set SW1 to the distance adjustment mode as illustrated below Set DIP switches No 4 to OFF and 5 6 to ON Other DIP switch settings depend on the type rear nuege Turn on the power to the plotter First the Initial menu appears and then the Media Select 1 00 HL menu ER RAM CHECKING Press the F3 QUALITY key to select SHEET the initialization routine is executed to determine the paper size The adjustment menu appears Press the F3 QUALITY key to select PATTERN PLOT mode the following menu appears If you known the values to DISTANCE ADJUST enter press the F4 OFFSET key to begin the parameter set X 0 Y 0 mode PATTERN PLOT PARAMETER SET CUTTING PRO FC5100 Parameter Settings C3 21 6 Press the ENTER key to start the test The plotter immediately plots the test pattern the following menu appears The plotter plots four lines Fo
34. digit 15 LEFT ARROW 1 row 8 digit 18 st i Status Bit Key 1st row 1 digit 1 UP ARROW ke 15 row 2 digit NEXT ke 15 row 3 digit ALIGN 1st row 4 digit Not applicable 15 row 5 digit CONDITION ke 15 row 6 1 DOWN ARROW ke 15 st 14 12 digit__F4 ke 14 ___137 digit__ COPY ke i row _ 14 TEST ke 15 _ 15 digit ORIGIN ke 1 ___167 ENTER ke igi ORIGIN ke i row 15 digit i 2174 row 274 digit 2 LEFT ARROW 214 row 34 digit MENU ke 279 row 4 digit HOLD ke Press the MENU key the status will change to 1 and the lamp will light Press the MENU key again the status will change to 0 and the lamp will turn off Press the HOLD key the status will change to 1 Press the HOLD key again the status will change to 0 Press the ARROW key the 1st level of the key status will change to 1 Press the ARROW key again the 2nd level of the key status will change to 1 4 When testing is completed turn off the power to the plotter Return the SW1 setting to normal mode as illustrated below Normal mode Factory shipment Standard model ETT EEUU ENTIS Auto registration model TONBO PRG RUM FC5100 75 FC5100 100 FC5100 130 FC5100 150 2 pen model 10000 TRA AOU dun 12345678 12345678 12345678 12345678 5100 75 5100 100 5100 130 5100 150 CUTTING
35. for more information 3 Loosen the three 3 M3 SEMS pan head screw with flat washer screws that hold the X drive motor to the right side plate 4 Remove the X drive belt from the X drive motor and X drive pulley CAUTION The motor has a strong magnet The motor will stick to the steel plate when you remove the mounting screws If the motor hits the steel plate with excessive force it may damage the motor or the steel plate Storage Procedure Carefully place the part onto flat surface to prevent damage Reinstallation Procedure Install the X drive belt onto the X motor pulley on the X drive motor Install the X drive belt onto the X drive pulley on the right side plate Adjust the X drive belt tension see Adjustments section for details Apply silicon grease onto the tooth side of the X drive belt Install the PCA Main board onto the right side plate oa e Install the right side cover onto the plotter Checks All torque settings for the assembly of components to be set at standard settings CUTTING PRO FC5100 Removal and Replacement Procedures C2 29 Adjustments X belt tension adjustment is needed to set proper tension of the belt to maintain machine 1 performance reduce motor shaft deformation and extend the machine s operational life Tighten the three 3 M3 SEMS screws that hold the X drive motor to the right side plate 2 Turn the mounting screws 180 degrees cou
36. re start the download and then press the F4 OFFSET key to select MODE2 If you are using the USB interface press the F3 QUALITY key or the F4 OFFSET key and go to the next step 7 The Flash Clear menu appears The plotter will immediately FLASH CLEAR start to clear the programs in flash memory ECTOR BLOCK 8 When the program is clear the Send Boot Program menu SEND BOOT PROGRAM appears 000KB COMPLETED CUTTING PRO FC5100 Firmware C4 4 9 Set the File to the loader x file on the Data File EDIA Output Utility Program to select the boot program Click on the Print button to start downloading After the downloading INITIAL MENU gt is complete the LOAD MEDIA menu appears 10 Turn off the plotter s power and disconnect the interface cable Checks you need to do Verify that the plotter starts after turning on the power If it does not start the plotter has lost the boot program You must replace the flash memory located on the PCA Main board or replace the PCA Main board Adjustments you may need to do Clear the system control parameters on the NOVRAM and make the adjustment if necessary CUTTING PRO FC5100 Firmware C4 5 3 Downloading the Main Program The main program has a code to control the moving mechanisms the control panel interface and other systems The main program source file is called 51 100 for the FC5100 75 1
37. 0 5kg CUTTING PRO FC5100 Diagnosing Problems C1 13 Tips For details see Chapter 2 5 16 How to replace the Pinch Roller Spring section 2 5 Pen Head Position Remove the pen cover Check the position of the pen head in relation to the cutting mat surface Specification The length between the bottom of the pen head and the cutting mat surface is 10mm Tips For details see Chapter 2 5 17 How to replace and adjust the Pen Head Block section 2 6 Pen Arm Move the pen arm up and down front to back and clockwise CW to counterclockwise CCW Specification The pen arm moves up and down smoothly The pen arm has no play between front to back or CW to CCW Tips For details see Chapter 2 5 18 How to adjust the Pen Arm section CUTTING PRO FC5100 Diagnosing Problems 3 Running the Aging Patterns This step will set the aging test The test pattern is stored on the Flash ROM Tools Pen size ANSI D size paper Printing Requirements 1 C1 14 Attach the pen to the penholder Load the paper into the plotter with the longer edge in the X axis Turn on the power to the plotter The Initial menu appears then the Media Type menu Press the F3 QUALITY key to select SHEET The initialization routine is executed to determine the paper size The Ready menu appears Set the condition as follows FORCE 12 SPEED 20 QUALITY 6 Tool PEN Press the MENU key to obt
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40. As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information Disconnect the cables from P6 and P7 on the PCA Main board Remove the cable clamp and the wire tie from the cable as stated above Remove the four 4 M3 SEMS pan head screw with flat washer screws that hold the Y drive motor to the bracket on the right side plate Remove the Y drive motor from the plotter 6 Remove the two 2 M3 socket set screws that hold the Y motor pulley to the shaft of the Y drive motor 7 Remove the Y motor pulley from the Y drive motor if necessary CAUTION The motor has a strong magnet The motor will stick to the steel plate when you remove the mounting screws If the motor hits the steel plate with excessive force it may damage the motor or the steel plate Storage Procedure Carefully place the part on a flat surface to prevent damage Carefully place the Y drive motor onto a clean area to prevent damage the motor will pick up steel components or dust CUTTING PRO FC5100 Removal and Replacement Procedures C2 23 Reinstallation Procedure 1 Install the Y motor pulley onto the shaft of the Y drive motor if necessary Tighten the two 2 M3 x 4mm socket set screws which are aligned with the flat surface on the shaft of the Y drive motor The top surface of the Y motor pulley aligns to the
41. Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information Disconnect the flat flexible cable FFC from J5 on the PCA Main board and J1 on the PCA Pen board Loosen but do not disengage from the square nut inside the Y rail the M3 Binder head screws that hold the flat cable support shelf bracket to the flat cable support bracket Remove the FFC which is taped to the FFC bracket Pull the FFC out from the plotter Remove the Teflon tape from the FFC Storage Procedure Carefully place the part onto a flat surface to prevent damage Reinstallation Procedure 1 2 9 Apply the Teflon tape to the FFC starting at 120mm from the tip of the FFC Apply two 2 pieces of double coated adhesive tape onto the FFC bracket slot The first piece of tape should start at 85mm from the right end of the FFC bracket The second piece of tape should start at 300mm off from the right end of the FFC bracket Insert the taped side of the FFC into the hole on the right side plate Connect the FFC into J1 on the PCA Pen board Move the Y slider to the left end Fit the FFC into the FFC bracket slot The FFC should touch the left end wall of the FFC bracket There should be no bump over the FFC bracket Secure the FFC onto the FFC bracket slot using the double coated ad
42. Insert the two 2 black zinc plated M3 x 8mm Binder head screws into the left side plate 3 4 Insert the two 2 x 8mm SEMS screws into the bottom of the left side plate 5 Tighten the screws that hold the left side cover 6 Tighten the screws that hold the top cover assembly Checks All torque settings for the assembly of components to be set at standard settings Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 8 4 3 How to remove and install the Top Cover Assembly Overview Replace the top cover assembly if the top cover and or control panel have experienced failure are damaged or to replace other components Tools Phillips screwdriver for screw Cutter Pliers As required Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Disconnect the cables that connect to J3 J4 P2 and P10 on the PCA Main board Remove the cable clamp and the wire tie from the cables as stated above 4 Remove the M3 Binder head screw that holds the grounding tab running from the control panel to the right side plate Remove the six 6 M3 Binder head screws that hold the top cover assembly to the plotter Lift the top cover assembly up on the right side disconnect the cable from the
43. L key Wrench size 1 5mm for an Socket Set screw Cutter Pliers As required Force Gauge range 5kg V type force gauge head B Screw Locker Adhesive type 14018 As required Silicon Grease type G501 As required Cable Clamp and or Wire Tie As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the PCA Main board from the right side plate See Chapter 2 Section 4 7 How to Replace the PCA Main board for more information Remove the cable clamp and the wire tie from the cables running from the X drive motor 4 Remove the three 3 SEMS pan head screw with flat washer screws that hold the X drive motor to the right side plate Remove the X drive belt from the X drive motor and the X drive pulley 6 Pull the X drive motor out through the hole on the right side plate Remove the two 2 M3 Socket Set screws that hold the X motor pulley to the shaft of the X drive motor if necessary CAUTION The motor has a strong magnet The motor will stick to the steel plate when the mounting screws are removed If the motor hits the steel plate with excessive force damage may result to the motor or to the steel plate Storage Procedure The Main board should be handled following standard anti static procedures Carefully place the Y drive motor onto a clean area to pre
44. PRO 5100 Diagnosing Problems C1 24 Troubleshooting Tips m key does not respond properly check the following Check the connection of the cables to the Main board Check the components on the Main board Connector J3 or J4 Filter FL21 FL23 FL25 FL37 FL44 Diode D13 D19 Resistor RA35 RA36 IC U3 U21 Check the switch contact of each switch Replace the necessary component s Checks Not required Adjustments Main board is replaced you must re enter adjustment CUTTING PRO FC5100 Diagnosing Problems C1 25 5 Special Condition Settings 5 1 Special Condition Setting The following special condition settings are available with the control panel key operation 5 1 1 UP ARROW Key POWER ON Turn on the power to the plotter while pressing the UP ARROW key The NOV RAM Clearing menu appears For more information see Chapter 3 Factory Preset Settings section 5 1 2 DOWN ARROW Key POWER ON Turn on the power to the plotter while pressing the DOWN ARROW key The Multilanguage setting and Other Background setting menu appears For more information see Chapter 5 Background Settings section in the User Manual 5 1 3 RIGHT ARROW Key POWER ON Turn on the power to the plotter while pressing the RIGHT ARROW key The Downloading menu appears For more information see Chapter 4 Firmware section 5 1 4 LEFT ARROW Key POWER ON Turn on the power to the plotter while
45. The Menu Mode menu appears Press the NEXT key until the Option menu appears Press the F4 OFFSET key to select OPTION 2 Press the F4 OFFSET key to select TEST Press the F1 FORCE key to select the special test mode Press the F1 FORCE key and the ENTER key at the same time The Test menu will then appear Press the F3 QUALITY key to select the SKEW TEST 1 00 HL RAM CHECKING CONDITION 2 EADY DITION 2 EADY BACKGROUND SETTINGS gt OPTION 1 gt OPTION 2 gt INITIAL DOWN FORCE gt DISTANCE ADJUST gt TEST gt CONDITION 1 SELF TE DATA MECHA gt AGING gt EW TEST gt PATTERN gt CUTTING PRO FC5100 Diagnosing Problems 1 11 10 Skew Test Check menu appears the plotter immediately starts plotting the test pattern NOTE If you want to cancel the test pattern plot turn off the power to the plotter 11 When plotting is complete return to the Condition menu CONDITION 2 EADY Checks Check the skew test pattern by measuring the length between the marks If the plotter has a skew problem the length between the marks will not be the same Adjustments B Not required Troubleshooting Tips Check the pinch roller pressure If the right pinch roller pressure and the left pinch roller pressure are unequal feeding problems will result Check t
46. This is an option for the FC5100 75 FC5100 100 FC5100 130 and FC5100 150 model cutting plotters CAUTION Improper assembly of these pieces may cause the unit to become unstable when heavy loads are added In extreme cases the unit may tip over A NOTE Always keep the wheels in a locked position when operating your plotter Tools Hex L key Wrench size 5mm for M6 Socket Cap screw How to disassemble the Media Roll Holder 1 Remove the stock rollers from the MRH option 2 Remove the two 2 M6 Socket Cap screws that hold the MRH bracket onto the right side leg of the stand remove the MRH bracket 3 Remove the two 2 M6 Socket Cap screws that hold the MRH bracket onto the left side leg of the stand remove the MRH bracket Storage Procedure Lay the components onto flat surface to prevent damage How to assemble the Media Roll Holder 1 Install the bracket onto the right side leg of the stand using the two 2 M6 x 16mm Socket Cap screws 2 Install the MRH bracket onto the left side leg of the stand using the two 2 M6 x 16mm Socket Cap screws 3 Install the stock rollers onto the MRH bracket CAUTION The longer length leg platform is installed towards the rear of the unit If installed backwards the unit may tip over when larger media is loaded onto the plotter Checks Make sure the stock rollers are aligned with the plotter Adjustments B Not required CUTTING PRO FC510
47. Top Cover Assembly for more information Lower the pinch roller lever to raise the pinch roller assemblies off the grit rollers 4 Remove the rear cover from the plotter See Chapter 2 Section 4 6 How to Remove and Install the Rear Cover for details 5 Remove the front cover from the plotter See Chapter 2 Section 4 5 How to Remove and Install the Front Cover for details 6 Disconnect the cable from the front sensor and or the rear sensor 7 Remove the M3 Binder head screw that holds the sensor to the bracket 8 Remove the sensor from the plotter Storage Procedure Carefully place the part onto flat surface to prevent damage Reinstallation Procedure 1 Install the sensor onto the front sensor bracket and or the rear sensor bracket using the M3 x 10mm Binder head screw Connect the cable to the sensor Lower the pinch roller lever to raise the pinch roller assemblies off the grit rollers Install the rear cover onto the plotter Install the front cover onto the plotter Install the top cover assembly onto the plotter NO a hom Install the right side cover onto the plotter Checks Make sure the X sensor is visible and centered the writing panel window B Make sure the grit rollers do not make contact with the front writing panel Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 62 5 25 How to replace the Power Supply Unit Overview Replac
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49. arm 3 Install the E style retaining ring on the right of the pinch roller shaft Checks Make sure the pinch rollers turn smoothly Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 46 5 16 How to replace the Pinch Roller Spring Overview Replace the pinch roller spring if it is damaged If the plotter exhibits a media feeding problem the pinch roller pressure may be too low Another possibility might be that the pinch roller pressure is uneven between the right and left pinch rollers Replace the pinch roller spring accordingly The FC5100 100 FC5100 130 and FC5100 150 model cutters have a middle pinch roller The pressure of the middle pinch roller is lower than that of the right and left pinch rollers If the pressure of the middle pinch roller is too high a media feeding problem may result Tools Philips screwdriver for an M3 screw Cutter Pliers As required Tweezers Force Gauge range 10kg Pinch Roller Lifter Jig Metal Strip Jig Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information 3 Remove the pinch roller spring from the top bracket
50. base bar the shorter length of the base bar is for the front side Proceed with caution taking care not to drop the plotter from the stand 3 Tighten the two 2 M6 x 16mm Socket Cap screws to secure the plotter onto the right side leg of the stand 4 Tighten the two 2 x 16mm Socket Cap screws to secure the plotter onto the left side leg of the stand CAUTION The longer length leg platform is installed towards the rear of the unit If the leg is installed backwards the unit may tip over when larger media is loaded on the plotter Checks Make sure the front and rear of the stand are in the proper position The shorter length leg platform with the locking caster should be at the front of the machine Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 68 7 2 The Basket Option Overview The FC5100 basket is used to keep your media clean during long length cuts This option is for the FC5100 75 FC5100 100 FC5100 130 and FC5100 150 model cutting plotters A WARNING Two people should pick up the plotter CAUTION The longer length leg platform is installed towards the rear of the unit CAUTION Improper assembly of these pieces may cause the unit to become unstable when heavy loads are added In extreme cases the unit may tip over A NOTE Always keep the wheels in a locked position when operating your plotter Tools Hex L key Wrench size 5mm for M6 Socket
51. bottom of the control panel using the four 4 M2 x 4mm Binder head screws Insert the cables running from the control panel through the hole on the top cover 4 Attach the control panel to the top cover using the six 6 M3 x 4mm Binder head screws Do not clip the cable under the control panel Install the harness wrap onto the cable running from the LCD Unit 6 Install the top cover assembly onto the plotter 7 Install the right side cover onto the plotter CUTTING PRO FC5100 Removal and Replacement Procedures C2 60 A NOTE Do not use the longer screws to mount the control panel If the screw is longer than 4mm the control panel will not secure to the Top cover even when tightening the screws Checks Make sure the control panel is mounted flush with the top and rear surfaces of the top cover Make sure the LCD unit is centered in the window opening of the sheet switch Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 61 5 24 How to replace the Front and Rear Paper Size Sensor Overview Replace the sensor if there is damage or component failure Tools Phillips screwdriver for screw Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the
