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Service Manual SummaCut D60 and D120

Summa NV Rochesterlaan 6 8470 Gistel Belgium

Service Manual

SummaCut D60-D120

TABLE OF CONTENTS......................................................................Page

SECTION 1 KEYBOARD CONTROL


1.1. THE CONTROL PANEL .......................................................................................1.1 1.1.1. THE LIQUID CRYSTAL DISPLAY ....................................................................1.1 1.1.2. THE MENU KEY ...............................................................................................1.2 1.1.3. THE X KEY .......................................................................................................1.3 1.1.4. THE V KEY .......................................................................................................1.3 1.1.5. THE TEST KEY ...............................................................................................1.3 1.1.6. THE JOGGING KEYS .....................................................................................1.3 1.2. COMMON MENU ITEMS ......................................................................................1.4 1.2.1. VELOCITY .........................................................................................................1.4 1.2.2. PEN PRESSURE ...............................................................................................1.4 1.2.3. KNIFE PRESSURE ...........................................................................................1.4 1.2.4. KNIFE OFFSET..................................................................................................1.5 1.2.5. POUNCING PRESSURE ...................................................................................1.5 1.2.6. POUNCING GAP ...............................................................................................1.5 1.2.7. RESET ...............................................................................................................1.6 1.2.8. RECUT ..............................................................................................................1.6 1.2.9. LOAD .................................................................................................................1.6 1.2.10. ALIGN LOAD ..................................................................................................1.6 1.2.11. SYSTEM SETUP .............................................................................................1.6

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1.3. SYSTEM SET UP .................................................................................................1.7 1.3.1. CONFIDENCE ...................................................................................................1.8 1.3.2. DIN CUT ............................................................................................................1.8 1.3.3. TOOL .................................................................................................................1.8 1.3.4. FLEX-CUT .........................................................................................................1.8 1.3.5. OVERCUT .........................................................................................................1.9 1.3.6. OPTICUT ...........................................................................................................1.9 1.3.7. EMULATION ...................................................................................................1.10 1.3.8. BAUD RATE ....................................................................................................1.10 1.3.9. PARITY ............................................................................................................1.11 1.3.10. RTS/DTR .......................................................................................................1.11 1.3.11. RS 232 TEST .................................................................................................1.12 1.3.12. ALIGN MODE ................................................................................................1.12 1.3.13. AUTOLOAD ..................................................................................................1.12 1.3.14. LANGUAGE ..................................................................................................1.13 1.3.15. MENU UNIT ...................................................................................................1.13 1.3.16. ROM REVISION ............................................................................................1.13 1.3.17. MEDIA SENSOR ...........................................................................................1.13 1.3.18. SENSOR SETUP ...........................................................................................1.13 1.3.19. CALIBRATE X/Y ...........................................................................................1.14 1.3.20. COIL SETUP .................................................................................................1.14

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SECTION 2 REPLACEMENT GUIDELINES


2.1. REMOVING THE LEFT-HAND COVER................................................................2.3 2.2. REMOVING THE RIGHT-HAND COVER..............................................................2.3 2.3. REMOVING THE BOTTOM PLATE......................................................................2.5 2.4. REPLACING THE CAMROLLERS.......................................................................2.5 2.5. REPLACING THE X-MOTOR ..............................................................................2.7 2.6. REPLACING THE Y-MOTOR...............................................................................2.9 2.7. REPLACING THE LCD OR THE KEYBOARD...................................................2.11 2.8. REPLACING THE MAIN PCB.............................................................................2.13 2.9. REPLACING A DRAG HEAD ............................................................................2.16 2.10. REPLACING THE FLAT CABLE FOR THE HEAD..........................................2.22 2.11. REPLACING THE Y-BELT...............................................................................2.22 2.12. REPLACING THE CUTTING STRIP.................................................................2.23 2.13. REPLACING THE SENSOR.............................................................................2.23 2.14. REPLACING THE FAN MOTOR.......................................................................2.24 2.15. REPLACING THE DRIVE DRUM......................................................................2.25

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SECTION 3 MAINTENANCE

3.1. MAINTENANCE & CLEANING.............................................................................3.2 3.1.1. CLEANING THE DRIVE SYSTEM.....................................................................3.2 3.1.2. CLEANING THE SENSORS..............................................................................3.3 3.2. OPERATING VOLTAGE.......................................................................................3.4

SECTION 4 CALIBRATION
4.1. MEDIA CALIBRATION.........................................................................................4.2 4.2. HEAD CALIBRATION...........................................................................................4.4 I. KNIFE CALIBRATION .............................................................................................4.4 II. COIL CALIBRATION...............................................................................................4.4 4.3.MACHINE TYPE.....................................................................................................4.6 4.4. SENSOR TESTS...................................................................................................4.8 4.5. AUTOMATIC TESTS............................................................................................4.9

SECTION 5 ERROR CODES - TROUBLESHOOTING

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5.1. ERROR IN X-AXIS................................................................................................5.2 5.2. ERROR IN Y-AXIS POSITION..............................................................................5.3 5.3. SYNTAX ERROR..................................................................................................5.3 5.4. NVRAM FAILURES AND MESSAGES.................................................................5.4 5.5. RS232 ERROR......................................................................................................5.4 5.6. INTERNAL ERRORS............................................................................................5.5 5.7. FLASHING ERRORS AND MESSAGES .............................................................5.6 5.8. RAM ERROR.........................................................................................................5.6