52. depend on the type of model DTE Turn on the power to the plotter First the Initial menu appears and then the first item selection V 1 00 HL menu appears 1 ER RAM CHECKING Press the NEXT key to obtain the PLOT AREA XY GAIN ADJUSTMENT menu EN FO PEN PARALLEL F I Press the F2 SPEED key to select PLOT AREA ED PEN ADJUSTME ADJUSTMENT The following menu appears with instructions AREA ADJUSTMENT for this adjustment BO OSAE SIKII CHI TONBO SENSOR POS CUTTING PRO FC5100 Parameter Settings C3 18 6 10 11 Press the ENTER key to initiate this adjustment The ENTER START following menu appears Press the F2 SPEED key or F3 QUALITY key ROLL 1 gt ROLL 2 gt SHEE CONTINUE The initialization routine is executed to determine the paper size The plotter will immediately feed the paper and make a footprint on the paper The following menu appears Use the RIGHT or LEFT ARROW key to move the pen position Move the pen to the inside edge of the right footprint Push the top of the pen to make a mark on the paper and then check the position of the pen If the position is correct press the ENTER key to store the setting Use the RIGHT or LEFT ARROW key to move the pen position Move the pen to the inside edge of the left footpr
53. information 2 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 3 Remove the top cover assembly See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information 4 Remove the six 6 black zinc plated M3x6mm PBH screws that hold the front cover to the top of the plotter 5 Remove the six 6 black zinc plated M3x6mm PBH screws with washers that hold the front cover to the bottom of the plotter 6 On 5100 75 model plotters remove the one 1 M3x4 PBH screw located on the top left side of the front cover On FC5100 100 FC5100 130 and FC5100 150 model plotters remove the two 2 M3x4 PBH screws located on the top left and top right sides of the front cover 7 Loosen rear cover screws on top toward the front of the plotter 8 Pull the front cover off toward you then upward Storage Procedure Carefully place the front cover onto a flat surface to prevent damage Reinstallation Procedure 1 Align the hole at the upper side of the front cover 2 On FC5100 75 model plotters insert the one 1 M3x4 PBH screw located on the top left side of the front cover On FC5100 100 FC5100 130 and FC5100 150 model plotters remove the two 2 M3x4 PBH screws located on the top left and top right sides of the front cover 3 Insert the six 6 black zinc plated M3x6mm PBH screws with washers that hold the front
54. lever arm sensor that is mounted on the Y rail assembly 7 Pullthe top cover assembly up remove it from the plotter Storage Procedure Carefully place the top cover assembly onto a static free surface to prevent damage to the components Reinstallation Procedure 1 Mount the top cover assembly onto the plotter 2 Liftthe top cover assembly up on the right side insert the FPC cable running from the control panel into the hole on the right side plate Connect the cable onto the lever arm sensor that is mounted on the Y rail assembly Pull the cable out through the cut off area at the top of the right side plate Connect the cables onto J3 J4 P2 and P10 on the PCA Main board Insert the lock washer flat washer and ground tab running from the control panel through the oa M3 x 8mm Binder head screw to hold the grounding tab 7 Tighten the screw to the right side plate to secure the grounding tab onto the right side plate 8 Install the cable clamp and the wire tie onto the cables as stated above 9 Install the right side cover to the plotter 10 Tighten the six 6 M3 x 6mm Binder head screws to secure the top cover assembly Checks Alltorque settings for the assembly of components to be set at standard settings Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 9 4 4 How to remove and install the Pen Head Cover Overview Replace the pen cover if it is damaged or
55. pressing the LEFT DOWN ARROW key Use this mode for the Servo Gain Adjustment and the Auto Registration Mark Sensor option adjustment For more information see Chapter 3 Adjusting the Servo section or Chapter 3 Adjusting Auto Registration Mark Sensor 5 1 5 CONDITION Key POWER ON Turn on the power to the plotter while pressing the CONDITION key The Parallel Interface Condition Setting menu appears For more information see Chapter 1 Setting the Parallel Interface Condition section CUTTING PRO FC5100 Diagnosing Problems C1 26 5 2 Setting the Pen Up Condition This step will set the response of the PEN UP condition Tools Phillips screwdriver for an M3 screw Preparation Requirements 1 Tips Set 1 Note 5 Remove the right side cover from the plotter For details of step 1 see Chapter 2 Section 4 1 Up Requirements Set SW1 to the system parameter setting mode as illustrated below ment Turn on the power to the plotter First the Initial menu appears and then the item selection V 1 00 HL menu appears ER RAM CHECKING Press the F3 QUALITY key to select PEN UP Press the F3 QUALITY key to select SERVO OFF or press the FA OFFSET key to select SERVO ON If you select the SERVO OFF mode the pen is raised by the spring when the plotter is in the pen up condition If you select the SERVO ON mode the plotter controls the pen up po
56. proper distance between the pen and the cutting mat to ensure proper and consistent cutting performance See Chapter 2 Section 5 18 How to Replace and Adjust the Pen Head Block for more information The system control parameters are stored in the Non Volatile RAM that is located on the board The system control parameters are related to the moving mechanisms You must re set the system control parameters after replacing components or adjusting the moving mechanisms See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 45 5 15 How to replace the Pinch Roller Overview Replace the pinch roller if it is damaged or does not turn smoothly The plotter may exhibit a media feeding problem if the pinch roller does not turn properly Replace the pinch roller accordingly Tools Needle Nose Pliers E style Retaining Ring Insert Tool size 3mm Removal Procedure 1 Lower the media set lever to raise the pinch roller 2 Remove the E style retaining ring on the right of the pinch roller shaft 3 Pull the pinch roller shaft to the left and remove it 4 Remove the pinch roller from the pinch roller arm Storage Procedure Carefully place the part onto a flat surface to prevent damage Reinstallation Procedure 1 Install the pinch roller into the pinch roller arm 2 Insert the pinch roller shaft into the pinch roller through the pinch roller
57. re set the system control parameters after replacing components or adjusting the moving mechanism 1 1 Replacing the PCA Main Board If the PCA Main board has been replaced you must perform the following adjustment and setting process Clear the non volatile RAM Adjust the pen force Adjust the servo gain Adjust the LED pointer offset Adjust the plot area Adjust the distance accuracy Set the servo gain compensation value For the FC5100 100 and FC5100 130 Plot and inspect the mechanical check pattern Set the factory preset settings If you do not know the firmware version on the PCA Main board you must download the firmware to the PCA Main board See Chapter 4 Firmware for more information 1 2 Replacing or Adjusting the X axis or Y axis moving mechanism If the motor belt or Y slider is replaced or adjusted you must perform the following adjustment and setting process Adjust the servo gain Adjust the LED pointer offset Adjust the plot area Adjust the distance accuracy Plot and inspect the mechanical check pattern Setting the factory preset settings 1 3 Replacing the Pen Head Assembly If the pen head assembly is replaced you must perform the following adjustment and setting process Adjust the pen force Plot and inspect the mechanical check pattern Set the factory preset settings CUTTING PRO FC5100 Parameter Settings C3 2 1 4 Replacing the PCA Pen Board If the Pen PCA Pen Board is repl
58. s setup parameters to the factory default parameters Run this step before you run the adjustments step and after testing NOTE Before you change to the factory preset settings run the CONDITION LIST function to plot all of the user s setup parameters on the paper Tools B Not required Set Up Requirements 1 1 4 Set Up Requirements 2 1 Turn on the power while pressing the UP ARROW key The setup menu appears Press the F1 FORCE key to set the factory default setup with EFAULT HP GL gt the HP GL command set for the English language SETUP GP GL gt HP GL w inch gt Press the F2 SPEED key to set the factory default setup with the GP GL command set for the Japanese language Press the F3 QUALITY key to set the factory default setup with the HP GL command set for the English language and the length unit to inch The plotter immediately clears the parameters on NOVRAM NOVRAM CLE and sets the factory default When the programming is complete the following menu appears Turn off the power to the plotter Turn on the power to the plotter and load the media in the CONDITION 1 14 normal way 30 The READY menu appears EADY 4 BO9Ux 0 Press the MENU key to select menu mode CONDITION 1 14 Press the NEXT key until the BACKGROUND SETTINGS 30 MENU MODE 4 CB09Ux 0 menu appears Press the F1 FORCE key and then press the F1 FORCE key and the ENTER key at the s
59. tension pulley adjustment screw is unevenly tightened the Y slider belt will move up and down when the Y slider is moved from left to right When the Y slider belt edge touches the side plate or pulley sidewall it may degrade machine performance or cause damage to the Y slider belt Re adjust the servo gain The system control parameters are stored in the Non Volatile RAM that is located on the Main board The system control parameters are related to the moving mechanisms like the Y slider belt You must re set the system control parameters after replacing components or adjusting moving mechanisms See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 19 5 3 How to replace and adjust the Y drive Belt Overview Replace the Y drive belt if it is damaged or remove it to replace other components If the plotter exhibits poor cutting plotting results one possibility might be loose Y drive belt tension Adjust the Y drive belt tension accordingly Tools Phillips screwdriver for an M3 screw Cutter Pliers As required Force Gauge range 1kg and 5kg Steel Rule Scale metric scale at least 30mm long Wire or Rope Screw Locker Adhesive type 1041B As required Silicon Grease type G501 As required Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1 Remove the right side cover from the plotter See Ch
60. the LCD assembly if there is damage or component failure Tools B Philips screwdriver for an screw Cutter Pliers As required B Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information Remove the six 6 M3 Binder head screws that hold the control panel to the top cover 4 Pull the control panel out from the top cover assembly 5 Remove the four 4 M2 Binder head screws that hold the LCD assembly to the bottom of the control panel 6 The LCD assembly is taped to the sheet switch Gently separate the LCD unit from the sheet Switch 7 Remove the harness wrap from the cable running from the LCD Unit CAUTION Gently separate the sheet switch from the LCD unit area If the sheet switch is pulled too hard damage may result to the LCD or the LCD panel may come off If the panel is separated from the LCD unit it is not repairable Storage Procedure Carefully place the control panel and the top cover onto a flat surface to prevent damaging the components Reinstallation Procedure 1 Center the LCD assembly in the window opening of the sheet switch 2 Mount the LCD assembly to the
61. top surface of the Y drive motor shaft 2 Mount the Y drive motor into the bracket on the right side plate using the four 4 M3 x 8mm SEMS screws do not tighten the screws Install the Y drive belt into the Y motor pulley 4 Adjust the Y drive belt tension See Chapter 2 Section 5 3 How to Replace and Adjust the Y Drive Belt for more information 5 Connect the cables onto P6 and P7 on the PCA Main board 6 Install the cable clamp and the wire tie to the cables as stated above 7 Install the right side cover onto the plotter Checks All torque settings for the assembly of components to be set at standard settings Adjustments The Y drive belt tension adjustment maintains machine performance reduces motor shaft deformation and extends the machine s operational life See Chapter 2 Section 5 3 How to Replace and Adjust the Y Drive Belt for more information Re adjust the servo gain The system control parameters are stored in the Non Volatile RAM that is located on the Main board The system control parameters are related to the moving mechanisms like the Y drive belt You must re set the system control parameters after replacing components or adjusting the moving mechanisms See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 24 5 5 How to replace the Y drive Pulley Assembly Overview Replace the Y drive pulley assembly if it i
62. two 2 M3 x 20mm binder head screws that hold the Y tension pulley on the left side plate 2 Pass the Y slider belt through the hole of the Y rail Install the two 2 belt mounting brackets onto the Y slider using the two 2 M3 x 6mm Binder head screws do not tighten the screws 4 Insert the Y slider belt into the space between the belt mounting bracket and the Y slider Place the fifth 5 to sixth 6 tooth into the belt mounting bracket 5 Tighten the screws that hold the belt mounting bracket You should be able to see the belt through the access hole 6 Mount the pen head assembly to the Y slider assembly using the two 2 M4 x 8mm screws 7 Position the pen head assembly so that the bottom surface of the penholder clamp is 21mm 0 83 in from the cutting mat surface and at the same time parallel to the cutting mat surface Tighten the mounting screws after these two conditions are met 8 Apply the silicon grease onto the tooth side of the Y slider belt 9 Adjust the Y slider belt tension as directed in the Adjustments section 10 Install the top cover assembly onto the plotter 11 Install the left side covers onto the plotter 12 Install the right side covers onto the plotter Checks m Ensure that the roller bearings are able to spin freely when mounted to the Y slider CUTTING PRO FC5100 Removal and Replacement Procedures C2 18 Adjustments Belt tension adjustment is required to set proper tension of the b
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64. 0 Removal and Replacement Procedures C2 70 7 4 The Pounce Tool Option Overview Pouncing is a method used to create a punched outline on media This is done by inserting a special tool in the plotter that produces holes instead of plotting with a pen or cutting with a blade A WARNING To prevent bodily injury handle the pouncing tool with care A NOTE The Pounce Tool is not repairable If the Pounce Tool is damaged replace it Tools B required Removal Procedure 1 Loosen the penholder thumbscrew 2 Remove the pounce tool Storage Procedure m Pounce tool points are very sharp While handling the pounce tool be careful to avoid cutting your fingers or other parts of your body Reinstallation Procedure 1 Make sure the penholder screw is loose 2 While holding the penholder upward push the pouncing tool all the way into the holder until its rim contacts the pen stopper The flat side of the tool must face the pen carriage 3 Once the pouncing tool has been properly mounted tighten the screw Checks B Not required Adjustments B Not required CUTTING PRO FC5100 Parameter Settings C3 1 Chapter 3 System Control Parameter Settings This chapter describes the system control parameter settings for the plotter 1 Overview The system control parameters are stored in the Non Volatile RAM that is located on the Main Board The system control parameters are related to the moving mechanism You must
65. 00 130 When updating the main program you may have a different file name CAUTION You must complete the entire process If it is not completed you will lose the plotter s main program and will not be able to start the machine If this occurs you must replace the flash memory Setting the plotter to download mode 1 Connect the Parallel printer cable or the USB cable between the plotter and the computer 2 on the power of the plotter while pressing the RIGHT PASSWORD V1 00 ARROW key Continue to press the RIGHT ARROW key until a beeper sounds 3 The password menu appears Input the password press BOOT the keys in the following order DOWN ARROW key UP MAIN ARROW key RIGHT ARROW key LEFT ARROW key 4 The program type selection menu appears Press the F2 SPEED key to select MAIN 5 The mode of the Parallel interface selection menu ELE END MODE appears Press the F3 QUALITY key to select MODE1 If communication between the plotter and computer does not MODE1 gt MODE2 gt work successfully re start the download and then press the FA OFFSET key to select MODE2 If you are using the USB interface press the F3 QUALITY key or the FA OFFSET key and go to the next step 6 The FLASH CLEAR menu appears The plotter will FLASH CLEAR immediately start to clear the programs on the flash memory ECTOR BLOCK 7 When FLASH CLEAR is completed the SEND MAIN SEND MAIN P
66. 12mm 0 12mm gt Ae FC5100 150 Ae is below 0 12mm 0 12mm gt Circularity Measure the inner diameter at eight points using a glass scale and loupe Check maximum difference within eight diameters Model Specification FC5100 75 The diameter difference is below 0 12mm 0 12mm 2 diameter difference maximum diameter minimum diameter FC5100 100 The diameter difference is below 0 12mm 0 12mm 2 diameter difference maximum diameter minimum diameter F C5100 130 The diameter difference is below 0 12mm 0 12mm 2 diameter difference maximum diameter minimum diameter FC5100 150 The diameter difference is below 0 12mm 0 12mm 2 diameter difference maximum diameter minimum diameter CUTTING PRO FC5100 Diagnosing Problems C1 4 Repeatability Measure the distance and on the six patterns using a glass scale and loupe Model Specification FC5100 75 The distance a and is from 0 2mm to 0 4mm 0 4mm gt a gt 0 2mm 0 4mm gt gt 0 2mm FC5100 100 The distance and is from 0 2mm to 0 4mm pu 0 4mm 2 a 2 0 2mm 0 4mm 2 f 2 0 2mm FC5100 130 The distance and is from 0 2mm to 0 4mm 0 4mm gt gt 0 2 0 4mm gt gt 0 2mm FC5100 150 The distance and is from 0 2mm to 0 4mm peu 0 4mm gt gt 0 2mm 0 4mm gt f gt 0 2mm NOTE The specification of rep
67. 2 00 for the FC4100 75 100 130 Install a Pen in the plotter Load the Vinyl Film in the plotter Film size FC4100 75 30inch W 40inch L FC4100 100 30inch W 48inch L FC4100 130 40inch W 48inch L Hold down LEFT ARROW Key while you POWER UP the plotter Set the condition on the plotter RS232C Interface 9600 BAUD 8 BIT NONE PARITY HARDWIRE Command Others COMMAND GP GL STEP SIZE 0 1mm Plot condition FORCE 12 SPEED 60 QUALITY 8 OFFSET PEN Action Item Selection Press 8 Key to TEST the Servo Gain Press 9 Key to SET the Servo Gain Press 0 Key to RETURN to the Interface Port Selection menu Press Key to EXIT this Program Press the 8 Key to start the Servo Gain Test program 5 The Servo Gain test routine is executed the measurement value appears Press 8 Key to TEST the Servo Gain Press 9 Key to SET the Servo Gain Press 0 Key to RETURN to the Interface Port Selection menu Press Q Key to EXIT this Program Check the waveform and the Maximum Error value the maximum error specification for this value is below 10 9 maximum error value If the error value is below 10 the Servo Gain Adjustment is finished If the error value is over 10 press the 9 Key to set the new servo gain value to the plotter Attempt to make the Maximum Error as low a number as possible CUTTING PRO FC5100 Parameter Settings C3 28 6 Press the 9 Key and the Servo Gain Set menu a
68. 4 The plotter is then initialized and the media selection menu appears Press the necessary key to continue Signal Timing Chart Select Parameter 1 to set the BUSY signal and the ACK signal timing as follows This is the factory default setup MODE 1 ACK BUSY Select Parameter 2 to set the BUSY signal and the ACK signal timing as follows MODE 2 ACK BUSY Checks B Not required Adjustments B Not required CUTTING PRO FC5100 Diagnosing Problems C1 31 Set Up Requirements 2 CONDITION 1 14 1 the power to the plotter and load the media in the 30 EADY 4 normal way CB09Ux 0 The READY menu appears 2 Press the MENU key to select menu mode CONDITION 1 14 Press the NEXT key until the BACKGROUND SETTNG 30 EADY 4 B09Ux 0 menu appears 3 Press the F1 FORCE key and then press the F1 FORCE key and the ENTER key at the same time BACKGROUND SETTINGS Press the ENTER key while pressing the CONDITION OPTION 1 OPTION 2 key and then keep pressing the CONDITION key until the following menu appears 4 Press the UP ARROW key or the DOWN ARROW key to change the setting Press the ENTER key to store the setting 5 The plotter is initialized the media selection menu appears Press the necessary key to continue using the plotter CUTTING PRO FC5100 Removal and Replacement Procedures C2 1 Chapter 2 Removal and Replacement Procedures This