SECTION 6 FIGURES

FRONT SIDE................................................................................................................6-2 REAR SIDE .................................................................................................................6-3 D120 X MOTOR...........................................................................................................6-4 BRAKE.........................................................................................................................6-5 KEYBOARD.................................................................................................................6-6 KEYBOARD.................................................................................................................6-7 BOTTOM PLATE.........................................................................................................6-8 RIGHT SIDE.................................................................................................................6-9 LEFT SIDE.................................................................................................................6-10

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MEDIA SENSOR SYSTEM........................................................................................6-11 D60 X-MOTOR ..........................................................................................................6-12 DRUM ASSY..............................................................................................................6-13 MEDIA GUIDE SYSTEM............................................................................................6-14 CARRIAGE.................................................................................................................6-15 FRONT SIDE..............................................................................................................6-16 BOARDS....................................................................................................................6-17 COVERS.....................................................................................................................6-18 CARRIAGE.................................................................................................................6-19 MOTOR CONNECTIONS...........................................................................................6-20 MEDIA SELECT.........................................................................................................6-21

SECTION 7 SPARE PARTS LIST

SUMMACUT D60 SPARE PARTS...............................................................................7-1 SUMMACUT D120 SPARE PARTS.............................................................................7-3

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Table of Contents

INTRODUCTION

1. OVERVIEW
This is the Summa Service Manual for the SummaCut D60 and D120 cutters. It provides information for servicing the cutters. All repairs are to be made by, or under the direction of, authorised Summa service personnel. This manual is copyrighted by Summa 1999. Summa reserves the right to change any information contained in this manual without prior notice. Unauthorised copying, modification, distribution, or display is prohibited. All rights reserved.

2. MANUAL ORGANIZATION
This manual is divided into the following sections:

Table of Contents Introduction Keyboard controls General replacement guidelines Maintenance Calibration Troubleshooting List recommended spare parts with pictures

Keyboard control contains the following:

INTRODUCTION

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This part contains an overview of the various tests and configurations that can be accessed via the keyboard.

General replacement guidelines contains the following: An overview of the removal and the replacement of various parts of the unit in the form of separate chapters. It is advisable to carefully read the procedure described in each of the chapters prior to removing or replacing a particular part. In addition to straightforward step by step procedures you will often find Notes and Cautions. Make sure you read these remarks as they will often facilitate re-installation and avoid malfunctioning.

Maintenance contains the following: An overview of the maintenance of various parts of the unit. It is advisable to carefully read the procedure described in each of the chapters prior to removing or replacing a particular part. You will often find Notes and Cautions. Make sure you read these remarks as they will often avoid malfunctioning.

Calibration: An overview of all the possible calibrations of the unit. Each time the machine is serviced check this section to see if any recalibration needs to be done. Troubleshooting: An overview of all the possible error messages that could appear on the LCD screen, and the possible solutions

Spare parts list An overview of all the recommended spare parts. Normally only the parts figuring on this list will be provided by Summa.

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3. KNOWING YOUR CUTTER


3.1 POSITION OF THE CUTTER ON A TABLE

The cutter is equiped with an extra media guide. In order not to damage this part, special attention when putting a machine on a surface. The figure below explains the right position. part 1 should always be over an edge.

POSITION OF THE CUTTER ON A SURFACE

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3.2. CUTTER COMPONENTS In order to get acquainted with your SummaCut D60 and D120, read the following description of components.
3.2.1. REAR PANEL CONTROLS

The figure below shows the location of the main components.

SUMMACUT D60 REAR VIEW

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SummaCut D60-D120

USB interface: - This interface is based on the standards specified in Universal Serial Bus Specifications Revision 1.1. It allows a high-speed serial bi-directional communication between the host computer and the cutter. RS-232-C Port: - This DB-9P connector provides the communication link between the cutter and a host computer. It allows bi-directional communication between the host computer and the cutter. Parallel Port: - This IEEE1284 -B connector provides a bi-directional communication link between the cutter and a host computer. Note: only one interface can be active at a time. The first port that receives data will be the active interface until the cutter is reset. Power ON/OFF switch - This rocker switch sets the cutters power to ON or OFF. To switch the power ON, press the I side of the rocker switch. To switch the power OFF, press the O side of the rocker switch. Power Entry Module: - The fuse box and the AC power cord receptacle are located in the power entry module. The power-up procedure is explained in detail in Section 1.6. Fuse box: - For information about changing of the fuse, see Section 4.2. Roll Media Guide Bushes: - The two guide bushes serve to keep the media roll in place when media is pulled from the roll. Media Flanges: - The media flanges ensure proper routing of the media roll. Media Support Roller: - Rotating support rollers for the media roll. Alignment Strip: - Rear alignment strip for easier media loading.

2.

3.

4.

5.

6. 7.

8. 9. 10.

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3.2.2. FRONT PANEL CONTROLS

The figure below shows the location of the main components.

SUMMACUT SERIES, FRONT VIEW

1.

Pinch roller lever arm: - This lever is used to raise and lower the pinch rollers during media loading. Media Drive Sleeves: - The media drive sleeves move the media only when the pinch rollers are in the down position. Tool Carriage: - The tool carriage is the mount for the knife holder and the pen. Control Panel: - The control panel contains 8 keys. All cutter activity can be initiated from the control panel. Each control panel function is explained in Section 1. Display: - The 16-character display informs the user about the current status of the cutting process or actions, which need to be taken. Sensor: - The sensor detects the end of media to avoid any damage to the cutting strip

2.

3. 4.

5.

6.

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SummaCut D60-D120

Pinch rollers: - The pinch rollers (one at each side) hold the media clamped between the rubber rollers and the media drive sleeves. (The D120 has an extra guidin pinch roller in the middle) Cutting strip: - Soft strip to avoid any damage to the knife tip when no media has been loaded. Since cutting is done on the cutting strip it is essential that the cutting strip remains intact. Alignment strip: - Front alignment strip for easier media loading.

8.

9.

10.

Media guide : - Extra guide to prevent badly curled up media from jamming under the cutter (not in 120 Model)

Introduction

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SECTION 1 Keyboard control


1.1. THE CONTROL PANEL

The figure below shows the control panel of the SummaCut D60 and the D120. The main functions of the liquid crystal display (LCD) and the control panel keys are explained in the following paragraphs.

CONTROL PANEL SUMMACUT D60

1.1.1. THE LIQUID CRYSTAL DISPLAY The liquid crystal display (LCD) contains one line of 16 characters. The LCD provides cutter status information during operations and displays menu options for the configuration of the cutter. The various menu and submenu items are always presented in a loop, which means that, when the last menu or submenu item is displayed, pressing the appropriate key will automatically take you back to the first item of the same menu or submenu.

1.1.2.

THE MENU KEY

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The Menu key is used to reach the most common menu items of the cutter quickly. A last menu item in the row gives access to a submenu with which all the other functions of the cutter can be reached (see section 1.3). The various menu items are illustrated in the figure below.

Menu differ according to the selected tool (1) If the PEN is the default tool (2) If the KNIFE is the default tool (3) If the POUNCER is the default tool

MAIN MENU SUMMACUT D60 AND THE D120

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1.1.3.

THE X KEY

The x key (cancel key) cancels the current operation

Pressing this key when the cutter is cutting stops the current job.

1.1.4.

THE V Key

The V Key (confirm key) confirms a selected menu or a changed menu item. As long as this key is not pressed a changed value of a menu item is not saved internally and can will be lost if the menu is left.

1.1.5.

THE

TEST Key

If there is a certain test routine in a submenu, then it can be activated to start it.

1.1.6.

THE

jogging Keys

The use of the jogging keys varies according to the operation in progress. For example, when working with different submenus, the used to select the next or previous submenu. or jogging key is

When in a submenu the values can be changed by pressing or . When the cutter is normal operation, then by pressing either one of the jogging keys, the origin can be changed.

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1.2.

COMMON MENU ITEMS

Following paragraphs explain the different submenus. 1.2.1 VELOCITY

The VELOCITY submenu is used to set or modify the velocity of the tool. The default velocity is 700 mm/s (20 ips). After pressing the key then press the or jogging key until the desired to confirm. speed is displayed on the LCD and press The velocity can be set between 50 mm/s (2 ips) and 800 mm/s (40 ips). On the LCD, the active plotting speed is marked with an *. 1.2.2 PEN PRESSURE

The PEN PRESSURE parameter is used to set or modify the cutting pressure of the pen. The default pen pressure value is 80 grams. After pressing the key then press the or jogging key until the desired pressure is displayed on the LCD and press to confirm. The pen pressure can be set between 0 and 400 grams. The pen pressure value is set in 5 gram increments. On the LCD, the active pen pressure is marked with an *. 1.2.3 KNIFE PRESSURE

The KNIFE PRESSURE parameter is used to set or modify the cutting pressure of the knife. The default knife pressure value is 120 grams. After pressing the key then press the or jogging key until the desired to confirm. pressure is displayed on the LCD and press The knife pressure can be set between 0 and 400 grams. The knife pressure value is set in 5 gram increments. On the LCD, the active knife pressure is marked with an *.

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1.2.4

KNIFE OFFSET

The KNIFE OFFSET parameter is used to set or modify the distance between the knife blade tip and the centre axis. The default knife offset value is .45 mm. After pressing the key then press the knife offset is displayed on the LCD and press or jogging key until the desired to confirm.

The value can be set between 0 and 1 mm. Make sure that the selected knife offset value matches that of the knife. Some fine-tuning may be necessary because of the mechanical tolerances on the knife. To verify the knife offset, a test can be cut by pressing on the key. If the offset value is set too low, the rectangles will not close. When the offset value is set too high, the rectangles will be distorted. The offset test is illustrated below.

1.2.5

POUNCING PRESSURE

The POUNCING PRESSURE submenu is used to set or modify the pouncing pressure of the pouncing tool. The default pouncing pressure value is 120 grams. After pressing the key then press the or jogging key until the desired pressure is displayed on the LCD and press to confirm. The pouncing pressure can be set between 0 and 400 grams. The pouncing pressure value is set in 5 gram increments. On the LCD, the active pouncing pressure value is marked with an *. Pouncing pressure set-up is explained in detail in section 1.8.1. 1.2.6 POUNCING GAP

The pouncing gap submenu is used to set or modify the distance between the pounced wholes. This routine applies to the pouncer only. The default pouncing gap value is 1 mm. After pressing the key then press the or jogging key until the desired to confirm. pouncing gap is displayed on the LCD and press The value can be set between 1 mm and 50 mm. On the LCD, the active pouncing gap value is marked with an *.