69. 5 17 How to Replace and Adjust the Pen Head Block for more information 6 Remove the Y slider belt from the plotter See Chapter 2 Section 5 2 How to Replace and Adjust the Y slider Belt for more information 7 Disconnect the flat ribbon cable from the Pen board Remove the two 2 M3 x 16mm Binder head screws and two 2 M3 washers Remove the Pen board from the pen head CAUTION The moving coil type actuator that mounts on the Pen Head Block has a very strong magnet The actuator will stick to the steel plate The actuator can pick up steel components or dust Storage Procedure Carefully place the part onto a flat surface to prevent damage Carefully place the pen head block onto a surface that is clear of steel components or dust The pen head block has a very strong magnet The actuator may be damaged if steel dust is captured between the moving coil and its case CUTTING PRO FC5100 Removal and Replacement Procedures C2 38 Reinstallation Procedure 1 2 OM NAAR w Make the adjustment to the Y slider assembly see the Adjustments section for details Install the Pen board to the pen head with two 2 M3 x 16mm Binder head screws and two 2 M3 washers Connect the flat ribbon cable to the Pen board tie wrap the flat cable to the Pen board Install the Y slider belt and adjust the Y slider belt tension Install the pen head block and adjust the pen head block position in relation to the Y slider pla
70. 50 CUTTING PRO FC5100 Parts List C5 2 5 2 Outer Casing we ____ 1 792117708 Side Cover R Assy E d E 3 621174000 1 EN S 792117728 51 Center Cover 150E 5 682117110 Keypad for FC5100 English Sheet Switch English 500051097 Keypad for FC5100 Japanese 1 Sheet Switch Japanese 6 772117660 LCD Unit Assy LM1105SGR 1 LCD CUTTING PRO FC5100 C5 3 Parts List 5 3 Main Frame CUTTING PRO FC5100 Parts List C5 4 Ree Plate R 500051091 Motor UJGMEE A7MGR71 1 or 2 Y Motor for all model X motor for FC5100 75 s 792417705 Drive Pulley Assy eee ee 2 7 Drive 121 621173213 Y Drive Bracket for 5100 75 2 gt 5 5 75 Fs emer 3 _ Fw smmono Center CoverRear Bracket 2 S S S 13 621120060 X Drive Pulley 85Z 1 e2me0812 rewGuwercsto on ssos2 Front freson _ Front Gue 621180510 Cutting Mat for FC5100 100 1 FC5100 100 Ep d 0 621200510 cwineWartrrCswn so
71. 73160 Sensor Bracket8 100 77247660 Pinch 7 247630 s 621173160 CUTTING PRO 5100 Parts List C5 11 5 10 Pinch Roller Assy Pinch Roller Assy Right Pinch Roller Assy Left Pinch Roller Assy Center Pinch Roller Assy Parts List No Part No Description QTY Remarks 792117713 Pinch Roller R Assy 1 792117712 Pinch Roller L Assy 1 772118260 Pinch Roller Center Assy 1 FC5100 100 130 150 1 621112100 Pinch Roller Arm 1 2 621172202 Pinch Roller Arm Base FC 51 1 3 092002041 Push Roller Arm Shaft 1 621182223 Push Roller Arm Shaft L 1 FC5100 100 130 150 Center Pinch Roller 4 621172210 Spring 51 L R 1 621182210 Spring 51 CT 1 FC5100 100 130 150 Center Pinch Roller 5 095002121 Push Roller 1 6 621112120 Push Roller Shaft 1 1 7 621172330 Stopper Plate R 1 For Right Pinch Roller Assy 621172340 Stopper Plate L 1 For Left Pinch Roller Assy 8 E Ring 4mm 2 9 E Ring 3mm 2 10 021900883 Cam 2190 1 11 380101111 Pressure Spring C 111 1 For Center Pinch Roller Assy CUTTING PRO FC5100 Parts List C5 12 5 11 Stand Assy Stand Assy Parts List enmmo 2 621171002 s 621171220 cewerarrcso s emenso CenterBarFcst00 100 1 foson 621191130 CenterBarFcst00 130 3 Fc
72. ASAN or 48000 0 12345678 12345678 12345678 12345678 5100 75 5100 100 5100 130 FC5100 150 OFF OFF OFF Auto registration model TONBO FC5100 75 FC5100 100 FC5100 130 FC5100 150 2 pen model 00000 0 12345678 12345678 12345678 12345678 5100 75 5100 100 5100 130 FC5100 150 Signal Timing Chart Select Parameter 1 to set the BUSY signal and the ACK signal timing as follows This is the factory default setup MODE 1 ACK Select Parameter 2 to set the BUSY signal and the ACK signal timing as follows MODE 2 ACK BUSY Checks Not required Adjustments B Not required CUTTING PRO FC5100 Diagnosing Problems C1 30 5 3 1 Method 2 The Parallel Interface Condition is set by the menu setup Tools Not required Set Up Requirements 1 1 Turn on the power to the plotter while pressing the CONDITION Key 2 First the Initial menu appears and then the Item Selection V 1 00 HL menu appears ER RAM CHECKING 3 Press the UP ARROW key or the DOWN ARROW key to change the setting Press the ENTER key to store the setting Note Setting the parameter to 1 or 2 will change the timing of the BUSY signal When you have a problem on the parallel interface change the setting of the parameter and then use the parallel interface
73. C5100 Removal and Replacement Procedures C2 50 7 Install the top cover assembly onto the plotter 8 Install the right side cover onto the plotter CAUTION When securing the FPC to the Y slider plate check the length to the moving coil There should be room when the penholder moves to the lowest position If there is not enough room incorrect pen force will result CAUTION Do not clip the pen head wires when installing the pen head cover The pen head cover has a recess to accommodate the wires Checks m Insure that pen head is properly grounded to the Y slider Take measurements off of the unpainted surface on the pen base and the Y slider Make sure that pen head cover does not clip the pen head wires There is a special recess in the pen head cover for the wires Adjustments The pen height adjustment sets the proper distance between the pen and the cutting mat to ensure proper and consistent cutting performance 1 The base of the pen head block should be at an elevation of 10mm 2 Pen model 11 5mm above the cutting mat surface 2 Measure the distance between the bottom of the pen head block and the cutting mat at the right and left ends of the pen head block These left and right measurements should be equal and confirm that the pen head is parallel to the cutting mat CAUTION The pen head block must be parallel to the cutting mat surface If it is not parallel it may cause the pen to chip or resul
74. Cap screw B Mallet or Rubber Hammer How to disassemble the Basket 1 Unsnap the basket from the front and rear basket tubes and the middle bar 2 Remove the cloth basket from the stand 3 Remove the four 4 tube stoppers from the two 2 basket tubes 4 Remove the two 2 basket tubes from the stand 5 Remove the two 2 M6 Socket Cap screws that hold the tube bracket to the right side leg of the stand 6 Remove the two 2 M6 Socket Cap screws that hold the tube bracket to the left side leg of the stand Storage Procedure Lay the components on flat surface to prevent damage How to assemble the Basket 1 Install the tube bracket onto the right side leg of the stand using the two 2 M6 x 16mm Socket Cap screws 2 Install the tube bracket onto the left side leg of the stand using the two 2 M6 x 16mm Socket Cap screws Insert the two 2 basket tubes into the tube bracket from the front and rear sides 3 4 Install the four 4 tube stoppers into each end of the basket tube 5 Install the cloth basket onto the stand 6 Snap the basket to the front and rear basket tubes and the middle bar Checks Make sure the basket is aligned straight and not skewed Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 69 7 3 The Media Roll Holder Option Overview The FC5100 Media Roller Holder MRH allows multiple roll capabilities and easy storage of your common media colors
75. ECKING Press the F1 FORCE key to select XY GAIN XY GAIN EN FORCE PEN UF PARALLEL The X axis servo gain setting menu appears and displays the servo gain value Use the UP ARROW key or the DOWN M 28 ARROW key to change the X axis servo gain value Press the ENTER key to store the gain settings The Y axis servo gain setting menu appears and displays Y GAIN the servo gain value Use the UP ARROW key or the DOWN 28 ARROW key to change the Y axis servo gain value Press the ENTER key to store the gain settings CUTTING PRO FC5100 Parameter Settings C3 11 The item selection menu appears XY GAIN EN FORCE PEN UP PARALLEL 6 If you wish to continue the parameter setting press the necessary key to select other parameters If you wish to finish the parameter setting or when all of the parameters are set turn off the power to the plotter Return the SW1 setting to normal mode as illustrated below NORMAL OPERATING mode Factory shipment Standard model Auto model 2 model Checks Plot and inspect the mechanical check pattern Adjustments The following adjustments are required after this step LED Pointer Adjustment Plot Area Adjustment CUTTING PRO FC5100 Parameter Settings C3 12 7 Adjusting the Pen Force This adjustment will set the pen force Run these tests if you replace the moving coil the pen block assembly or the M
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77. ROGRAM PROGRAM menu appears 000KB COMPLETED 8 Setthe File to the fc51v100 X file on the Data File LOAD MEDIA Output Utility Program to select the main program Click the Print button to start downloading After the downloading INITIAL MI is complete the LOAD MEDIA menu appears Checks you need to do Verify that the plotter starts after turning on the power If it does not start the plotter has lost the main program You must then download the main program again m Make sure you are loading the correct version number of the main program CUTTING PRO FC5100 Firmware C4 6 Adjustments you may need to do Clear the system control parameter on the NOVRAM and make the adjustment if necessary CUTTING PRO FC5100 Parts List C5 1 Chapter 5 Parts List 51 List of Recommended Parts ay 792117700 Main Board 1 Eres petias E E 772117650 Pinch Roller Sensor 1 500051095 Power Supply Unit 1 Same as FC4100 500051093 692117041 Y Flexible Cable CA091004 1 Y Flexible Cable for FC5100 150 792117716 621180350 Cutting Mat Assy for FC5100 100 1 FC5100 100 Cutting mat with base 621190350 621183200 Y belt for FC5100 100 200S2M1339LWC For FC5100 100 621193200 belt for 5100 130 250S2M1602LWC For FC5100 130 621203201 Y belt for FC5100 150 300S2M1756LWC 1 ForFC5100 150 095002121 792117706 Drive Pulley Assy for FC5100 100 130 and FC5100 150 1 For FC5100 100 130 and 1
78. ST 5 12 5 12 Accuload System Components C5 13 Accuload System components Parts C5 13 C5 13 Chapter 6 ELECTRICAL 6 1 Circuit INNS E 6 1 6 2 Circuit wiring rc TENE C6 2 Main Board Clock amp C6 2 Main Board CPU 22 1 1 C6 3 Main Board PLD dpa baa MPa PME eu RM dd C6 4 Main Board Memory 2 C6 5 Main Board Motor Control Section C6 6 Main Board Motor Drive C6 7 Main Board Interface C6 8 Main Board USB Interface Section C6 9 Main Board I O Connection C6 10 Main Board I O Connection 2
79. aced you must perform the following adjustment and setting process Adjust the plot area Plot and inspect the mechanical check pattern Set the factory preset settings CUTTING PRO FC5100 Parameter Settings C3 3 2 Locations of the Components on the Main Board Tools Phillips screwdriver for screw Preparation Requirements 1 Remove the right side cover from the plotter Tips For details of step 1 see Chapter 2 Section 4 1 How to Remove and Replace the Right Side Cover Locations of the Components on the Main Board CUTTING PRO FC5100 Parameter Settings C3 4 3 Setting the DIP Switches Set SW1 on the Main board to test or adjust The following setups are available For more information see the appropriate section Set Up Requirements NORMAL OPERATING mode Factory shipment Standard model PARDO Or 00000 0 12345678 12345678 12345678 12345678 FC5100 75 FC5100 100 FC5100 130 FC5100 150 Auto registration model TONBO 5100 75 5100 100 5100 130 FC5100 150 2 pen model Test amp adjustment mode NV RAM Clear mode Set DIP Switches No 2 and 3 5 6 7 to ON 12345678 Warning After NV RAM clear you have to re adjust all the electric adjustment Distance adjustment mode Set the distance adjustment parameters 000
80. ain board Before you replace the Main board record the pen force numeric value After you replace the Main board reset the pen force numeric value Tools Phillips screwdriver for screw Force gauges range 0 50g 0 200g 0 500g Preparation Requirements 1 Remove the right side cover from the plotter Tips For details of step 1 see Chapter 2 Section 4 1 How to Remove and Replace the Right Side Cover Adjustment Set Up Requirements 1 2 Attach the pen to the penholder Set SW1 to the system parameter setting mode as illustrated below Production adjustment mode for the standard model and Auto registration model Set DIP switches No 4 and 5 6 to OFF Other DIP switch settings depend on the type of model CERT Production adjustment mode for 2 pen model Set the distance parameters to exchange Pen 1 and Pen 2 Set DIP switch No 4 to ON and 5 6 to OFF Other DIP switch settings depend on the type of model Turn on the power to the plotter First the Initial menu appears and then the Item Selection 1 00 HL ER RAM CHECKING menu appears Press the F2 SPEED key to select PEN FORCE XY GAIN EN FORCE PEN UP PARALLEL CUTTING PRO FC5100 Parameter Settings C3 13 5 When the F1 FORCE key is pressed the pen is lowered EN U D gt or raised After lowering the pen use the force gauge to measure the actual force
81. ain the MENU mode The Menu Mode menu appears Press the NEXT key until the Option menu appears Press the F4 OFFSET key to select OPTION 2 Press the F4 OFFSET key to select TEST Press the F1 FORCE key to select the special test mode Press the F1 FORCE key and the ENTER key at the same time The Test menu appears Press the F2 SPEED key to select AGING 1 00 ER RAM CH CONDITION 2 EADY CONDITION 2 EADY HL ECKING BACKGROUND SETTINGS gt OPTION 1 gt OPTION 2 gt INITIAL DOWN FORCE gt DISTANCE ADJUST gt CONDITION TEST gt SELF TE DATA MECHA gt AGING gt EW TEST gt PATTERN gt CUTTING PRO FC5100 Diagnosing Problems C1 15 The Aging menu appears and the plotter will immediately 8H AGING begin to plot the test pattern This test pattern will run for approximately 8 hours NOTE If you want to cancel the test pattern plot turn off the power to the plotter 10 When plotting is complete the pen will stop Turn off the power to the plotter Checks Examine the plot test pattern For more information see the Mechanical Check Pattern section Adjustments B Not required CUTTING PRO FC5100 Diagnosing Problems C1 16 4 Test Methods for Hardware Problems 4 1 Checking Operation 4 1 1 Checking the Power Supply Tools B Phillips screwdriver for an scr
82. all the Top Cover Assembly for more information Remove the Y slider belt from the plotter See Chapter 2 Section 5 2 How to Replace and Adjust the Y slider Belt for more information Remove the two 2 M3 Binder head screws that hold the Y tension pulley to the bracket on the left side plate Pull the shaft out from the Y tension pulley Remove the Y tension pulley and the two 2 spacers from the bracket Remove the two 2 spacers from the shaft of the Y tension pulley Storage Procedure Carefully place the parts onto a flat surface to prevent damage Reinstallation Procedure 1 Insert the Y tension pulley and two 2 spacers into the bracket 2 Insert the shaft into the Y tension pulley through the bracket and the spacers 3 Insert the two 2 M3 x 20mm Binder head screws into the shaft through the bracket 4 Install the Y slider belt onto the plotter and adjust the Y slider belt tension For details see section 5 2 How to Replace and Adjust the Y slider Belt 5 Install the top cover assembly onto the plotter 6 Install the left side cover onto the plotter 7 Install the right side cover onto the plotter Checks All torque settings for the assembly of components to be set at standard settings CUTTING PRO FC5100 Removal and Replacement Procedures C2 27 Adjustments The Y slider belt tension adjustment sets proper belt tension Incorrect tension can cause Y axis issues such as overshoot errors a
83. ally true for the upper pen force adjustment 10 If you wish to continue the parameter settings press the necessary key to select other parameters If you wish to finish the parameter setting or when all of the parameters are set turn off the power the plotter Return the SW1 setting to normal mode as illustrated below NORMAL OPERATING mode Factory shipment Standard model PRAGA Auto registration model cr WOU mnm FC5100 75 FC5100 100 FC5100 130 FC5100 150 2 pen model MAO OU 00000 oe 12345678 12345678 12345678 12345678 FC5100 75 FC5100 100 FC5100 130 FC5100 150 CUTTING PRO FC5100 Parameter Settings C3 14 Specification of the actual pen force Specified pen force Actual force range 17g 19g 36g 440 108g 132g 239g 291g 440g 480g Checks B Not required Adjustments B Not required CUTTING PRO FC5100 Parameter Settings 8 Adjusting the LED Pointer Offset This adjustment will set the offset between the center of the LED pointer and the center of the pen Run this test if you replace the LED pointer the pen block assembly or Main board Run this test if you move the position of the LED pointer or the pen block assembly Tools B6 Philips screwdriver for an screw Ceramic pen 0 2mm tip size A4 size ANSI A size or larger size paper Preparat
84. ame time BACKGROUND SETTINGS gt OPTION 1 gt Press the ENTER key while pressing the UP ARROW key OPTION 2 gt continue pressing the UP ARROW key until the following menu appears CUTTING PRO FC5100 Parameter Settings C3 7 4 Press the F1 FORCE key to set the factory default setup with EFAULT the HP GL command set for the English language SETUP GP GL gt Press the F2 SPEED key to set the factory default setup with the GP GL command set for the Japanese language Press the F3 QUALITY key to set the factory default setup with the HP GL command set for the English language and the length unit to inch 5 The plotter will immediately clear the parameters NOVRAM CLE on and set the factory default When the programming is complete the following menu appears 6 Turn off the power to the plotter Checks B Not required Adjustments B Not required CUTTING PRO FC5100 Parameter Settings C3 8 5 Clearing the Non Volatile RAM The system control parameters are stored on the Non Volatile RAM NOVRAM When you replace the following items you must reset the system control parameters e Replace moving mechanisms for example motor pen block grit roller etc Adjust moving mechanisms for example belt Y slider etc Replace the Main board This step will change the system control parameters to the factory default parameters NOTE If you clea
85. apter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the left side cover from the plotter See Chapter 2 Section 4 2 How to Remove and Install the Left Side Cover for more information 3 Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information 4 Remove the Y slider belt from the plotter See Chapter 2 Section 5 2 How to Replace and Adjust the Y Slider Belt for more information 5 Remove the four 4 M3 SEMS pan head screw with flat washer screws that hold the Y drive motor to the Y motor bracket remove the Y drive motor 6 Remove the Y drive pulley and the Y drive belt from the bracket Remove the Y drive belt from the Y driver pulley CAUTION The motor has a strong magnet The motor will stick to the steel plate when the mounting screws are removed If the motor hits the steel plate with excessive force damage may result to the motor or to the steel plate Storage Procedure Carefully place the part onto a flat surface to prevent damage Carefully place the Y drive motor onto a clean area to prevent damage the motor will pick up steel components or dust CUTTING PRO FC5100 Removal and Replacement Procedures C2 20 Reinstallation Procedure 8 9 10 11 12 13 14 15 16 17 Install the Y drive belt onto the Y drive pulley Install the Y drive
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87. ble Cable C2 53 5 20 1 For th FC5100 75 TED C2 53 5 20 2 For the 5100 100 5100 130 and 5100 150 Models C2 55 5 21 How to replace the Cutting C2 56 5 22 How to replace the Control panel Sheet Switch C2 57 5 23 How to replace the LCD C2 59 5 24 How to replace the Front and Rear Paper Size Sensor C2 61 5 25 How to replace the Power Supply C2 62 6 BraGKets em C2 64 6 1 How to assemble the Media C2 64 r9 Sato eis C2 66 TA Ihe Stand ed C2 66 7 2 The Basket C2 68 7 3 The Media Roll Holder C2 69 7 4 The Pounce Tool Option trap kou RR ducet i o t a Rd C2 70 Chapter 3 System Control Parameter Settings Qe p n C3 1 1 1 Replacing the PCA Main C3 1 1 2 Replacing or Adjusting the X axis or Y axis moving mechanism C3 1