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1.2.7

RESET key to

The RESET instruction performs a complete reset of the cutter. Press the execute a reset. 1.2.8 RECUT

The RECUT instruction recuts the last file sent to the cutter (provided that it fitted into the buffer). Press the key to execute the instruction. 1.2.9 LOAD key to jogging key

The LOAD instruction is used to initiate a load sequence. Press the execute. First the origin can be changed if necessary. Press the or

to change the origin in the Y-direction. Press the or jogging key to change key to confirm. Then the media window the origin in the x-direction. Press the can be changed. Press the or jogging key to change the length of the window or press the key to change the value of the length of the media window. The or jogging key change the value in steps of 100mm, the or jogging key change it in steps of 10mm (When the machine is set up in English units, key to finish the the step sizes are respectively 0.5 and 2.5). Then press the load procedure. 1.2.10 ALIGN LOAD The Align load sub menu is used for contour cutting. Refer to section 3 in the Users manual for the complete explanation on contour cutting. Section 1.3.11 explains how to change the align method. Press the key to execute. 1.2.11 SYSTEM SETUP The SYSTEM SETUP submenu covers the menu items you normally only need when establishing the initial set-up e.g. when you install the cutter in combination with the software you use. Press the confirmation key to access the different submenu items, which are explained in section 1.3.

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1.3.

SYSTEM SETUP

This sub menu contains parameters and info, which normally are necessary when the machine is first installed, or when certain problems occur. Figure below gives the different options in this submenu.

(*) only available when the tool is set to drag knife SYSTEM SETUP SUMMACUT D60

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1.3.1. CONFIDENCE The CONFIDENCE cut performs an electrical and mechanical test of the cutter to make sure that the cutter is fully operational. A media sheet of at least A3/A- size should be used for this plot. Press the key to execute. 1.3.2. DIN CUT The DIN CUT also performs an electrical and mechanical test of the cutter, in order to check the cut quality, but also provides the user with feedback on knife setting, knife pressure, knife offset and cutting depth. This cut is always run as a DIN A4 portrait/A-size image, regardless of the actual size of the media loaded. If the media loaded is smaller than DIN A4/A-size, part of the outer box will be clipped (not cut). This cut is always executed in the sequence prescribed by the ISO DIN standard. Press the key to execute. 1.3.3. TOOL The TOOL submenu is used to select the default tool at power up. key then press the or jogging key until the desired After pressing the tool is displayed on the LCD and press to confirm. To configure the cutter for plotting operations, select PEN. To configure the cutter for cutting operations, select the DRAG KNIFE option. To configure the cutter for pouncing operations, select the POUNCING TOOL option. On the LCD, the active tool setting is marked with an *. 1.3.4. FLEX-CUT FLEX-CUT can be set to OFF, to Mode 1 or Mode 2. When the cutter is set to mode 1 or mode 2, it will alternately cut one length with full pressure, and one length with reduced pressure (length is later referred to as HALF. The feature FLEX-CUT offers the advantage that it cuts completely through the material, yet allowing the material to stay together by means of the small media bridges. MODE 1 is the quickest mode, but it is less precise because the pressure changes during the cutting. MODE 2 is a lot slower, but at the same time it is much more precise, as the cutter stops at every change of pressure.

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After pressing the key then press the or jogging key until the desired mode is displayed on the LCD and press to confirm. On the LCD, the active setting is marked with an *. Pressing the key will activate the configuration menu. The different configuration jogging key. All the

or sub menus can be accessed by pressing the values are metric regardless the MENU UNITS setting. 1. CUT

This parameter determines the length that is cut with full pressure. Press the

or

jogging key to change the value. By pressing the key, the FLEX-CUT test pattern will be cut. 2. HALF This parameter determines the length that will be cut with reduced pressure or without pressure. Press the or jogging key to change the value. By pressing the key, the FLEX-CUT pattern will be cut. 3. PRES This parameter determines the pressure of HALF. Press the change the value. By pressing the or jogging key to

key, the FLEX-CUT test pattern is cut.

1.3.5. OVERCUT The OVERCUT submenu enables you to generate an overcut in order to facilitate weeding the cut. Press the or jogging key to change the value. The default overcut is set to 1. The overcut setting can be disabled (=0) or set to any value between 0(=off) and 10. One unit is about 0.1 mm or 0.004 ". On the LCD, the active value is marked with an *. 1.3.6. OPTICUT The OPTICUT submenu enables you to generate an enhanced overcut in order to facilitate weeding the cut. This feature however does leave little scratch on your design and may not be appropriate for some media. Press the or jogging key to change the value. The default value is set to OFF. On the LCD, the active value is marked with an *.

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1.3.7. EMULATE The EMULATE submenu is used to select the active cutting/plotting language for the cutter. After pressing the key then press the or jogging key until the desired language is displayed on the LCD and press to confirm. The SummaCut D60 and theD120 supports DM/PL , HP/GL and HP/GL/2. On the LCD, the active plotting language setting is marked with an *.

NOTE The active cutting/plotting language MUST match the cutting software. Always select a language that is supported by the host computer's cutting software.