88. ce the pen head block onto a surface that is clear of steel components or dust The pen head block has a very strong magnet The actuator may be damaged if steel dust is captured between the moving coil and its case Reinstallation Procedure 1 2 a gt Insert the Y slider assembly onto the Y rail assembly Adjust the Y slider assembly See Chapter 2 Section 5 12 How to Adjust the Y slider for more information Install the Pen board to the pen head with two 2 M3 x 16mm Binder head screws and two 2 M3 washers Connect the flat ribbon cable to the Pen Board tie wrap the flat cable to the Pen Board Install the Y slider belt and adjust the Y slider belt tension Install the pen head block onto the Y slider assembly adjust the position of the pen head block Install the top cover assembly onto the plotter Install the left side cover onto the plotter Install the right side cover onto the plotter Checks Make sure that the roller bearings are able to spin freely before they are mounted to the Y slider All torque settings for the assembly of components to be set at standard settings Make sure the Y slider belt position to the Y tension pulley is correct Make sure the pen head block position to the cutting mat is correct and parallel Verify the perpendicularity between the X axis and the Y axis Run the mechanical check pattern and inspect it See Chapter 1 Diagnosing Problems section for details
89. cover to the bottom of the plotter 4 Insert the six 6 black zinc plated M3x6mm PBH screws that hold the front cover to the top of the plotter 5 Install the top cover assembly onto the plotter 6 Install the right side cover onto the plotter 7 Tighten all of the screws including the loosened screws on the rear cover Checks All torque settings for the assembly of components to be set at standard settings Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 13 4 7 How to replace the PCA Main Board Overview Replace the PCA Main board if is damaged fails diagnostics or to replace other components Tools Phillips screwdriver for screw Hex Nut driver size 3 16 inches Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the two 2 3 16 hex standoffs that hold the RS232C interface connector to the CPU bracket 3 Remove the two 2 4 Pan head screws that hold the parallel interface connector to the CPU bracket Disconnect all cables from the PCA Main board Making sure that you are static free remove the six 6 M3 SEMS pan head screw with flat washer screws that hold the PCA Main board to the right side plate 6 Remove the PCA Main board from the right side plate Storage Procedure The Main board should be handled follow
90. d in the Non Volatile RAM that is located on the Main board The system control parameters are related to the moving mechanisms You must re set the system control parameters after replacing components or adjusting the moving mechanisms See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 42 5 14 How to replace and adjust the Y Slider Assembly Overview Replace the Y slider assembly if it is damaged or remove it to replace other components If the plotter exhibits poor cutting plotting results one possibility may be that the Y slider roller is dented or worn out Replace the Y slider bearing Tools Phillips screwdriver for an M3 and M4 screw Hex Nut driver size 5 5mm Hex L key Wrench size 1 5mm for the M3 Socket Set screw Cutter Pliers As required Force Gauge range 300g and 1kg Steel Rule Scale or Caliper metric scale at least 30mm or longer Screw Locker Adhesive type 1401B As required Silicon Grease type G501 As required Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the left side cover from the plotter See Chapter 2 Section 4 2 How to Remove and Install the Left Side Cover for more information 3 Remove the top co
91. d on the PCA Pen board Tools Phillips screwdriver for screw Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information 3 Remove the cables from J2 P2 P1 Option on the PCA Pen board J2 is held on by a tie wrap 4 Remove the two 2 M3 PBH screws that hold the Pen board to the Y slider plate Storage Procedure The Pen board should be handled following standard anti static procedures Reinstallation Procedure 1 Mount the Pen board to the Y slider plate using the two 2 M3 PBH screws 2 Connect the cables into J2 P2 P1 Option on the PCA Pen board J2 is held on by a tie wrap 3 Install the top cover assembly onto the plotter 4 Install the right side cover onto the plotter Checks Alltorque settings for the assembly of components to be set at standard settings Adjustments m The system control parameters are stored in the Non Volatile RAM that is located on the Main board The system control parameters are related to the moving mechanisms You must re set the system control parameters after replacing components or adjusting moving mechanisms like the Y home flag and the pinch roller flag sensors located on the PCA Pen board See Chapt
92. e COM 1 port Press 2 Key to select the COM 2 port Press Key to EXIT this Program CUTTING PRO FC5100 Parameter Settings C3 24 2 Or open the working folder and then right click the SERVO EXE icon Select Create Shortcut Move the Shortcut icon to the desk top Then double click on the SERVO shortcut icon the Start menu appears on the computer monitor CUTTING PRO FC5100 Parameter Settings 11 2 Adjusting the Servo Gain Adjustment Set up Requirements 1 2 Connect the RS232C serial cable between the plotter and the computer Turn on the power to the plotter while pressing the LEFT ARROW key Continue to press the LEFT ARROW key until the beeper sounds The Initial menu appears Load the media in the plotter Press the F3 QUALITY key to select SHEET The initialization routine is executed the Ready menu then appears Attach a pen to the penholder and set the conditions as follows FORCE 12 SPEED 60 QUALITY 8 Tool PEN Set the RS232C conditions as follows Baud 9600 Data 8 Bits Parity None Control Hardwire Set the COMMAND to GP GL 1 00 CONDITION 1 EADY 96 NONE COMMAN HARDWIRE C3 25 HL ER RAM CHECKING 00 BAUD 8 BIT PARITY CUTTING PRO FC5100 Parameter Settings C3 26 Adjustments 1 Start the Servo Adjustment Program the Start menu appears on the computer monitor the
93. e the power supply unit if there is damage or component failure Tools Phillips screwdriver for an M3 and M4 screw Cutter Pliers As required Double Coated Adhesive Tape As required Silicon Adhesive As required Cable Clamp and or Wire Tie As required Removal Procedure 1 6 7 Remove the left side cover from the plotter See Chapter 2 Section 4 2 How to Remove and Install the Left Side Cover for more information Remove the wire tie that holds the cables running from the power switch Remove the two 2 wires connected to the bottom tab on the power switch Remove the two 2 M4 screws holding the ground cable running from the power supply unit to the left side plate Disconnect the cable from TB2 on the power supply unit Making sure you are static free remove the five 5 M3 SEMS pan head screw with flat washer screws that hold the power supply unit to the left side plate Remove the power supply unit from the left side plate Remove the vibration spacer that is mounted to the solder side of the power supply unit Storage Procedure The power supply unit should be handled following standard anti static procedures Reinstallation Procedure 1 Install the vibration spacer onto the solder side of the power supply unit using silicon adhesive Apply the double coated tape onto the other side of the vibration spacer and remove the tape liner If the vibration spacer remains on the left side panel push i
94. eatability is 0 1mm for FC5100 75 100 130 150 The test pattern has 0 3mm offset The measurement and p is the total value of the repeatability and 0 3mm offset B Line Quality Use this to check the plotted line quality There should be no skipping or unsteadiness Specification The pen does not skip db The line is steady ULT The pen skipped here CUTTING PRO FC5100 Diagnosing Problems C1 5 B Phase Measure the length a and b on the seventeen lines using a glass scale and loupe Check the maximum difference between a and b Specification FC5100 75 The maximum difference is below 0 12mm 0 12mm gt difference b a FC5100 100 The maximum difference is below 0 12mm 0 12mm gt difference b a FC5100 130 The maximum difference is below 0 12mm 0 12mm gt difference b a FC5100 150 The maximum difference is below 0 12mm 0 12mm gt difference b a Perpendicularity Measure the length 7 using a glass scale and loupe and master film that has two reference lines Use three cross marks to measure the perpendicularity Measure the length 7 using one on the cross mark that is located 400mm from the reference cross mark Specification FC5100 75 The difference between the cross mark and reference line is below 0 3mm 0 3mm gt Z FC5100 100 The difference between the cros
95. ection 4 2 How to Remove and Install the Left Side Cover for more information 3 Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information 4 Disconnect the cable and the connectors that are J3 J4 and J5 on the PCA Main board 5 Disconnect the P2 connector from the Main board 6 Remove two 2 M3 x 4mm Binder Head black zinc screws M4 washer and 2mm thick spacer holding the lever cam spring to the right side plate 7 Remove the lever held by two 2 M3 x 6mm Binder Head screws from the square camshaft 8 Remove the white plastic collar in the left side plate holding the square camshaft fastened by an M3 x 10mm screw 9 the square camshaft through the pinch rollers out the right side plate 10 Remove the cable clamp and or the wire ties from the cables as stated above 11 Remove five 5 of the M4 Washer Head screws that hold the Y motor bracket to the right side plate 12 Remove two 2 of the M4 Washer Head screws that hold the Y rail assembly to the left side plate 13 Pull the Y rail assembly upward pull the cables out and remove it CAUTION The Y drive motor that mounts on the Y rail assembly has a very strong magnet The motor will stick to the steel plate The motor can pick up steel components or dust Storage Procedure Carefully place the part on a flat surface to prevent damage Carefully place the Y drive mo
96. ed adhesive tape onto the FFC bracket slot The first piece of tape should start at 85mm from the right end of the FFC bracket The second piece of tape should start at 300mm off from the right end of the FFC bracket Insert the taped side of the FFC into the hole on the right side plate 4 Connect the FFC into J1 on the PCA Pen board 5 Move the Y slider to the left end Fit the FFC into the FFC bracket slot The FFC should touch the left end wall of the FFC bracket There should be no bump over the FFC bracket 6 Secure the FFC onto the FFC bracket slot using the double coated adhesive tape 7 Connect the FFC into J5 on the PCA Main board 8 Install the top cover assembly onto the plotter 9 Install the right side cover onto the plotter Checks B Make sure the Teflon tape on the FFC is located on the hole of the right side plate Make sure that the FFC fits into the FFC bracket slot and does not rub between the edges of the FFC or the FFC bracket CUTTING PRO FC5100 Removal and Replacement Procedures C2 54 Make sure the pen head Y slider assembly moves completely left and right on the Y rail Adjustments The flat cable support shelf bracket should be positioned 10mm 0 39 from the right side plate CUTTING PRO FC5100 Removal and Replacement Procedures C2 55 5 20 2 For the FC5100 100 FC5100 130 and FC5100 150 Models Removal Procedure 1 5 6 f Remove the right side cover from the plotter See
97. elt to maintain machine performance reduce overshoot and out of phase in the Y axis 1 With the Y slider on the Y rail and the belt attached adjust the Y tension pulley adjustment screws that hold the Y tension pulley onto the left side plate in order to tighten the Y slider belt Do not over tighten Move the Y slider from left to right several times to verify that the tension is set correctly 2 Move the Y slider all the way to the right and pull the belt 20 mm towards center using a force gauge Adjust the Y tension pulley adjustment screws evenly until the tension reads as follows Specification of the Belt Tension Model Force gauge reading specification FC5100 75 160 209 140g to 180g FC5100 100 220 20g 200g to 240g FC5100 130 220 20g 200g to 240g FC5100 150 220 20g 200g to 240g Y Rail 20mm Surface 9 4 Y Belt Surface B Ej Surface A and B shoud be parallel when pulling the Y belt 3 Verify that the Y slider belt is centered and does not move up and down when the Y slider is moved from left to right several times The clearance between the Y slider belt and the side plate should be more than 1mm The Y slider belt should not move up and down more than 2mm 4 Ifthe Y slider belt continues to move up and down or exhibits less clearance re adjust the Y tension pulley adjustment screws and check the belt tension again CAUTION If the Y
98. er 3 System Control Parameter Setting for more information CAUTION If the plot area settings are incorrect the Y slider may be damaged when it strikes the side plate CUTTING PRO FC5100 Removal and Replacement Procedures C2 53 5 20 How to replace the Y Flat Flexible Cable FFC Overview Replace the Y FFC flat flexible cable if it is damaged or there is component failure Tools Phillips screwdriver for an M3 screw Double Coated Adhesive Tape size 10mm x 10mm As required Adhesive Teflon Tape size 50mm x 60mm As required Cable Clamp and or Wire Tie As required Harness Wrap As required 5 20 1 For the FC5100 75 Removal Procedure 1 4 5 6 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information Disconnect the Flat Flexible Cable FFC from J5 on the PCA Main board and J1 on the PCA Pen board Remove the FFC that is taped to the FFC bracket Pull the FFC out from the plotter Remove the Teflon tape from the FFC Storage Procedure Carefully place the part onto a flat surface to prevent damage Reinstallation Procedure 1 Apply the Teflon tape to the FFC starting at 120mm from the tip of the FFC 2 Apply two 2 pieces of double coat
99. er 5 Parts List 5 1 List of Recommended 22 C5 1 9 2 Qu uter Casing Ret rc C5 2 5 3 enorme erie ere nee oy E M C5 3 5 4 Frame 5100 100 130 150 C5 6 Frame FC5100 100 130 150 Parts List 5 6 9 9 Pen P C5 7 Block Parts LIST Rae deu RET RAE C5 7 5 6 2 Pen Holder amp Station C5 8 2 Pen Holder amp Station Parts List C5 8 SW duel mE E ETE C5 8 Light Pointer Assy Parts LS ca undis C5 8 5 8 Y 5100 0002 02655 lt C5 9 Y Slider FC5100 75 Parts C5 9 5 9 Y Slider FC5100 10030 15D aero retta ed trnbx ai enters C5 10 Y Slider FC5100 100 130 150 Parts 15 C5 10 5 10 Pinch Roller C5 11 Pinch Roller Assy Parts 154 C5 11 Stand ASSY qe m C5 12 Stand Assy Parts LI
100. er in this condition If the plot area setting is incorrect the cutting mat may be damaged if there is no media between the blade and the mat If the pen carriage strikes the side plate the position alarm will trigger 12 Replace the sensor after using the plotter Checks B Not required Adjustments B Not required CUTTING PRO FC5100 Diagnosing Problems C1 22 4 4 Testing the Control Panel Keys Run this test if a control panel key does not respond Tools Phillips screwdriver for an screw Preparation Requirements 1 Remove the right side cover from the plotter Tips For details of step 1 see Chapter 2 Section 4 1 Test Set Up Requirements 1 Set SW1 to the key testing mode as illustrated below Key test mode Set all DIP switches to OFF eum Turn on the power to the plotter 2 The status of the key appears on the LCD KEY T EST MODE 00000000000000000 0011 3 Press the key the status will change to 1 0 KEY T EST MODE For example press the NEXT key the second digit of the 01000000000000000 first status row will change to 1 CUTTING FC5100 Diagnosing Problems C1 23 Key Status Bit 1 ke 1st row 9 gigit F2 ke 1 row _ 10 digit F3 ke 1 row 118 digit F4 ke 1 row _ 12 digit MENU ke 275 row 34 digit NEXT ke 1 row 274 digit 2 UP ARROW ke 1 row 18 digit 15 RIGHT ARROW 1 row 7 digit 2 RIGHT ARROW ke 279 row 15
101. er the NOVRAM clearing Pen force adjustment Servo gain set or adjustment LED pointer offset adjustment Plot area adjustment Servo gain compensation value setting For the FC5100 100 5100 130 and FC5100 150 models CUTTING PRO FC5100 Parameter Settings C3 10 6 Setting the Servo Gain Use this step to set the servo gain or view the servo gain value This step does not test the servo gain If you need to test the servo gain you are required to run the servo gain test program on the computer For more information see Chapter 3 Section 11 Adjusting the Servo Gain Tools Phillips screwdriver for screw Preparation Requirements 1 Remove the right side cover from the plotter Tips For details of step 1 see Chapter 2 Section 4 1 How to Remove and Replace the Right Side Cover Set Up Requirements 1 Set SW1 to the system parameter setting mode as illustrated below Production adjustment mode for the standard model and Auto registration model Set DIP switches No 4 and 5 6 to OFF Other DIP switch settings depend on the type of model coun Production adjustment mode for 2 pen model Set the distance parameters to exchange Pen 1 and Pen 2 Set DIP switch No 4 to ON and 5 6 to OFF Other DIP switch settings depend on the type of model Turn on the power to the plotter First the Initial menu appears and then the Item Selection V 1 00 HL menu appears ER RAM CH
102. et Up Requirements 1 Set SW1 to the Sensor Disable Mode as illustrated below und SW1 1 to and 7 depend on the model see the previous page for normal mode DIP switch settings Note When turning on the power to the plotter the plotter initialization action does not sense the media size and set the origin to the lower left corner of the effective plotting area In this mode the current pen position is automatically set as the origin point You must load the media onto the plotter first and then locate the media and the Y Slider before turning on the power to the plotter This will establish the origin point of the plotter 2 Turn on the power to the plotter CUT ARE 3 The media selection menu will not appear The plotter will not perform the initialization routine a SES The effective cut area menu appears 4 The following menu appears CONDITION 1 14 30 EADY 4 CB09Ux 0 5 plot area For more information see Chapter 5 AREA in the User Manual CAUTION Exercise extreme caution when using the plotter in this condition If the plot area setting is incorrect the cutting mat may be damaged if there is no media between the blade and mat If the pen carriage strikes the side plate the position alarm will trigger 6 Replace the sensor after using the plotter CUTTING PRO FC5100 Diagnosing Problems 4 3 2 Method 2 The sensor can be disabled by the menu setup Tools
103. ew Voltmeter or multi function meter Preparation Requirements 1 Remove the right side cover from the plotter Tips For details of step 1 see Chapter 2 Section 4 1 Checking Requirements 1 on the power to the plotter 2 Measure the voltage at the P3 connector on the PCA Main board Voltage Pin Pin Voltage 6 1 5 NC 7 2 127 40V 8 93 40 40 91 4 GND 10 5 3 If the measured voltage does not match the table above then disconnect the connector on the PCA Main board If the measured voltage does not match the table above then there may be a problem with the power supply unit Checks Not required Adjustments B Not required 4 1 2 The Protective Circuit This power supply unit has an overload protection function If the system experiences an overload the POSITION ALARM message appears on the LCD or the power will shut down If the overload protection is activated turn off the power switch and unplug the power cable After 5 to 10 minutes reconnect the power cable and turn on the system If the power does not return check the FUSE located in the power supply unit CUTTING PRO FC5100 Diagnosing Problems C1 17 4 2 Testing the Sensors The plotter has four sensors to detect the size of the media the position of the pinch roller and the position of the media set lever Run this test if a sensor is not responding Tools B Phillips screwdri