Whenever possible, select the DM/PL menu option to set the active cutting/plotting language to Houston Instrument Digital Microprocessor/Plotting Language (DM/PL). This selection will allow the cutter to operate with DM/PL-based cutting / plotting software. This language, having special command extensions for cutting, normally gives superior cutting performance. 1.3.8. BAUD RATE The BAUD RATE submenu is used to set or modify the operating baud rate for RS232-C serial communications between your cutter and the host computer. The default baud rate is 9600 bps. After pressing the key then press the or jogging key until the desired to confirm. baud rate is displayed on the LCD and press The baud rate can be set to any of the following values: 2400 bps, 4800 bps, 9600 bps, 19200 and 38400 bps. On the LCD, the active baud rate value is marked with an *. NOTE The baud rate setting of your cutter MUST match the host computer's baud rate setting.

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1.3.9. PARITY The PARITY submenu is used to set or modify the byte format and parity type for RS232-C serial communications between your cutter and the host computer. The default parity setting is bit 8 = 0 (8 data bits, no parity, the 8th bit being a low bit). The parity can be set to any of the following values: LCD information BIT 8 = 0 BIT 8 = 1 EVEN ODD Parity setting 8 data bits, no parity 8 data bits, no parity 7 data bits, 1 parity bit 7 data bits, 1 parity bit Remarks bit 8 = low (0) bit 8 = high (1) parity bit = even parity bit = odd

key then press the or jogging key until the desired After pressing the to confirm. setting is displayed on the LCD and press RTS/DTR can be set to TOGGLE (hardware handshaking) or HIGH (software handshaking). On the LCD, the active parity setting is marked with an *.

NOTE The parity setting of your cutter MUST match the host computer s parity setting. 1.3.10. RTS/DTR The RTS/DTR submenu controls the Request To Send (RTS) and Data Terminal Ready (DTR) signals of the cutter's RS-232-C serial communications interface for hardware handshaking. The RTS/DTR default value is TOGGLE. After pressing the key then press the or jogging key until the desired setting is displayed on the LCD and press to confirm. RTS/DTR can be set to TOGGLE (hardware handshaking) or HIGH (software handshaking). On the LCD, the active handshaking setting is marked with an *.

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1.3.11. RS 232 TEST

The RS232 TEST routine verifies the cutters RS-232-C serial communications (transmit data, receive data, and hardware handshaking) circuits. This test does not require pen, knife or media to be loaded. 1. 2. To run the RS-232-C test, proceed as follows: Unplug the RS-232-C data cable from the rear panel of the cutter. Use a loopback test cable to connect pin 2 of the cutters data connector to pin 3 and pin 7 to pin 8. With RS232 TEST displayed, press the key. The cutter will start transmitting and receiving data at all available baud rates and parity settings. The length of the transmissions will vary because of the different baud rates used. The unit then checks the hardware handshake lines.

3.

If the RS232 port is not working correct, then the cutter returns an error message. 1.3.12. ALIGN MODE The parameter ALIGN MODE in the menu determines which alignment method is used. (See section 3 in Users Manual for complete explanation) After pressing the key then press the or jogging key until the desired to confirm. setting is displayed on the LCD and press On the LCD display, the active setting is marked with an *. 1.3.13. AUTOLOAD The AUTOLOAD option enables the user to the change the vinyl unroll proceedings. When AUTOLOAD is ON, the cutter will automatically unroll the vinyl when needed. When the AUTOLOAD option is OFF, the operator himself should unroll enough media before starting to cut. The default setting is ON. The best results and performance are guaranteed when using this setting. After pressing the key then press the or jogging key until the desired setting is displayed on the LCD and press to confirm. On the LCD display, the active setting is marked with an *.

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1.3.14. LANGUAGE The MENU LANGUAGE submenu is used to set or modify the dialogue language on key then press the or jogging key until the the LCD. After pressing the desired language is displayed on the LCD and press to confirm. The information on the LCD can be displayed in English, French, German, Spanish, Italian or Dutch. On the LCD, the active plotting language setting is marked with an *. 1.3.15. MENU UNIT The MENU UNITS submenu allows you to select English or metric menu units. After pressing the key then press the or jogging key until the desired to confirm. menu unit is displayed on the LCD and press On the LCD, the active menu units setting is marked with an *. 1.3.16. ROM REVISION Selecting the ROM REVISION option, by pressing the key will furnish the details on the cutters ROM revision. This information is often helpful to technicians when diagnosing problems over the telephone. 1.3.17. MEDIA SENSOR The MEDIA SENSOR submenu is used to activate or deactivate the media sensor. The sensor detects the end of media. In that way the sensor prevents damage to the cutting strip and knife tip. After pressing the key then press the or jogging key until the desired to confirm. setting is displayed on the LCD and press On the LCD, the active setting is marked with an *. 1.3.18. SENSOR SETUP The SENSOR SETUP submenu is used to activate or deactivate the media. After pressing the key follow the instructions on the LCD. Put a piece of media half on the sensor and then press the key. The machine will show on the LCD whether the sensor works or not.

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1.3.19. CALIBRATE X/Y Calibration allows changing the length of the lines that are cut to be adjusted to within the specifications. For instance, if a cut line should measure 100 mm exactly, the cutter can be adjusted for any discrepancy. First make sure the media is loaded, and then press the key to perform a test. Measure the lines and enter the measured x-value by pressing the jogging keys. The the or jogging key change the values in big steps,

or jogging key change the value in small steps. After pressing the key, the y-value can be changed in the same way. Do not perform this test when the machine is working properly. 1.3.20. COIL SETUP This test is used to calibrate knife and pen pressure and to set the knife and pen landing. After adjustment, the value is saved in the systems non-volatile RAM. To execute this test a tension gauge of 100 gr. and 500 gr. is required. In the upper line of the display the desired pressure appears and in the bottom line of the display the value that has to be sent to the head to reach this pressure (this value is between 0 and 127). Press the key to enter the test and follow the guidelines on the LCD screen.