104. ft to right If the edge of the Y slider touches the sidewall of the pulley damage to the Y drive belt may result or the cutter may not maintain optimum performance Grease may reduce belt deformation and extend the belt life CUTTING PRO FC5100 Removal and Replacement Procedures C2 21 The Y slider belt tension adjustment sets proper belt tension Incorrect tension can cause Y axis issues such as overshoot errors and out of phase alignment problems See Chapter 2 Section 5 2 How to Replace and Adjust the Y slider Belt for more information Re adjust the servo gain The system control parameters are stored the Non Volatile RAM that is located on the Main board The system control parameters are related to the moving mechanisms like the Y drive belt You must re set the system control parameters after replacing components or adjusting the moving mechanisms See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 22 5 4 How to replace the Y drive Motor and Y motor Pulley Overview Replace the Y drive motor or the Y motor pulley if they are damaged Tools Philips screwdriver for an M3 screw Hex L key Wrench side 1 5mm for an M3 Socket Set Screw Cutter Pliers As required Force Gauge range 5kg Wire or Rope Screw Locker Adhesive type 1401B As required Silicon Grease type G501 As required Cable Clamp and or Wire Tie
105. gt DISTANCE ADJUST gt TEST gt CONDITION LIST gt SELF TEST gt DATA DUMP gt MECHA gt AGING gt EW TEST gt PATTERN gt CUTTING PRO FC5100 Diagnosing Problems ISO PATT 10 The ISO Pattern menu appears the plotter immediately starts plotting the test pattern NOTE If you want to cancel the test pattern plot turn off the power to the plotter 11 When plotting is complete the pen will stop Turn off the power to the plotter Checks Check the test pattern s line quality Adjustments B If test pattern s line quality is poor plot the mechanical check pattern and inspect it Make any necessary adjustments CUTTING PRO FC5100 Diagnosing Problems 1 3 Printing the Skew Test Patterns This step will run the feed test The test pattern is stored on the Flash ROM Tools Ceramic pen 0 2mm tip size A1 size or ANSI D size tracing or vellum paper Printing Requirements 1 C1 10 Attach the pen to the penholder and load the paper into the plotter with the longer edge in the X axis Turn on the power to the plotter First the Initial menu appears then the Media Type menu 3 Press the F3 QUALITY key to select SHEET The initialization routine is executed to determine the paper size The Ready menu appears Set the condition as follows FORCE 12 SPEED 20 QUALITY 6 Tool PEN Press the MENU key to obtain the MENU mode
106. he grit rollers If the grit rollers are worn feeding problems will result Note that using harder material shortens the life of the grit roller CUTTING PRO FC5100 Diagnosing Problems C1 12 2 Mechanical Adjustment This section describes the specifications of mechanical adjustments See Chapter 2 Removal and Replacement Procedures section for more information 2 1 Y Slider Belt Tension Move the Y slider completely to the right Pull the belt 20mm from the Y rail in the center using a force gauge The pull force should meet the following specifications Specification FC5100 75 force is 160 20g 140g to 180g force FC5100 100 Pull force is 220 20g 200g to 2400 force FC5100 130 all Pull force is 220 20g 200g to 240g force FC5100 150 Pull force is 220 20g 200g to 2409 force Tips For details see Chapter 2 5 How to replace and adjust the Y Slider Belt section 2 2 Y Drive Belt Tension Pull the Y drive motor forward secure the Y drive motor FC5100 75 all Pullforceis2 25kg 0 2kg 5100 100 Pullforceis2 25kg 0 2kg 2 5100 1334 Pullforceis2 25kg 0 2kg 5100 152 Pullforceis2 25kg 0 2kg Tips For details see Chapter 2 5 3 How to replace and adjust the Y Drive Belt section 2 3 X Drive Belt Tension Pull the X drive motor downward secure the X drive motor FC5100 75 al
107. hesive tape Connect the FFC into J5 on the PCA Main board Install the flat cable support shelf bracket to the flat cable support bracket onto the M3 x 8mm Binder head screws attached to the square nuts in the Y rail Install the top cover assembly onto the plotter 10 Install the right side cover onto the plotter Checks Make sure the Teflon tape on the FFC is located on the hole of the right side plate Make sure that the FFC fits into the FFC bracket slot and does not rub between the edges of the FFC or the FFC bracket Make sure the pen head Y slider assembly moves completely left and right on the Y rail Adjustments The flat cable support shelf bracket should be positioned 10mm 0 39 in from the right side plate CUTTING PRO FC5100 Removal and Replacement Procedures C2 56 5 21 How to replace the Cutting Mat Overview The cutting mat is a Teflon coated strip that is used to reduce damage to the plotter and increase the life of the blade Replace the cutting mat when it is dented or worn out Tools B Not required Removal Procedure 1 Remove the cutter pen from the penholder 2 Lower the media set lever 3 Move the Y slider assembly to the right side of the plotter 4 Starting from the left side of the plotter lift up the cutting mat the black Teflon layer while holding down the cutting mat base Pull the cutting mat slowly toward the center of the plotter 5 When you reach the center move the Y slide
108. ieog C V 001111664 NIV 200012209 LNOYA YPENAS 200012205 0 3 099111244 7601500058 HOSN3S VO 099411244 YOSNAS HOSN3S d 0LL090d4 960150005 LHON LASHS OSL 70016099 081 09921 269 001 009711269 82 OpSZLLZ69 Od4A 0200 6049 079411514 Nad 1 061 1890 07099 OSL 6001 60 2 S601S000S AlddNS O 94 60150005 NS MS ES HI a Y31714 3SION 001 1850 07098 8 LAINI OV 091 081 1270 07098 091 0 1 001 260190009 9 60190009 YOLOW X 160150009 YOLOW A CUTTING PRO FC5100 C6 2 ELECTRICAL 6 2 Circuit wiring Main Board Clock amp Reset 49 9 12150 LN 13538 lt 213599 lt lt S WoS ND lt lt 52 Inox19 ZHW00 05 500 3 ZHINDS 9SQ 49019 90SVZ1599 019A3N 5 NOSTO Wa fo 214 wo m anyo anyo p Hey gno el pT 99 zHWSZ 19 lt ZHWOS NTO C YEON fm 0100712 jew 14 201VZLS99 019A4N AS CUTTING PRO FC5100 C6 3 ELECTRICAL Main Board CPU Section isi ola cz Lv Ke vive pX XOL tive v X301 evu
109. implify the process 1 Place the metal strip jig under the pinch roller raise the media set lever to lower the pinch roller 2 Install the pinch roller lifter jig onto the pinch roller arm 3 Pull the pinch roller lifter jig using the force gauge measure the force when the metal strip jig drops from the pinch roller The force gauge measurement should read as follows The pressure difference between the right pinch roller and the left pinch roller should be less than 400g CAUTION Always measure the right pinch roller and the left pinch roller pressure If the pinch roller pressure is uneven a media feeding problem may result Replace the pinch roller spring if the pressure is out of the specified range Specification of the Pinch Roller Pressure Machine Right and Left Pinch Pressure Center Pinch afew mener FC5100 75 Rev A 6 5kg 0 5kg Less than Not applicable FC5100 100 Rev A 6 5kg 0 5kg Less than 5 2kg 0 5kg Rev AB 6 5kg 0 5kg Less than 5 2kg 0 5kg FC5100 130 Rev A 6 5kg 0 5kg Less than 5 2kg 0 5kg Rev AB 6 5kg 0 5kg Less than 5 2kg 0 5kg FC5100 150 Rev 6 5kg 0 5kg Less than 5 2kg 0 5kg me dene CUTTING PRO FC5100 Removal and Replacement Procedures C2 48 Adjustments The pinch roller pressure adjustment sets the feeding performance 1 If the pinch roller pressure does not meet the stated specification adjust the pressure by adding or re
110. information Move the pen head slider assembly completely to the left Remove the flat cable support bracket by loosening it but do not disengage the screws from the square nuts inside the Y rail Remove the flat cable support bracket from the Y rail Detach the flat ribbon cable from the bracket it is attached with double sided tape Place the flat cable support bracket on a flat surface to prevent damage Remove the six 6 black zinc plated M3x6mm PBH screws that hold the rear cover to the top of the plotter Remove the six 6 black zinc plated M3x6mm PBH screws with washers that hold the rear cover to the bottom of the plotter On FC5100 75 model plotters remove the one 1 M3x4 PBH screw located on the top left side of the rear cover On FC5100 100 FC5100 130 and FC5100 150 model plotters remove the two 2 M3x4 PBH screws located on the top left and top right sides of the rear cover Pull the rear cover off toward you then upward Storage Procedure Carefully place the rear cover onto flat surface to prevent damage Reinstallation Procedure 1 2 Align the hole at the upper side of the rear cover On FC5100 75 model plotters insert the one 1 M3x4 PBH screw located on the top left side of the rear cover On FC5100 100 FC5100 130 and FC5100 150 model plotters remove the two 2 M3x4 PBH screws located on the top left and top right sides of the rear cover Insert the six 6 black zinc plated M3x6mm PBH screws with washer
111. ing Film sheet 24 inches wide by 24 inches long for the FC5100 75 Media Cutting Film sheet 30 inches wide by 48 inches long for the FC5100 100 Media Cutting Film sheet 40 inches wide by 48 inches long for the FC5100 130 Pen 11 1 Installation and Starting the Servo Gain Adjustment Program Minimum System Requirements Computer with a 486 or higher processor Microsoft Windows 95 Windows 98 or Windows NT Windows 2000 16MB of memory RAM 1MB of free hard disk space to install this program CD ROM drives for installation Set up for the Servo Gain Adjustment Program 1 2 9 4 5 Turn on the computer and start Windows Create a working folder on the hard drive Insert the CD in the CD ROM drive Open the CD in Windows Explorer and then open the Program folder on the CD Copy the following files to the working folder SERVO EXE Servo Gain Adjustment program file F1AORN60 DLL DLL file for Servo Gain Adjustment program NOTE The F1AORNG60 DLL file is needed to run the Servo Gain Adjustment program It should be in the same location as the Servo Gain Adjustment program which is the SERVO EXE file Starting the Servo Gain Adjustment Program 1 Open the working folder and then double click on the SERVO EXE icon the Start menu appears on the computer monitor Graphtec Cutter Servo Gain Adjust Program Version 2 00 Computer s Serial RS232C Interface Port Selection Press 1 Key to select th
112. ing standard anti static procedures Reinstallation Procedure 1 Making sure that you are static free mount the PCA Main board onto the standoffs using the six 6 M3 x 6mm SEMS screws Do not tighten the screws 2 Install the two 2 3 16 hex standoffs into the RS232C interface connector through the CPU bracket Do not tighten the hex standoffs 3 Install the two 2 4 x 72 inch Pan head screws into the parallel interface connector through the CPU bracket Do not tighten the screws 4 Tighten the 3 16 hex standoffs and the 4 screws to secure the interface connector to the CPU bracket 5 Tighten the mounting screws that hold the PCA Main board onto the right side plate 6 Re install all cables onto the PCA Main board T Install the right side cover onto the plotter Checks Check the cable connections particularly the cable running from the motors The X axis motor cable should be connected to the and P5 connectors which have an X mark on the PCB The Y axis motor cable should connect onto the P6 and P7 connectors which have a Y mark on the PCB All torque settings for the assembly of components to be set at standard settings Adjustments The system control parameters are stored in the Non Volatile RAM that is located the board The system control parameters are related to the moving mechanism You must re set CUTTING PRO FC5100 Removal and Replacement Procedures C2 14 the system contro
113. ing the Microsoft Windows operating system Microsoft Windows 95 98 Me 2000 or Windows NT4 0 Required capacity of the memory RAM depends upon the operating system 1MB of free hard disk space to install this program CD ROM drive or floppy drive for installation NOTE If you wish to use the USB interface to download the file to the plotter you must use Windows 98 or Me 2000 XP operating systems only The Windows 95 and NT4 0 operating systems do not support the USB interface Set up and starting the Data File Output Utility Program 1 Obtain the Data File Output Utility program and the necessary firmware files from your Graphtec distributor 2 Create a working folder on the hard drive 3 Once you obtain the program on CD or floppy disk insert it into the drive and then open it using Windows Explorer Copy the SEND exe file to the working folder on the hard drive When you download this program or receive it by e mail save it in the working folder on the hard drive If the file is archived open the archived file and then place the SEND exe file into the working folder 4 Copy the necessary firmware file to the working folder on the hard drive If you wish to use the USB interface for downloading the firmware set the plotter driver before starting Step 5 5 In Windows Explorer open the working folder and double click the SEND exe file icon to start the program 6 The following menu appears CUTTING PRO FC5100
114. ing the clearance It minimizes the front to back pivoting of the pen arm and moving friction it also reduces bearing overload or overbidding 1 Turn the two 2 M3 Binder head screws that hold the pen arm guide to the pen head 90 degrees counterclockwise CCW 2 Rotate the pen arm guide until there is no gap between the pen arm guide and the pen arm shaft Tighten the mounting screws Make sure that the bearing does not spin freely 4 Move the pen arm front to back There should no play If there is any play the clearance is too large Re adjust the pen arm guide position by rotating it CCW 5 While using your finger to hold down the front side bearing move the penholder up and down It should move smoothly If it is tight the clearance is too small Re adjust the pen arm guide position by rotating it clockwise CW While using your finger to hold down the front side bearing move the penholder up and down If the penholder does not move up the clearance is too large Re adjust the pen arm guide position by rotating it CCW 6 Move the penholder up and down It should move freely Next move the penholder slowly to verify that it does not stick or rub Make sure that the moving coil does not touch the outer case CUTTING PRO FC5100 Removal and Replacement Procedures C2 52 5 19 How to replace the PCA Pen Board Overview Replace the PCA Pen board if there is component damage or if the flag sensor fails The flag sensor is mounte
115. int Push the top of the pen to make a mark on the paper and then check the position of the pen If the position is correct press the ENTER key to store the setting In few seconds the following message appears Then the adjustment item selection menu appears EN ADJUSTMENT PL EA ADJUSTMENT TONBO OSAE SIKII CHI TONBO SENSOR POS If you wish to continue the parameter settings press the necessary key to select other parameters If you wish to finish the parameter setting or when all of the parameters are set turn off the power to the plotter Return the SW1 setting to normal mode as illustrated below NORMAL OPERATING mode Factory shipment Standard model Auto registration model or DUMB OMA Are GELT RD FC5100 75 FC5100 100 FC5100 130 FC5100 150 CUTTING PRO FC5100 Parameter Settings C3 19 2 pen model 0710 80000 Nor 12345678 12345678 12345678 12345678 FC5100 75 5100 100 5100 130 FC5100 150 Checks B Not required Adjustments B Not required CUTTING PRO FC5100 Parameter Settings C3 20 10 Adjusting the Distance Accuracy Run this test if the actual plot length is longer or shorter than the plot data or if the grit roller has been replaced Tools
116. ion Requirements 1 Tips Remove the right side cover from the plotter C3 15 For details of step 1 see Chapter 2 Section 4 1 How to Remove and Replace the Right Side Cover Adjustment Set Up Requirements 1 Note Attach the pen to the penholder Load the paper into the plotter Move the pen carriage near the right pinch roller manually so that it is inside of the pinch roller Set SW1 to the LED pointer adjustment mode as illustrated below Production adjustment mode for the standard model and Auto registration model Set DIP switches No 4 and 5 6 to OFF Other DIP switch settings depend on the type of model CRT Turn on the power to the plotter First the Initial menu appears and then the first item selection menu appears Press the NEXT key to obtain the LED PEN ON OFF menu Press the F3 QUALITY key to select LED PEN ON OFF setup mode Press the F3 QUALITY key to select enabled Press the ENTER key to register the setting If the x mark is on ENABLED press the F3 QUALITY key press the NEXT key to cancel the LED PEN ON OFF setup mode 2 V 1 00 XY GAIN HL ER RAM CHECKING EN FORCE 1 F PEN ADJUSTMENT ADD CAM OPT ED PEN ON OFF If the LED PEN is set to disabled the LED pointer never turns on illuminates The previous menu appears CUTTING PRO FC5100 Parameter Se
117. isfactorily adjusted set a lower gain value set a higher gain value CUTTING PRO FC5100 Parameter Settings C3 29 Check the Maximum Error value the value must be below 10 9 gt Maximum Error value Try to make the Maximum Error as low a number as possible Checks Plot and inspect the mechanical check pattern Adjustments ifthe mechanical check pattern fails check the moving mechanisms and then re adjust the servo gain CUTTING PRO FC5100 Firmware C4 1 Chapter 4 Firmware This chapter explains how to download the Firmware The firmware is stored on the flash memory and can be upgraded if necessary Remember if you need the newest version of firmware contact your Graphtec distributor Tools Computer Windows based Software the Data File Output Utility Ver 2 08 program with the executable file named 1 Installation and Starting the Data File Output Utility Program The Data File Output Utility program outputs specified data from the computer to the plotter It can use the parallel interface printer port or the USB interface If you wish to use the USB interface you must install the plotter driver OPS628 Ver 7 12 or later into the your computer You can use this utility program to download the firmware or the plotting data to the plotter This utility program is designed for the Windows operating system Minimum System Requirements Computer capable or load
118. l parameters after replacing components or adjusting the moving mechanism See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 15 5 Replacing and Adjusting Procedures 5 1 How to replace and adjust the Lever and Lever Cap Overview Replace the lever cap if it is damaged Adjust the lever if it easily disengages Tools Phillips screwdriver for screw Force gauge range 2kg Removal Procedure 1 Remove the two 2 black zinc plated M3 SEMS pan head screw with flat washer screws that hold the lever cap to the lever arm 2 Pullthe lever cap off from the media set lever Storage Procedure Lay the lever cap on a flat surface to prevent damage Reinstallation Procedure 1 Mount the lever cap to the media set lever and insert the two 2 black zinc plated M3 x 6mm SEMS screws 2 Make sure the lever cap is secured to the control panel Checks Do not tighten until a proper fit is established between the lever cap and the control bezel Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 16 5 2 How to replace and adjust the Y slider Belt Overview Replace the Y slider belt if it is damaged or remove it to replace other components If the plotter exhibits poor cutting plotting results one possibility might be loose Y slider belt tension Adjust the Y slider belt tension accordingl
119. lley out from the X drive shaft Storage Procedure Carefully place the part onto a flat surface to prevent damage Reinstallation Procedure 1 Insert the X drive pulley onto the X drive shaft set the position so that it has a 2mm space between the X drive pulley and the right side plate 2 Tighten the two 2 M3 x 4mm Socket Set screws to secure the X drive pulley to the X drive shaft 3 Install the X drive belt onto the X drive motor and X drive pulley adjust the X drive belt tension See Chapter 2 Section 5 7 How to Replace and Adjust the X drive belt for more information 4 Install the PCA Main board onto the plotter 5 Install the right side cover onto the plotter Checks All torque settings for the assembly of components to be set at standard settings CUTTING PRO FC5100 Removal and Replacement Procedures C2 33 Adjustments The X drive belt tension adjustment maintains machine performance reduces motor shaft deformation and extends the machine s operational life See Chapter 2 Section 5 7 How to Replace and Adjust the X drive belt for more information Re adjust the servo gain The system control parameters are stored in the Non Volatile RAM that is located on the Main board The system control parameters are related to the moving mechanisms like the X drive belt You must re set the system control parameters after replacing components or adjusting the moving mechanisms See Chapter 3 Sys