CAUTION Do not perform the coil test when the machine is working properly. Changing the parameters to a wrong value may seriously affect the quality and even damage the cutter.

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SECTION 2 Replacements guidelines


General
This section contains information on replacing defective parts and adjustment procedures. A step-bystep removal/assembly procedure is provided in this section. On the left page you will find drawings indicating the position of the parts.

Precautions
Observe simple, common sense rules and procedures whilst servicing the unit. They include, but are not limited to the following:

The base of the unit has been assembled on a fixture to assure straightness all along the y-axis. To keep this :DO NOT REMOVE THE Y-GUIDING. Unplug the line cords and host cables before transporting the unit to other places. Reassemble ALL parts (screws, ferrite shield, etc.) to maintain EMI integrity, and guide the loose wires afterwards with tie-wrap in the same manner they were before Watch for sharp edges on the metal strips etc. When the covers are off or open:

The printed circuits boards are electrostatically sensitive; use the proper handling techniques. Keep sensors free of scratches and dirt. Keep the guiding, at least dirtfree where the wheels of the carriage pass.

Replacements Guidelines

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SummaCut D60-D120

Service Manual

1. 2. 3. 4. 5.

Body Cover Left/right 399-001 Cover Left/right 399-001 Screw ND5000-9556 : 4x (2x) Rozetring ND5000-9639 : 4x (2x)

2-2

Replacements Guidelines

Service Manual

SummaCut D60-D120

2.1.

REMOVING THE LEFT-HAND COVER

To remove the left-hand cover, proceed as follows: 1. Remove the four screws holding the left-hand cover in place. Two are located at the front and two at the rear. Pay close attention to where each of the screws goes. They should be returned to their original location when re-installed. 2. Gently tap the top of the cover. 3. Remove the cover. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

2.2.

REMOVING THE RIGHT-HAND COVER

To remove the right-hand cover, proceed as follows: 1. Remove the four screws holding the right-hand cover in place. Two are located at the front and two at the rear. Pay close attention to where each of the screws goes. They should be returned to their original location when re-installed. 2. Gently tap the top of the cover. 3. Remove the cover. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

1. CAUTION 2. 3. Make sure that you do not jam any wires between the cover and the side plate as this may cause considerable damage. 4. Give special attention to the flat cables. 5.

1. screw ND5000-9795 : 7x 2. screw ND5000-9556 +rozetring ND5000-9639 : 4x (only 2 lower screws on each side).

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6.

7. 8.

1. 2. 3. 4.

camroller assy camroller 391-326 : 1x camrollershaft 391-142 : 1x setcrew ND5000-9196 : 2x

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SummaCut D60-D120

2.3.

REMOVING THE BOTTOM PLATE

To remove the bottom plate, proceed as follows: 1. Turn the unit in a position that front of the unit is facing to the bench. 2. Remove 2 lower screws of each cover. 3. Remove the screws holding the bottom plate in place. Unscrew first the bottom screws (4 screws) Then remove the 3 top screws. 4. Remove the bottom plate. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 9. Note: 10. Make sure the bottom plate is placed correctly and no wires are are been damaged. 11.

2.4.

REPLACING THE CAM ROLLERS

To replace the cam rollers, proceed as follows: 1. Remove the set screw on either side of the cam rollers . 2. Remove the cam roller shaft (push against the left side of the shaft). 3. Remove the cam roller.

12. Note: 13. 14. Cam rollers come in pairs. When one is malfunctioning or broken, both cam rollers need to be replaced. 15. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

16. Note: 17. 18. It is extremely important that the cam roller be stable and stationary. To achieve this, press one side of the camshaft while tightening the set screws. 19.

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1. Motor with encoder 2. Screws (3x) 3. Belt 110 teeth : MB9124

2-6

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SummaCut D60-D120

2.5.

REPLACING THE X-MOTOR

To replace the X-motor in these models, proceed as follows: 1. Remove the left hand cover (see Chapter 2.1, Removing the left hand cover). 2. Remove the Bottom plate (see Chapter 2.3, Removing the bottom plate). 3. Push the motor towards the drum and gently remove the belt. 4. Remove the connector from the encoder and solder off the black and the red wire to expose the X-motor. 5. Remove the three screws holding the X-motor in place. 6. Remove the X-motor. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

20. 21. 22.

Note: When re-installing: a.Make sure the wire of the connector attached to the encoder runs outward.

23. b.Make sure to solder the black wire to the minus (-) entry and the red wire to the plus (+) entry. The (+) and (-) signs are located in the corners of the motor's label. 24. c.Be extremely careful to plug the connector into the correct holes of the encoder. Move the pulley on the motor shaft to prevent the belt from slipping against the big pulley. Make sure to firmly tighten the set-screw. The D120 han in the X axis 2 motors, one with an encoder and one without an encoder.

1 2 3 4

motor capacitor connector encoder wires motor

WATCH ORIENTATION !

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1. 2.

Motor with encoder Screws (3x)

1 2 3 4

motor capacitor connector encoder wires motor

WATCH ORIENTATION !

2-8

Replacements Guidelines

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SummaCut D60-D120

2.6.