120. may short the electrical components and cause damage to the plotter Checks All torque settings for the assembly of the components to be set at standard settings Make sure that all screws are tightened CUTTING PRO FC5100 Removal and Replacement Procedures C2 65 A NOTE Be sure to tighten all the screws to ensure accurate media loading The Accuload system may not function properly if even one of the screws is loose Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 66 7 Options 7 1 The Stand Option Overview The FC5100 stand is used to make the unit more portable and to free up counter space to make storing your plotter easier The stand is an option for the FC5100 75 model and a standard accessory for the FC5100 100 FC5100 130 and FC5100 150 model cutting plotters A WARNING Two people should pick up the plotter CAUTION Improper assembly of these pieces may cause the unit to become unstable when heavy loads are added In extreme cases the unit may tip over v NOTE Always keep the wheels in a locked position when operating your plotter Tools Hex L key Wrench size 5mm that is for an 6 Socket Cap screw How to remove the plotter from the Stand 1 Remove the two 2 M6 Socket Cap screws that hold the plotter onto the right side leg of the stand 2 Remove the two 2 M6 Socket Cap screws that hold the plotter onto the left side leg of the stand
121. ment Procedures C2 35 5 11 How to replace and adjust the X drive Shaft with the Grit Rollers Overview Replace the X drive shaft and the grit rollers if they are damaged or if the grit rollers are worn When using harder material the life of the grit rollers will be shortened Tools Phillips screwdriver for an screw Hex Nut driver size 6mm and 3 16 inch Hex L key Wrench size 1 5mm for an Socket Set screw Cutter Pliers As required Force Gauge range 5kg Wire or Rope Screw Locker Adhesive type 14018 As required Silicon Grease type G501 As required Cable Clamp and or Wire Tie As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the PCA Main board from the plotter See Chapter 2 Section 4 7 How to Replace the PCA Main board for details 3 Remove the X drive belt from the plotter See Chapter 2 Section 5 7 How to Replace and Adjust the X Drive belt for details 4 Remove the X drive pulley from the X drive shaft See Chapter 2 Section 5 9 How to Replace the X Drive Pulley for details 5 Remove the front cover from the plotter See Chapter 2 Section 4 5 How to Remove and Install the Front Cover for details 6 Remove the rear cover from the plotter See Chapter 2 Section 4 6 How to Remove and Install the Rear Co
122. ment of the Y rail and the grit rollers 3 2 Pillow Blocks The pillow blocks mount onto the chassis The position of the pillow blocks is critical for the correct alignment of the grit rollers The pillow blocks are positioned by use of a special jig Do not remove the pillow blocks f the grit rollers are not properly aligned a media feeding problem may result 3 3 Pen Head Block There is a very small separation gap between the moving coil and the moving coil case Special care is required to ensure the correct distance is set between the moving coil and its case If the moving coil touches the moving coil case the raise lower pen feature may malfunction and or the coil may burn CUTTING PRO FC5100 Removal and Replacement Procedures C2 4 4 Common Removal and Replacement Procedures 4 1 How to remove and install the Right Side Cover Overview Replace the right side cover if it is damaged or remove it to replace other components Tools B Philips screwdriver for screw B Hex nut driver size 5 5mm As required Removal Procedure 1 2 Loosen the two 2 M3 Binder head screws that hold the top cover assembly to the back of the right side plate Loosen the two 2 M3 Binder head screws Loosen the one 1 M3 Binder head screw that holds the top cover assembly to the front of the right side plate Loosen the one 1 M3 Binder head screw Remove the two 2 black zinc plated M3 Binder head
123. model Auto registration model WOU ARAN FC5100 75 FC5100 100 FC5100 130 FC5100 150 2 pen model m mmmmnanos 12345678 12345678 12345678 12345678 FC5100 75 FC5100 100 FC5100 130 FC5100 150 Troubleshooting Tips m Ifa sensor is not responding properly check the following Check the wiring of the cable Check the connection of the connector Check the components on the Main board Connector J5 P8 P9 or P10 Filter FL3 FL7 FL8 FC11 FL34 FL35 or FL36 Transistor Q1 or Q6 Check the components on the Pen board Connector J1 or J3 Sensor U1 Diode D1 or D2 Resistor R1 Check the components on the Pinch Roller Sensor board Connector J1 Sensor U1 Replace the necessary component s Checks B Not required Adjustments B Ifthe Main board has been replaced you must re enter adjustment CUTTING PRO FC5100 Diagnosing Problems C1 19 4 3 Temporary Use of the Plotter without the Sensor The sensor can be disabled for temporary use of the plotter 4 3 1 Method 1 The sensor can be disabled by the hardware setup Tools B Phillips screwdriver for an screw Preparation Requirements 1 Remove the right side cover from the plotter Tips For details of step 1 see Chapter 2 Section 4 1 S
124. moving washers 2 Measure the pinch roller pressure and adjust it by adding or removing washers as required Washer M 8mm H 3mm T 0 5mm CC CAUTION The center pinch roller uses a spring that is different from both the right and left pinch roller springs The hooks face the same direction for the left and right pinch roller springs The hooks for the center ni pinch roller spring face in opposite directions CUTTING PRO FC5100 Removal and Replacement Procedures C2 49 5 17 How to replace and adjust the Pen Head Block Overview Replace the pen head block if the plotter exhibits problems with raising or lowering the pen if it is damaged or to replace other components Tools Phillips screwdriver for the M3 and the M4 screw Steel Rule Scale or Caliper metric scale at least 30mm or longer Double Coated Adhesive Tape size 10mm x 20mm As required Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information 3 Remove the pen head cover from the plotter See Chapter 2 Section 4 4 How to Remove and Install the Pen Head Cove
125. nd out of phase alignment problems See Chapter 2 Section 5 2 How to Replace and Adjust the Y slider Belt for more information Re adjust the servo gain The system control parameters are stored in the Non Volatile RAM that is located on the Main board The system control parameters are related to moving mechanisms like the Y slider Belt You must re set the system control parameters after replacing components or adjusting moving mechanisms See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 28 5 7 How to replace and adjust the X Drive Belt Overview Replace the X drive belt if it is damaged or remove it to replace other components If the plotter exhibits poor cutting plotting results one possibility may be loose X drive belt tension Adjust the X drive belt tension accordingly Tools Phillips screwdriver for an M3 screw Hex Nut driver size 6mm and 3 16inch Cutter Pliers As required Force Gauge range 5kg Wire or Rope Screw Locker Adhesive type 14018 As required Silicon Grease type G501 As required Cable Clamp and or Wire Tie As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the PCA Main board from the plotter See section Chapter 2 Section 4 7 How to Replace the PCA Main board
126. ng 1 621170041 Sensor Plate CA 003310130 Shaft Holder 1721 34 792217713 Pinch Roller Assy 4 772118260 Pinch Roller Center Assy 1 For FC5100 100 130 and 150 792217712 Pinch Roller L Assy lt 792117725 FC51 Center Cover 75E 1 5100 75 792117726 51 Center Cover 100E FC5100 100 79217727 51 Center Cover 130E FC5100 130 792117728 FC51 Center Cover 150E 1 5100 150 38 621170361 Shaft 75 1 5100 75 621180361 Shaft 100 FC5100 100 621190631 Shaft 130 FC5100 130 621200360 Shaft 150 feet 0000 FC5100 150 621170082 Y Rail Bracket 41 621170370 Y Rail 75 1 5100 75 621180370 Y Rail 100 1 5100 100 621190370 Y Rail 130 FC5100 130 621200370 Y 150 FC5100 150 792117703 Block Assy for STD 1 Standard 792117704 Pen Block Assy for 2 pen 1 2 Pen remm pwweRolerAssforrcsto 00 _______ 1 osoon O 7e2tt7718 Drive Roller Assy forFosi00 130 _______ 1 osoon O O reattrret Drive Roller Assy forFosi00 150 _______ _ O 45 392080100 Drive Shaft Bush 1 46 310181022 Drive Shaft Holder Roller B 8516ZZRA3 5 7 90r 10 FC5100 75 is 5 100 is 7 130 is 9 150 is 10 Ell 621203001 Idler Pulley Bracket FC5100 150 only 5 gt es TS 621208010 Puey Shaft for FCS100 1650 er Pate Assy for FC5100 100 and 68100 1
127. nt Procedures C2 2 2 Safety Precautions This section covers special precautions you should take when working with the cutting plotter CAUTION Will cause damage to the unit During the course of turning on the plotter be sure to observe the following precautions 1 Keep your hands hair clothing and other objects out of the vicinity of the pen carriage grit rollers and loaded media 2 To prevent operator injury be careful not to allow your hands hair clothing or other foreign objects to become entangled with the pen carriage or loaded media while using the plotter A WARNING Will cause damage to the Operator During the course of working on the plotter be sure to observe the following warnings 1 Turn off the power switch and disconnect the power cord from the power supply 2 Observe anti static procedures Throughout the manual you will see notes that will help you work more efficiently 4 NOTE Information to simplify or correctly complete a task CUTTING PRO FC5100 Removal and Replacement Procedures C2 3 3 Components Not to be Removed Q CAUTION These are critical components that require special tools to ensure that they are assembled to tight tolerances They cannot be replaced in the field they must be replaced at the factory 3 1 Right side plate and Left side plate The right side plate and the left side plate mount to the chassis The position of the side plates is critical for the accurate align
128. nterclockwise CCW 3 Putthe V type force gauge head to the force gauge 4 Use the force gauge to push the X drive motor pulley flange with a 2 25kg 0 2kg force 5 Tighten the mounting screws that hold the X drive motor 6 Remove the wire rope from the X drive motor 7 Apply the screw locker adhesive to the screws that hold the X drive motor 8 Apply the silicon grease to the tooth side of the X drive belt CAUTION The X drive belt moves right and left when the X drive motor is turned clockwise CW or counterclockwise CCW If the X drive belt edge touches the side plate or pulley sidewall it may degrade machine performance or cause damage to the X drive Grease may reduce the belt deformation and extend the belt life Re adjust the servo gain The system control parameters are stored in the Non Volatile RAM that is located on the Main board The system control parameters are related to the moving mechanisms like the X drive belt You must re set the system control parameters after replacing components or adjusting the moving mechanisms See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 30 5 8 How to replace the X Motor and X Motor Pulley Overview Replace the X drive motor and or the X motor pulley if they are damaged Tools Phillips screwdriver for screw Hex Nut driver size 6mm and 3 16 inch Hex
129. ol parameters are related to the moving mechanisms like the X drive belt You must re set the system control parameters after replacing components or adjusting the moving mechanisms See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 32 5 9 How to replace the X Drive Pulley Overview Replace the X drive pulley if it is damaged or remove it to replace other components Tools Phillips screwdriver for an screw Hex Nut driver size 6mm and 3 16 inch Hex L key Wrench size 1 5mm for an Socket Set screw Cutter Pliers As required Force Gauge range 5kg V type force gauge head B Screw Locker Adhesive type 14018 As required Silicon Grease type G501 As required Cable Clamp and or Wire Tie As required Removal Procedure 1 4 5 6 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information Remove the PCA Main board from the plotter See Chapter 2 Section 4 7 How to Replace the PCA Main board for more information Loosen the three 3 M3 SEMS pan head screw with flat washer screws that hold the X drive motor to the right side plate Remove the X drive belt from the X drive motor and X drive pulley Remove the two 2 M3 Socket Set screws that hold the X drive pulley to the X drive shaft Pull the X drive pu
130. on the pinch roller arm assembly 4 Remove the pinch roller spring from the bottom bracket on the pinch roller arm assembly Storage Procedure Carefully place the part onto flat surface to prevent damage Reinstallation Procedure Install the bottom bracket onto the pinch roller arm Hook the pinch roller spring onto the bottom bracket Hook the pinch roller spring onto the top bracket Set the bottom bracket onto the front side Measure the pinch roller pressure see Checks section for detail Install the top cover onto the plotter g NS Install the right side cover onto the plotter CAUTION Do not bend the hook portion of the pinch roller spring If there is any deformation in the hook the pinch roller pressure will be lowered Lower pinch roller pressure may result in a media feeding problem CUTTING PRO FC5100 Removal and Replacement Procedures C2 47 Checks Make sure the position of the bottom bracket is set from the front side Check the pinch roller pressure 1 Raise the media set lever to lower the pinch roller 2 Wind the wire rope around the shaft of the pinch roller 3 Use the force gauge to pull the wire rope pull the gauge and measure the force when the pinch roller lifts up from the grit roller The pressure difference between the right pinch roller and the left pinch roller should be less than 400g A NOTE Use the pinch roller lifter jig and a metal strip jig to s
131. onto the plotter 14 Install the right side cover onto the plotter Checks All torque settings for the assembly of components to be set at standard settings m Make sure the Y slider belt position to the Y tension pulley is correct m Make sure the pen head block position to the cutting mat is correct and parallel m Make sure the X axis and the Y axis are perpendicular Run the mechanical check pattern and inspect it See Chapter 1 Diagnosing Problems for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 41 Adjustments The spring plate adjustment sets proper pressure between both the top and bottom Y slider rollers and the Y rail It also reduces roller bearing overload or overbidding it minimizes roller drag reduces roller wear and minimizes Y slider front to back pivot See Chapter 2 Section 5 12 How to Adjust the Y slider Assembly for more information The Y slider belt tension adjustment sets proper belt tension Incorrect tension can cause Y axis problems such as overshoot errors and out of phase alignment problems See Chapter 2 Section 5 2 How to Replace and Adjust the Y slider Belt for more information The pen height adjustment sets the proper distance between the pen and the cutting mat to ensure proper and consistent cutting performance See Chapter 2 Section 5 17 How to Replace and Adjust the Pen Head Block for more information The system control parameters are store
132. oot program source file is loader x CAUTION You must complete the entire process If the process is not completed you will lose the plotter s boot program and will not be able to start the machine If this occurs you must replace the flash memory How to download 1 Connect the parallel printer cable or the USB cable between the plotter and the computer Set the Output port on the Data File Output Utility Program to LPT1 when using the parallel interface Set the Output port on the Data File Output Utility Program to the name of the plotter assigned when you installed the plotter driver using the USB interface 2 on the power of the plotter while pressing the RIGHT ARROW key Continue to press the RIGHT ARROW key until a beeper sounds 3 The password menu appears Input the password press PASSWORD V1 00 the keys in the following order DOWN ARROW key UP ARROW key RIGHT ARROW key LEFT ARROW key 4 The program type selection menu appears Press the BOOT F1 FORCE key to select BOOT MAIN 5 The password menu appears Input the password press PASSWORD V1 00 the keys in the following order DOWN ARROW key DOWN ARROW key RIGHT ARROW key RIGHT ARROW key 6 The modes of the Parallel interface selection menu ELE END MODE appear Press the F3 QUALITY key to select MODE1 If communication between the plotter and computer does not 1 gt MODE2 gt work successfully
133. ppears Press 8 Key to TEST the Servo Gain Press 9 Key to SET the Servo Gain Press 0 Key to RETURN to the Interface Port Selection menu Press Q Key to EXIT this Program Enter new GAIN setting and then press ENTER Key Previous Settings X 28 Y 29 X GAIN Y GAIN The previous setting is shown for reference to determine the new gain value The first time this menu is seen the previous setting values are 30 and 32 Input the new X axis gain value and then press the ENTER key The Y axis Gain Set menu appears Input the new Y axis gain value and then press the ENTER key The servo gain test routine is executed and then the measurement value appears The Test or Set Gain menu appears again repeat step 5 set the new gain value 7 Turn off the power of the plotter and disconnect the interface cable Adjusting Tips m When you select TEST the servo gain test routine is executed the measurement value and the waveform are shown on the computer monitor This display shows the reference line and the waveform that was measured The X axis represents time and the Y axis represents speed If the plotter setup is not correct the waveform does not fit within the reference line Check the waveform Reference Reference line K line t Measured Measured Measured i line P line i line The Servo Gain is Excessive gain you must Insufficient gain you must sat
134. pulley and the Y drive belt onto the bracket on the right side plate Install the Y drive motor onto the bracket using the four 4 M3 x 8mm SEMS screws do not tighten the screws Install the Y drive belt onto the pulley on the Y drive motor Adjust the tension of the Y drive belt as directed in the Adjustments section Apply silicon grease onto the tooth side of the Y drive belt Install the Y slider belt and adjust the tension of the belt Install the top cover assembly onto the plotter Install the left side covers onto the plotter Install the right side covers onto the plotter Checks All torque settings for the assembly of components to be set at standard settings Adjustments pe 9 mc Adjust the Y drive belt tension to maintain machine performance reduce motor shaft deformation and extend the machine s operational life Tighten the four 4 M3 x 8mm SEMS screws that hold the Y drive motor Turn the mounting screws 180 degrees counterclockwise CCW Wind the wire rope around the shoulder of the Y drive motor Use the force gauge to pull the wire rope by a force of 2 25kg 0 2kg and tighten the mounting screws that hold the Y drive motor Remove the wire rope from the Y drive motor Apply the screw locker adhesive to the screws that hold the Y drive motor Apply the silicon grease onto the tooth side of the Y drive belt CAUTION The Y drive belt moves up and down when the Y slider is moved from le
135. r for more information 4 Disconnect the cable and the flexible printed circuit cable FPC from J2 and P2 P1 Option on the PCA Pen board 5 Remove the FPC from the Y slider The FPC will be taped to the Y slider plate 6 Remove the two 2 M4 Binder head screws that hold the pen head block to the Y slider plate 7 Remove the pen head block CAUTION The moving coil type actuator that mounts on the pen head block has a very strong magnet The actuator will stick to the steel plate The actuator can pick up steel components or dust Storage Procedure The Pen board should be handled following standard anti static procedures Carefully place the pen head block on to a surface that is clear of steel components or dust The pen head block has a very strong magnet The actuator may be damaged if steel dust is captured between the moving coil and its case Reinstallation Procedure 1 Install the two 2 x 8mm Binder head screws through the pen head block into the Y slider plate do not tighten the screws 2 Adjust the position of the pen head block in relation to the Y slider Plate see Adjustments section for details Tighten the two 2 mounting screws to secure the pen head block Connect the cable and FPC to J2 and P2 P1 Option on the PCA Pen board Use the double coated adhesive tape to secure the FPC onto the Y slider plate o o Install the pen head cover onto the pen head block CUTTING PRO F
136. r assembly to the left side of the plotter Continue pulling the cutting mat toward the right until it is completely removed 6 Make sure the groove is free from glue and dirt Clean off any dirt or glue with a cloth moistened in ethyl alcohol Storage Procedure Not required Reinstallation Procedure 1 Remove the backing sheet from the underside of the cutting mat 2 Move the Y slider assembly to the right side of the plotter 3 Starting from the left side of the plotter align the mat with the rear edge of the groove leave a 2 3mm gap between the side plate and the mat and then carefully attach the mat Take care that the mat does not buckle Work with a small area at a time 4 When you reach the center move the Y slider assembly to the left before attaching the remaining part of the mat CAUTION Make sure the cutting mat surface is smooth If the cutting mat has an air bubble it may cause skipping problems with the pen resulting in poor cutting quality Checks B Not required Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 57 5 22 How to replace the Control panel Sheet Switch Overview Replace the sheet switch if there is damage or component failure Tools Phillips screwdriver for an M3 screw Cutter Pliers As required Adhesive Teflon Tape size 50mm As required Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1
137. r the Non Volatile RAM you will lose the setup parameters for each adjustment You must re do all of the adjustments Tools Phillips screwdriver for an screw Preparation Requirements 1 Remove the right side cover from the plotter Tips For details of step 1 see Chapter 2 Section 4 1 How to Remove and Replace the Right Side Cover Set Up Requirements 1 Set SW1 to the NOVRAM Clear mode as illustrated below Turn on the power to the plotter 2 The NOVRAM Clear Start menu appears NOVRAM CLEAR START The plotter immediately starts to clear the parameters on NOVRAM and then sets the default value 3 When the programming is complete the NOVRAM Clear NOVRAM CLE End menu appears 4 Turn off the power to the plotter Return the SW1 setting to normal mode as illustrated below NORMAL OPERATING mode Factory shipment B Standard model EU a n Auto registration model TONBO 5100 75 FC5100 100 FC5100 130 FC5100 150 CUTTING PRO FC5100 Parameter Settings C3 9 2 pen model PRES PUTIN GOI 5100 75 5100 100 5100 130 5100 150 NOTE After this operation the plotter sets the condition to GP GL command set the language to English and the length unit to metric Checks Plot and inspect the mechanical check pattern Adjustments The following adjustments are required aft
138. r the X axis two lines are DISTANCE ADJUST parallel to the Y axis when the distance is set up to 400mm For the Y axis two lines are parallel to the X axis when the distance is set up to 300mm After the lines are plotted the following menu appears DISTANCE ADJUST 0 Y 0 PATTERN PLOT PARAMETER SE Remove the paper and measure between the lines DISTANCE ADJUST For the X axis measure the distance between the two 0 Y PATTERN PLO PARAMETER SEJ plotted lines that are parallel to the Y axis For the Y axis measure the distance between the two plotted lines that are parallel to the X axis If the measured distance for the X axis and Y axis are within specification press the NEXT key to cancel the adjustment mode If the measured distance for the X axis and Y axis are not within specification press the F4 OFFSET key to select the parameter set mode Input the value using the POSITION keys Press the LEFT or RIGHT ARROW key to move the cursor I to select the digit Press the UP ARROW key to increment the number Press the DOWN ARROW key to change the polarity The value to input is the difference between the set distance and the measured distance NOTE The formula of the input value is as follows Input value set up distance measured distance For X axis X 400mm measured distance For Y axis Y 300mm measured distance If the measured di
139. remove it to replace other components Tools Phillips screwdriver for an screw Removal Procedure 1 Remove the two 2 M3 Binder head screws the right and left sides of the pen head cover Storage Procedure Carefully place the pen head cover onto a flat surface to prevent damage Reinstallation Procedure 1 Slide the pen head cover over the pen head 2 Install the two 2 M3 Binder head screws on the right and left sides of the pen head cover Torque to 6Kgecm Checks Alltorque settings for the assembly of components to be set at standard settings Make sure that the pen head cover does not clip the pen head wires pen head cover has a recess to accommodate the wires Make sure that the pen head cover is on straight and completely fastened Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 10 4 5 How to remove and install the Rear Cover Overview Replace the rear cover if it is damaged or remove it to replace other components Tools Phillips screwdriver for screw Removal Procedure 1 9 Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information Remove the Y flexible cable guide from the plotter Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more
140. s damaged Tools Philips screwdriver for an M3 screw Cutter Pliers As required Force Gauge range 1kg and 5kg Steel Rule Scale metric scale at least 30mm or longer Wire or Rope Screw Locker Adhesive type 1401B As required Silicon Grease type G501 As required Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the left side cover from the plotter See Chapter 2 Section 4 2 How to Remove and Install the Left Side Cover for more information 3 Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information 4 Remove the Y slider belt from the plotter See Chapter 2 Section 5 2 How to Replace and Adjust the Y slider Belt for more information 5 Remove the Y drive motor from the plotter See Chapter 2 Section 5 4 How to Replace the Y drive Motor and Y drive Pulley Assembly for more information 6 Pull the Y drive pulley assembly out from the bracket on the right side plate and remove it 7 Remove the Y drive belt from the Y drive pulley See Chapter 2 Section 5 3 How to Replace and Adjust the Y drive Belt for more information CAUTION The motor has a strong magnet The motor will stick to the steel plate when yo
141. s mark and reference line is below 0 45mm 0 45mm 2 Z FC5100 130 The difference between the cross mark and reference line is below 0 45mm 0 45mm 2 Z FC5100 150 The difference between the cross mark and reference line is below 0 45mm 0 45mm 2 Z CUTTING PRO FC5100 Diagnosing Problems C1 6 Troubleshooting Tips Overshoot too large There may be play in the driving mechanism 1 2 3 4 5 a Make sure there are no loose mounting screws on the pulleys motors grit rollers pen head mechanism or Y slider Check the tension of the X drive belt Y drive belt and or the Y slider belt Check the movement friction of the Y slider and or the grit rollers Check the pen head and make sure there is no play on the pen arm mechanism Check the servo gain Circle distortion too large There may be play in the driving mechanism There may be friction in the driving mechanism 1 2 3 4 5 Make sure there are no loose mounting screws on the pulleys motors grit rollers pen head mechanism or Y slider Check the tension of the X drive belt Y drive belt and or the Y slider belt Check movement friction of the Y slider and or the grit rollers Check the pen head and make sure there is no play on the pen arm mechanism Check the servo gain Too large difference on the repeatability There may be play in the driving mechanism There may be friction in the driving mechanism 1 2 3 4 5
142. s that hold the rear cover to the bottom of the plotter Insert the six 6 black zinc plated M3x6mm PBH screws that hold the rear cover to the top of the plotter Move the pen head slider assembly completely to the left Using two 2 short strips of double sided tape attach the flat cable support bracket to the lower flange of the flat cable support bracket Mount the flat cable support bracket onto the screws with the square nuts located on the lower rear of the Y rail CUTTING PRO FC5100 Removal and Replacement Procedures C2 11 8 Position the flat cable support bracket 10mm 0 39 in from the left side plate Tighten the screws but make sure the pen head slider assembly moves completely to the left and completely to the right without binding on the flat ribbon cable 9 Install the top cover assembly onto the plotter 10 Install the right and left side covers onto the plotter 11 Tighten the screws Checks All torque settings for the assembly of components to be set at standard settings Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 12 4 6 How to remove and install the Front Cover Overview Replace the front cover if it is damaged or remove it to replace other components Tools Phillips screwdriver for screw Removal Procedure 1 Remove the rear cover from the plotter See Chapter 2 Section 4 5 How to Remove and Install the Rear Cover Assembly for more
143. screws Remove the two 2 M3 SEMS pan head screw with flat washer screws Remove the two 2 M3 SEMS pan head screw with flat washer screws that hold the right side cover to the bottom of the right side plate Remove the two 2 black zinc plated M3 Binder head screws that hold the right side cover to the right side plate Pull the right side cover out from the right side plate CUTTING PRO FC5100 Removal and Replacement Procedures C2 5 Storage Procedure Carefully place the right side cover onto flat surface to prevent damage Reinstallation Procedure 1 3 4 5 6 Make sure that the two 2 5 5mm hex standoffs mount onto the inside of the right side cover If there no standoffs install the two 2 5 5mm x 45mm L hex standoffs Mount the right side cover onto the right side plate the tab at the top of the cover goes into and under the top cover assembly Insert the two 2 black zinc plated M3 x 8mm Binder head screws into the right side plate Insert the two 2 M3 x 8mm SEMS screws into the bottom of the right side plate Tighten the screws that hold the right side cover Tighten the screws that hold the top cover assembly Checks All torque settings for the assembly of components to be set at standard settings Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 6 4 2 How to remove and install the Left Side Cover Overview Replace the left
144. se Y axis problems such as overshoot errors and out of phase alignment problems See Chapter 2 Section 5 2 How to Replace and Adjust the Y slider Belt for more information The pen height adjustment sets the proper distance between the pen and the cutting mat to ensure proper and consistent cutting performance See Chapter 2 Section 5 18 How to Replace and Adjust the Pen Head Block for more information Re adjust the servo gain The system control parameters are stored in the Non Volatile RAM that is located on the Main board The system control parameters are related to the moving mechanisms like the Y slider assembly and Y slider belt You must re set the system control parameters after replacing components or adjusting the moving mechanisms See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 39 5 13 How to replace and adjust the Y Rail Assembly Overview Replace the Y rail assembly if it is damaged or remove it to replace other components Tools Philips screwdriver for the and screw Cutter Pliers As required Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information 2 Remove the left side cover from the plotter See Chapter 2 S
145. section describes how to remove replace adjust and or calibrate components of the FC5100 1 Before You Start You will need the following equipment Adhesive Screw Locker Reference THREE BOND type 14018 As required Adhesive Thread Locker low strength Reference LOCTITE type 222 As required Adhesive Silicon As required Adhesive Tape Double Coated tape Reference NITTO type 500 As required Adhesive Tape Teflon 50mm wide As required Calipers Size 150mm long As required Gauge Force Range 20g 50g 100g 200g 500g 1kg 2kg and 10kg Grease Silicon Reference SHINETSU type G501 As required Harness Wrap As required Rubber Hammer or Mallet Insert tool E Style Retaining Ring Size for 4mm shaft Pliers Cutter Pliers Needle Nose Nut Driver Hex Size 5 5mm 6mm and 3 16 inch Scale Steel Rule Metric scale 30mm or longer length Screwdriver Phillips Size for the screw Tweezers Wire or Rope Wrench Hex L Key Size 1 5mm and 5mm Cable Clamp As required Wire Tie As required Pinch Roller Lifter Jig Metal Strip Jig All torque settings for the assembly of components to be set at standard settings M2 HW TORQUE PLASTIC amp PCB ASSY M3 HW TORQUE PLASTIC amp PCB ASSY M3 HW TORQUE SHEET METAL 10 12kg M4 HW TORQUE PLASTIC 12 14kg M4 HW TORQUE SHEET METAL 14 16kg M4 Thread Forming Screw TORQUE SHEET METAL CUTTING PRO FC5100 Removal and Replaceme
146. side cover if it is damaged or remove it to replace other components Tools Phillips screwdriver for screw Nut driver size 5 5mm As required Removal Procedure 1 Loosen the two 2 M3 Binder head screws that hold the top cover assembly to the back of the left side plate Loosen the two 2 M3 Binder head screws 2 Loosen the one 1 M3 Binder head screw that holds the top cover assembly to the front of the left side plate Loosen the one 1 M3 Binder head screw Remove the two 2 black zinc plated Binder head screws 3 Remove the two 2 M3 SEMS pan head screw with flat washer screws that hold the left side cover to the bottom of the left side plate Remove the two 2 M3 SEMS pan head screw with flat washer screws CUTTING PRO FC5100 Removal and Replacement Procedures C2 7 4 Remove the two 2 black zinc plated M3 Binder head screws that hold the left side cover to the left side plate 5 Pull the left side cover out from the left side plate Storage Procedure Carefully place the left side cover onto flat surface to prevent damage Reinstallation Procedure 1 sure that the two 2 5 5mm hex standoffs mount onto the inside of the left side cover If there are no standoffs install the two 2 5 5mm x 45mm L hex standoffs 2 Mount the left side cover onto the left side plate the tabs at the top of the cover go into and under the top cover assembly
147. sition by using the actuator for the pen up or down position when the plotter is in the pen up condition This condition is useful when you use heaver weight pens Press the ENTER key to store the setting X GAIN The following menu appears EN FORCE PEN UP PARALLEL CUTTING PRO FC5100 Diagnosing Problems C1 27 6 If you wish to maintain the settings press the necessary key to select other parameters If you wish to finish the parameter setting or when all of the parameters are set turn off the power to the plotter Return the SW1 setting to normal mode as illustrated below Normal mode Factory shipment Standard model MARANASAN or 48000 0 12345678 12345678 12345678 12345678 5100 75 5100 100 5100 130 FC5100 150 OFF OFF OFF Auto registration model TONBO DUMB OMA GEL DTP RD 5100 75 5100 100 5100 130 5100 150 2 pen model 10000 0000 or UAC AAU 12345678 12345678 12345678 12345678 5100 75 5100 100 5100 130 5100 150 Checks B Not required Adjustments B Not required CUTTING PRO FC5100 Diagnosing Problems C1 28 5 3 Setting the Parallel Interface Condition This step will set the BUSY signal and ACK signal timing Run this setup when the parallel interface has a communication problem with the computer
148. so 30 a 2 2 2 m m 6220800 CemerBerrcsin o 3 4 08002220 s emos 6 30112006 caserbNE s0 PU _ 2 WiSepe 30412006 58 0 _ 1 2 s emme s emmo 5 CUTTING PRO FC5100 Parts List C5 13 5 12 Accuload System Components Accuload System components Parts List No Part No Description QTY Remarks Media Alignment Bar for FC5100 75 FC5100 75 621189213 Media Alignment Bar for FC5100 100 FC5100 100 621199213 Media Alignment Bar for FC5100 130 FC5100 130 621209210 Media Alignment Bar for FC5100 150 FC5100 150 Right Media Bracket Stock Roller for FC5100 75 621189220 stokRolerforFC500 00 621199220 stokRolerforFC5100 50 621209220 stokRolerforFC5100 150 5 13 Other 621179230 6289290 621199230 _ 1 FC5100 75 FC5100 100 FC5100 130 FC5100 150 1 1 1 2 2 2 2 621209230 Packng 1 621171141 Packing Box for FCS100 76 stand option 1 o 62179380 instruction Manual for 5100 75 Stand Option 3 usesMameCDfoFCSt00 75 00 30 1 FCS100 COMOAM CUTTING PRO FC5100 6 1 ELECTRICAL Chapter 6 ELECTRICAL ircuit Diagrams 6 1C SOINOH LN3O NOILdO p
149. ss area of the control panel Remove the backing sheet from the underside of the sheet switch Starting from the right side of the control panel align the sheet switch with the bottom edge of the dented area on the control panel Take care that the sheet switch does not buckle Work with a small area at a time Apply the sheet switch with 30 pounds of pressure per square inch Insert the FPC and cable running from the LCD Unit into the hole on the top cover Mount the control panel to the top cover using the six 6 M3 x 4mm Binder head screws Do CUTTING PRO FC5100 Removal and Replacement Procedures C2 58 not clip the cables under the control panel Secure the FPC using the Teflon tape that is located 120mm off from the tip of FPC Install the top cover assembly onto the plotter 10 Install the right side cover onto the plotter A NOTE Do not use the longer screws to mount the control panel If the screw is longer than 4mm the control panel will not secure to the Top cover even when tightening the screws Checks Make sure the control panel is mounted flush with the top and rear surfaces of the top cover Make sure the LCD unit is centered in the window opening of the sheet switch m Make sure the Teflon tape on the FPC is located under the hole on the right side plate Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 59 5 23 How to replace the LCD Assembly Overview Replace
150. stance is longer than the set up distance the input value will be a negative value If the measured distance is shorter than the set up distance the input value will be a positive value CUTTING PRO FC5100 Parameter Settings C3 22 9 Press the ENTER key to store the setting The Distance Adjust menu appears DISTANCE ADJUST X 0 Y PATTERN PLOT PARAMETER SET 10 Turn off the power to the plotter Return the SW1 setting to normal mode as illustrated below NORMAL OPERATING mode Factory shipment Standard model EAE TUM ROT Auto registration model TONBO 5100 75 5100 100 5100 130 FC5100 150 2 pen model 5100 75 5100 100 5100 130 FC5100 150 Specification of the distance adjustment Set up distance to plot Measured distance range X axis 400mm 0 1 Distance 399 emm 1100 4mm Distance A 299 ed A 3mm Checks B Not required Adjustments B Not required CUTTING PRO FC5100 Parameter Settings C3 23 11 Adjusting the Servo Gain The Servo Gain parameter is the most important parameter of the X axis and Y axis control Set the Servo Gain parameter using the Servo Gain Adjustment Program Tools Computer Windows 95 Windows 98 Windows NT Windows 2000 Software Servo Gain Adjustment Program Version 2 00 Media Cutt
151. sure to place the plotter on a work surface that will accept a plotter Removal Procedure Remove the stock rollers Remove the two 2 M4 Flat head screws that hold the media alignment bar to the media brackets Remove the media alignment bar Remove the two 2 M4 Binder head screws that hold the left media bracket to the plotter a Remove the two 2 M4 Binder head screws that hold the right media bracket to the plotter Storage Procedure Lay the media brackets media alignment bar and roller shafts on a flat surface to prevent damaging the components Reinstallation Procedure 1 Place the right media bracket against the inside surface of the plotter s side box right 2 Insert an 4 x 6mm Binder head screw into the first hole from the front side of the plotter v NOTE Do not over tighten the screw The bracket should rotate easily Insert an M4 x 6mm Binder head screw into the second hole from the front side of the plotter Secure the first screw Secure the second screw Repeat steps 1 5 with the media bracket left Qa e o Place the media alignment bar in between the tabs of the media brackets that protrude from the front side of the plotter Secure the media alignment bar to the tabs at both ends with M4 x 8mm Flat head screws Install the stock rollers into the holes on the rear side of the media brackets CAUTION Always use the proper length screw If a screw is too long it