REPLACING THE Y-MOTOR

To replace the Y-motor, proceed as follows: 1. Remove the right-hand cover (see Chapter 2.1, Removing the right-hand cover). 2. Remove the connector from the encoder and solder off the black and the red wire to expose the Y-motor. 3. Remove the three screws holding the Y-motor in place. 4. Remove the Y-motor. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 25. 26. 27. Note: When re-installing: a.Make sure the wire of the connector attached to the encoder runs outward.

28. b.Make sure to solder the black wire to the minus (-) entry and the red wire to the plus (+) entry. The (+) and (-) signs are located in the corners of the motor's label. 29. c.Be extremely careful to plug the connector into the correct holes of the encoder. 30. d.Move the pulley on the motor shaft to prevent the belt from slipping against the big pulley. Make sure to firmly tighten the set-screw. 31.

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1 2

4 screws Keyboard and LCD 399-985

2-10

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SummaCut D60-D120

2.7.

REPLACING THE LCD OR THE KEYBOARD

To replace the keyboard, proceed as follows: 1. Remove the right-hand cover and the left hand cover (see Chapter 2.2, Removing the right-hand cover). 2. Take off the top beam. The keyboard and LCD are mounted on a PCB that is mounted in the top beam. 3. Pull the flat cable off the PCB. 4. Remove the four screws holding the keyboard in place. 5. Remove the keyboard PCB. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

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1 2 3 4 5 6

Power entery RS-232 cable Nut Screw Power supply Main board

2-12

Replacements Guidelines

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SummaCut D60-D120

2.8.

REPLACING THE MAIN PCB

To replace a PCB, proceed as follows: 1. Remove the bottom cover and the protection sheeld. 2. Disconnect the various connectors. Pay close attention to the positioning of the connectors. They should be returned to their original location when re-installed. 3. Remove the flat cable for the head by pulling the flat cable connector up. On both sides of the connector cover there is a small protuberance that you can pry up using a screwdriver. Gently pull the flat cable out of the connector. 4. Remove the flat cable for the keyboard. 5. Remove the flat cable for the LCD. At the rear of the PCB 6. Remove the safeguard located a few inches above the grounding wires. Loosen the two grounding clamps so that the earthing wires can be removed.

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At the front of the PCB 8. Remove the left screw holding the power entry module in place and sufficiently loosen the right screw of the power entry module. At the side of the PCB 9. Remove the three vertically-aligned screws located on the right-hand cover. On the bottom of the PCB 10.Remove the fan motor connector. 32. 33. Note: In the Type 1 models the connectors for the sensors also have to be removed.

11.Remove the PCB. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 34. Note:

35. a. When re-installing, be extremely careful to plug the connectors into the correct holes. 36. 37. Each connector on the PCB has a reference.

38. b. Once the new PCB has been installed, it is very important that the data stored on the PCB be brought in line with the head and vice versa. See section 4 on calibration.

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1 2 3 4 5

cover head Head screws cover head position screws to hold head Flatcable

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2.9.

REPLACING A DRAG HEAD

Below is the description for the replacement of a standard drag head. To remove the drag head, proceed as follows: 1. Take the knife holder out of the drag head. 2. Remove the front cover of the drag head by loosening the two screws . 3. Loosen the flat cable by pulling the flat cable connector cover up. On both sides of the connector cover there is a small protuberance that you can pry up using a screwdriver. Gently pull the flat cable out of the connector 4. Remove the drag head. To do this, loosen the three screws with two counterclockwise rotations using a small diameter screw driver and lift the head upwards to remove it from the screws. To re-install the drag head, proceed as follows: 1. Place the head back onto the screws. Tighten the screws with a 1 1/2 clockwise rotation. Do not tighten them firmly because the height and position of the head still need to be adjusted. 2. Put the knife holder into the drag head.

39. 40.

Caution: Make sure the tip of the knife does not protrude.

3. Secure the knife holder.

4. Adjust the height and position of the head.

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SummaCut D60-D120

1 2 3 4 5

cover head Head screws cover head position screws to hold head Flatcable

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Apart from the standard adjustment tools used in the standard operating procedure, you can use an ordinary 3" disk to adjust the height and position of the head. To do this, proceed as follows: a. Put the disk against the drag head (the same way as you would put an adjustment plate against it) to verify that the drag head is positioned perpendicularly to the cutting surface. b. Slide the disk under the knife holder. If the disk touches the knife holder this means that the head is mounted too low. Readjust the mounting of the head.

5. Firmly tighten the screws once the drag head is properly positioned. 6. Put the flat cable back into the connector and close the connector. To ensure good contact, the flat cable must be positioned as deeply as possible and in the middle of the connector. 7. Remount the front cover of the head and firmly tighten the screws. 8. Proceed in the reverse order of removal. Make sure to firmly tighten all screws.

41. Note: 42. Now that you have replaced the head, it is extremely important that you bring the data stored on the PCB in line with the head and vice versa. See Chapter 11, Configuration of the head or the PCB for detailed information on how to do this. 43. 44.

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SummaCut D60-D120

45.