152. t in poor cutting quality m Adjust the pen force The system control parameters are stored in the Non Volatile RAM that is located on the Main board The system control parameters are related to the moving mechanisms like the moving coil and the pen head You must re set the system control parameters after replacing components or adjusting the moving mechanisms See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 51 5 18 How to adjust the Pen Arm Guide Overview If the plotter exhibits poor cutting plotting results one possibility may be that the pen arm exhibits front to back play Adjust the pen arm guide accordingly Tools Phillips screwdriver for an screw Removal Procedure 1 Remove the pen head cover from the plotter See Chapter 2 Section 4 4 How to Remove and Install the Pen Head Cover for more information Storage Procedure Carefully place the part onto a flat surface to prevent damage Reinstallation Procedure 1 Install the pen head cover onto the pen head block Checks All torque settings for the assembly of components to be set at standard settings Make sure that the pen head cover does not clip the pen head wires There is a special recess in the pen head cover for the wires Adjustments The arm adjustment sets the proper pressure between the guide bearing and the pen arm shaft by adjust
153. t to make sure it sticks to the plate apply silicon adhesive to the vibration spacer if needed Making sure you are static free mount the power supply unit onto the standoffs using the five 5 M3 x 6 SEMS screws Connect the two 2 wires running from the power supply unit to the bottom tab of the power switch Connect the two 2 wires running from the AC power inlet to the center tab of the power switch Tie the cable using the wire ties to secure the cables running from the power switch Insert the M4 Lock Washer the ground cable lug running from the power supply unit and the 4 Tooth Lock Washer into the x 6mm Binder head screw Tighten the two 2 M4 screws with the ground cable onto the left side plate Connect the cable to TB2 on the power supply unit Install the left side cover onto the plotter CUTTING PRO FC5100 Removal and Replacement Procedures C2 63 Checks All torque settings for the assembly of components to be set at standard settings Make sure the ground cable running from the power supply unit is secured to the left side plate this is necessary to insure operator safety Adjustments B Not required CUTTING PRO FC5100 Removal and Replacement Procedures C2 64 6 Media Brackets 6 1 How to assemble the Media Brackets Overview The Accuload system consists of two media brackets two stock rollers and one media alignment bar Tools Philips screwdriver for an M4 screw A NOTE Be
154. te Install the pen head cover onto the pen head block Install the top cover assembly onto the plotter Install the left side cover onto the plotter Install the right side cover onto the plotter Checks All torque settings for the assembly of components to be set at standard settings Make sure the Y slider belt position in relation to the Y tension pulley is correct Make sure the pen head block position in relation to the cutting mat is correct and parallel Make sure that the pen head cover does not clip the pen head wires There is a special recess in the pen head cover for the wires Adjustments a 1 Adjust the Y slider assembly On the top of the Y slider assembly there are two 2 screws on the FC5100 75 model and four 4 screws on the FC5100 100 130 models Loosen the M3 x 6mm Flanged Binder head screws and the one 1 M3 x 6mm Socket Head screw holding the Y slider bracket Tighten the one 1 M3 x 6mm Socket Head screw While pushing the Y slider roller bracket toward the Y rail tighten the M3 x 6mm Flanged Binder screw from the inside out on both sides Check the Y slider assembly making sure that it is mounted firmly to the Y rail The Y slider assembly should not be loose from the Y rail If it is loose repeat steps 1 4 until the Y slider is firmly positioned against the Y rail but still slides smoothly from left to right The Y slider belt tension adjustment sets proper belt tension Incorrect tension can cau
155. tem Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 34 5 10 How to tighten the Grit Rollers Overview If the plotter exhibits media feeding problems one possibility may be that the grit roller attached to the X axis drive shaft is loose Tighten the mounting screw Tools Hex L key Wrench Size 1 5mm for Socket Set screw Thread Locker Adhesive type 222 As required How to tighten the Grit Roller Lower the media set lever to raise the pinch rollers Turn the grit roller so that the screw is visible through the slot on the rear cover Remove the M3 Socket Set screw from grit roller using the hex L key wrench Apply the thread locker adhesive to the screw Tighten the M3 x 3mm Socket Set screw using the hex L key wrench OF mm Raise the media set lever to lower the pinch rollers A NOTE The long grit rollers have two setscrews on both ends The short grit rollers have two setscrews one on each end CAUTION Do not apply too much of the thread locker adhesive Over application of the adhesive may close the hex hole on the setscrew Storage Procedure B Not required Checks Make sure the grit rollers are visible and centered in the rear cover grit roller opening Make sure the grit rollers do not make contact with the rear cover grit roller opening Adjustments B Not required CUTTING PRO FC5100 Removal and Replace
156. ten the two 2 Socket Set screws on the collar to secure the collar to the X drive shaft Make sure the X drive shaft does not move to the right or left 9 Install the front cover into the plotter 10 Install the rear cover onto the plotter 11 Install the drive pulley into the X drive shaft 12 Install the X drive belt and adjust the X drive belt tension 13 Install the PCA Main board into the right side plate 14 Install the right side cover onto the plotter Checks Make sure the grit rollers are visible and centered in the rear cover grit roller opening Make sure the grit rollers do not make contact with the rear cover grit roller opening Make sure the cutting mat is flat Make sure the X sensors are visible and centered in the front and rear cover grit roller opening Adjustments The X drive belt tension adjustment maintains machine performance reduces motor shaft deformation and extends the machine s operational life See Chapter 2 Section 5 7 How to Replace and Adjust the X drive belt for more information Re adjust the servo gain The system control parameters are stored in the Non Volatile RAM that is located on the Main board The system control parameters are related to the moving mechanisms like the X drive belt You must re set the system control parameters after replacing components or adjusting the moving mechanisms See Chapter 3 System Control Parameter Setting for more information
157. ter 2 Section 5 2 How to Replace and Adjust the Y slider Belt for more information Re adjust the servo gain The system control parameters are stored in the Non Volatile RAM that is located on the Main board The system control parameters are related to the moving mechanisms like the Y slider belt and Y drive belt You must re set the system control parameters after replacing components or adjusting the moving mechanism See Chapter 3 System Control Parameter Setting for more information CUTTING PRO FC5100 Removal and Replacement Procedures C2 26 5 6 How to replace the Y Tension Pulley with Bearing Overview Replace the Y tension pulley with bearing if it is damaged Tools Philips screwdriver for screw Cutter Pliers As required Force Gauge range 1kg Steel Rule Scale metric scale at least 30mm long B Screw Locker Adhesive type 14018 As required Silicon Grease type G501 As required Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1 6 T 8 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove and Install the Right Side Cover for more information Remove the left side cover from the plotter See Chapter 2 Section 4 2 How to Remove and Install the Left Side Cover for more information Remove the Top Cover Assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Inst
158. tor onto a clean surface to prevent damage the motor may pick up steel components or dust CUTTING PRO FC5100 Removal and Replacement Procedures C2 40 Reinstallation Procedure 1 Insert the cables running from the Y rail assembly into the hole on the right side plate mount the Y rail assembly onto the plotter 2 Insert five 5 of the x 8mm Washer Head screws that hold the Y motor bracket to the right side plate do not tighten the screws 3 Insert two 2 of the M4 x 8mm Washer Head screws that hold the Y rail assembly to the left side plate do not tighten the screws 4 Push the Y rail assembly downward and push it toward the front of machine holding the Y rail assembly tighten the five 5 mounting screws Push the square camshaft through the pinch rollers out the right side plate 6 Install the white plastic collar in the left side plate holding the square camshaft with x 10mm screw 7 Install the lever with two 2 x 6mm Binder head screws from the square camshaft 8 Install the two 2 M3 x 4mm Binder head black zinc screws 4 washer and 2mm thick spacer holding the lever cam spring to the right side plate 9 Connect the P2 connector onto the Main board 10 Connect the cables that connect J3 J4 J5 and P2 onto the Main board 11 Install the cable clamp and the cable ties onto the cables as stated above 12 Install the top cover assembly onto the plotter 13 Install the left side cover
159. ttings C3 16 7 Press the NEXT key to obtain the LED PEN ADJUSTMENT E EN ADJUSTMENT menu AREA ADJUSTMENT Press the F1 FORCE key to select the LED PEN BO SENSOR POS ADJUSTMENT mode 8 Use the POSITION key to move the pen position into the plot area to plot the cross target mark Press the ENTER ig E CARRIAGE key The plotter will immediately plot the target mark on the paper 9 The LED pointer turns on illuminates Use the POSITION key to move the LED pointer Match the center of the LED pointer to the center of the target mark Press the ENTER key to store the setting the next menu appears 10 When the LED pointer position is aligned with the center of ED ON CE the target mark turn off the power to the plotter If the LED pointer does not align with the center of the target mark Sones NO PRESS ENTE press the ENTER key and repeat step 8 11 Turn off the power to the plotter Return the SW1 setting to normal mode as illustrated below B Standard model nnnm nanmnnnm n annnm du mm m P 12345678 12345678 12345678 12345678 FC5100 75 FC5100 100 FC5100 130 FC5100 150 Auto registration model TONBO ON 1440 000 or 12345678 12345678 12345678 12345678 5100 75 5100 100 5100 130 5100 150
160. u remove the mounting screws If the motor hits the steel plate with excessive force it may damage the motor or the steel plate Storage Procedure Carefully place the part onto a flat surface to prevent damage Carefully place the Y drive motor on a clean area to prevent damage the motor may pick up steel components or dust CUTTING PRO FC5100 Removal and Replacement Procedures C2 25 Reinstallation Procedure ONO gr amp o M Install the Y drive belt onto the larger pulley of the Y drive pulley assembly Insert the Y drive pulley assembly into the U shape hole on the bracket Install the Y drive motor onto the bracket and install the Y drive belt onto the Y motor pulley Adjust the Y drive belt tension Install the Y slider belt and adjust the Y slider belt tension Install the top cover assembly onto the plotter Install the left side cover onto the plotter Install the right side cover onto the plotter Checks Alltorque settings for the assembly of components to be set at standard settings Adjustments The Y drive belt tension adjustment maintains machine performance reduces motor shaft deformation and extends the machine s operational life See Chapter 2 Section 5 3 How to Replace and Adjust the Y drive Belt for more information The Y slider belt tension adjustment sets proper belt tension Incorrect tension can cause Y axis issues such as overshoot errors and out of phase alignment problems See Chap
161. ularity The Y rail assembly and the grit rollers are not parallel 1 Check the position of the rail assembly to the side plate CUTTING PRO FC5100 Diagnosing Problems 1 2 Printing the ISO Patterns This step will plot the 150 test patterns that are stored on the Flash ROM Tools Ceramic pen 0 2mm tip size A2 size or ANSI size tracing or vellum paper Printing Requirements 1 C1 8 Attach the pen to the penholder and load the paper into the plotter with the longer edge in the X axis Turn on the power to the plotter First the Initial menu appears then the Media Type menu Press the F3 QUALITY key to select SHEET The initialization routine is executed to determine the paper size The Ready menu appears Set the condition as follows FORCE 12 SPEED 20 QUALITY 6 Tool PEN Press the MENU key to obtain the MENU mode The Menu Mode menu appears Press the NEXT key until the Option menu appears Press the F4 OFFSET key to select OPTION 2 Press the F4 OFFSET key to select TEST Press the F1 FORCE key to select the special test mode Press the F1 FORCE key and the ENTER key at the same time The Test menu will then appear Press the F4 OFFSET key to select the ISO PATTERN 1 00 HL ER RAM CHECKING CONDITION 2 READY CONDITION 2 EADY BACKGROUND SETTINGS gt OPTION 1 gt OPTION 2 gt INITIAL DOWN FORCE
162. vent damage the motor may pick up steel components or dust CUTTING PRO FC5100 Removal and Replacement Procedures C2 31 Reinstallation Procedure 1 Install the X motor pulley onto the shaft of the X drive motor if necessary Tighten the two 2 M3 x 4mm Socket Set screws which are aligned with the flat surface on the shaft of the X drive motor The top surface of the X motor pulley aligns with the top surface of the X drive motor shaft 2 Mount the X drive motor into the right side plate using the three 3 M3 x 8 SEMS screws do not tighten the screws 3 Install the X drive belt onto the X motor pulley and the X drive pulley adjust the X drive belt tension See Chapter 2 Section 5 7 How to Replace and Adjust the X drive belt for more information 4 Install the cable clamp and the wire tie to the cables running from the X drive motor 5 Install the PCA Main board onto the plotter 6 Install the right side cover onto the plotter Checks All torque settings for the assembly of components to be set at standard settings Adjustments The X drive belt tension adjustment maintains machine performance reduces motor shaft deformation and extends the machine s operational life See Chapter 2 Section 5 7 How to Replace and Adjust the X drive belt for more information Re adjust the servo gain The system control parameters are stored in the Non Volatile RAM that is located on the Main board The system contr
163. ver for details Loosen the M3 Socket Set screw on the collar that is located on the left side of the X drive shaft Move the collar to the right Remove the two 2 M3 Binder head screws on each pillow block that hold the pillow block cover bearing retainer to the pillow block 10 Pull the left end of the X drive shaft upward pull it off to the left to remove it along with the grit rollers from the plotter CAUTION If the grit roller hits another component with excessive force it may cause damage to the grit roller or to the other components Storage Procedure Carefully place the part onto a flat surface to prevent damage CUTTING PRO FC5100 Removal and Replacement Procedures C2 36 Reinstallation Procedure 1 Loosen the M3 Socket Set screw on the collar that is located on the left of the drive shaft move the collar to the right 2 Insert the right end of the X drive shaft with the grit rollers into the hole of the right side plate 3 Install the X drive shaft with the grit rollers onto the pillow block 4 Insert all of the bearings onto the pillow block 5 Install the pillow block cover bearing retainer onto the pillow block with the two 2 x 8mm Binder head screws for each pillow block 6 Push the X drive shaft to the right the collar on the right side of the shaft should touch the bearing 7 Move the collar on the left side of the shaft to the left the collar should touch the bearing 8 Tigh
164. ver assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information 4 Remove the pen head block from Y slider assembly See Chapter 2 Section 5 17 How to Replace and Adjust the Pen Head Block for more information 5 Disconnect J1 the flat ribbon cable from the Pen board 6 Remove the two 2 M3 x 16mm Binder head screws and two 2 M3 washers that hold the Pen board to the pen head assembly and remove the Pen board 7 Onthe top of the Y slider assembly there are two 2 screws on the FC5100 75 model and four 4 screws on the FC5100 100 130 models Remove the M3 x 6mm Flanged Binder head screws and the one 1 M3 x 6mm Socket Head screw holding the Y slider bracket 8 the Y slider assembly out from the Y rail assembly CAUTION The Y drive motor that mounts on the Y rail assembly has a very strong magnet The motor will stick to the steel plate The motor can pick up steel components or dust CAUTION The moving coil type actuator that mounts on the pen head block has a very strong magnet The actuator will stick to the steel plate The actuator can pick up steel components or dust CUTTING PRO FC5100 Removal and Replacement Procedures C2 43 Storage Procedure Carefully place the part onto a flat surface to prevent damage Carefully place the Y drive motor onto a clean surface to prevent damage the motor may pick up steel components or dust Carefully pla
165. ver for an screw Apiece of paper Preparation Requirements 1 Remove the right side cover from the plotter Tips For details of step 1 see Chapter 2 Section 4 1 Test Set Up Requirements 1 Set SW1 to the sensor testing mode as illustrated below Sensor test mode Set DIP switches No 3 and 4 5 6 7 to ON eme Turn on the power to the plotter 2 The status of the sensor appears on the LCD 3 Cover the front media size sensor with a piece of paper The status of PLUS X changes from L to 4 Cover the rear media size sensor with a piece of paper The status of MINUS X changes from L to H 5 Move the Y Slider to the far right When the Y Slider reaches the home position flag the status of Y HOME changes from L to H 6 Lower the media set lever to raise the pinch rollers The status of CAM changes from L to H 7 Move the Y Slider to the left or right When the Y Slider is located on the pinch roller the status of PINCH changes from L to H CUTTING PRO FC5100 Diagnosing Problems C1 18 8 Move the Y Slider to the left or right When the Y Slider is located on the pinch roller the status of PINCH changes from L to H When testing is complete turn off the power to the plotter Return the SW1 setting to normal mode as illustrated below Normal mode Factory shipment Standard
166. y Tools Phillips screwdriver for an M3 screw Cutter Pliers As required Force Gauge range 1kg Steel Rule Scale metric scale of at least 30mm long Screw Locker Adhesive type 1401B As required Silicon Grease type G501 As required Cable Clamp and or Wire Tie As required Harness Wrap As required Removal Procedure 1 Remove the right side cover from the plotter See Chapter 2 Section 4 1 How to Remove Install the Right Side Cover for more information Remove the left side cover from the plotter See Chapter 2 Section 4 2 How to Remove and Install the Left Side Cover for more information Remove the top cover assembly from the plotter See Chapter 2 Section 4 3 How to Remove and Install the Top Cover Assembly for more information Remove the pen head cover from the plotter See Chapter 2 Section 4 4 How to Remove and Install the Pen Head Cover for more information Disconnect the pen board cables from the pen board Remove two 2 M4 x 8mm screws mounting the pen head assembly Carefully place the pen head assembly on a flat surface to prevent damage Remove the four 4 M3 Binder head screws that hold the two 2 belt mounting brackets to the Y slider assembly Remove the Y slider belt Storage Procedure Carefully place the part on a flat surface to prevent damage CUTTING PRO FC5100 Removal and Replacement Procedures C2 17 Reinstallation Procedure 1 Loosen the

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FC5100 UM 252 07 9370

FC5100-UM-252-07-9370

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