Replacing the flat cable for the head

Below is the description for the replacement of the flat cable in small cutters. To replace the flat cable for the head, proceed as follows: 1. Remove the left-hand cover (see Chapter 1, Removing the left-hand cover). 2. Remove the right-hand cover (see Chapter 2, Removing the right-hand cover). 3. Remove the two screws on either side of the top cover on the D120 on the D60 there are no screws. 4. Remove the top cover. 5. Remove the bottom cover 6. Loosen one end of the flat cable (the one attached to the PCB) by pulling the flat cable connector cover up. On both sides of the connector cover there is a small protuberance that you can pry up using a screwdriver. Gently pull the flat cable out of the connector. 7. Pull the flat cable for the head off the flat cable for the keyboard. 46. Note: 47. Pay close attention to the way the flat cable has been folded. It is advisable to fold the flat cable in exactly the same way when re-installed. 7. Loosen the flat cable which has been glued to the inner side of the shaft's upright edge. 8. Remove the two screws of the top cover of the head holding the flat cable in place. 9. Remove the cover. 48. Note: 49. Pay close attention to the way the flat cable has been folded. The flat cable will need to be folded in exactly the same way when re-installed. 50. Loosen the end of the flat cable attached to the head. Follow the same procedure as before (see point 5).

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1 2 3 4 5 6

flatcable this edge is 110mm screw to hold flatcable holder screws to hold flatcable clamp flatcable holder flatcable clamp

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SummaCut D60-D120

To re-install, proceed as follows: 1. Put the flat cable into the connector of the head and close the connector. To ensure good contact, the flat cable must be positioned as deeply as possible and in the middle of the connector. 2. Put the flat cable across the top of the head and fold it correctly . 3. Remount the top cover of the head. Press the cover down while firmly tightening the screws. Check that the up/down part of the head can move freely. 4. Remount the flat cable clamp. Check that the flat cable runs parallel to the inner side of the shaft's upright edge and that the up/down part of the head can move freely. 5. Slide the flat cable in between the upright edge of the shaft and the top of the head. 6. Bring the head all the way to the left. Make a loop to allow the head to move unhampered along the length of the unit. 51. Caution: 52. Make sure the loop is neither too long nor too short. A very long loop may get caught behind other parts and break. A very short loop may break as the head moves along the length of the unit.

7. Glue the flat cable to the inner side of the shaft's upright edge, starting from the middle. 8. Slide the flat cable through the slot on the right-hand side of the shaft. 9. Put the flat cable into the connector and close the connector. The flat cable must be positioned as deeply as possible in the middle of the connector to have good contact. 10.Fold the cable into the correct position and press it onto the flat cable for the keyboard. 11.Proceed in the reverse order of removal. Make sure to firmly tighten all screws.

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2.10. REPLACING THE Y-BELT


To replace the belt, proceed as follows: 1. Remove the left-hand cover (see Chapter 2. 1, Removing the left-hand cover). 2. Remove the right-hand cover (see Chapter 2.2, Removing the right-hand cover). 3. Remove the 2 screws holding the belt against the carriage plate. One is located to the left of the head and the other to the right. 4. Remove the belt. To re-install, proceed as follows: 1. Screw one end of the belt firmly against the carriage plate. 2. Put the belt around the left-hand pulley. Pull it along the length of the unit and put it around the right-hand pulley. 3. Screw the other end of the belt firmly to the carriage plate. 4. Proceed in the reverse order of removal. Make sure to firmly tighten all screws. 53. Note: 54. Because the belt is equipped with a springload system, the belt tension need not be adjusted.

2.11. REPLACING THE CUTTING STRIP


To replace the cutting strip, proceed as follows: 1. Loosen the cutting strip on the left-hand (or right-hand) side . 2. Gently pull the cutting strip out of the strip slot. 3. Cut the new cutting strip to the correct length and stick it to the unit. 4. Cut the new strip to the correct length and stick it to the unit.

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2.12. REPLACING THE SENSOR


Cutters are equipped with one sensors. The sensor is lockated at the rear of the machine. To replace the sensors, proceed as follows: 1. Turn the unit upside down. 2. Remove the bottom plate (see Chapter 2.3, Removing the bottom plate). 3. Remove the screws holding the sensor in place. Pay close attention to the positioning of the distance sleeves. They should be returned to their original location when re-installed. 4. Disconnect the sensor wire from the sensor PCB. 5. Remove the sensors. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 55. Caution: 56. Make sure the sensor wire does not touch the drum. The rotating drum may damage the wire and cause malfunctioning.

2.13. REPLACING THE FAN MOTOR


To replace the fan motor, proceed as follows:

1. Turn the unit upside down. 2. Remove the bottom plate (see Chapter 2.3, Removing the bottom plate) 3. Remove the four screws holding the fan motor in place. 4. Disconnect the other end of the fan motor wire from the PCB. 5. Remove the fan motor. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 57. Caution: 58. Do not overtighten the 4 screws holding the fan in place as this may damage the fan's mounting flanges and cause malfunction. 59.

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60.

1 2 3

Bearing block gap Drum

det1 det2 det3

push all the bearing blocks in the same direction equal distances push the pillow blocks against the sleeves

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SummaCut D60-D120

2.14. 2.15. REPLACING THE DRIVE DRUM


To replace the drive drum, proceed as follows: 1. Remove the left-hand cover (see Chapter 2. 1, Removing the left-hand cover). 2. Turn the unit upside down. 3. Remove the bottom plate (see Chapter 2.3, Removing the bottom plate). 4. Remove the various screws holding the drum sleeves in place. The number of sleeves varies depending on the cutter type. 5. Remove the three screws holding the X-motor(s) in place and put the motor to the side. It is not necessary to disconnect the wires connected to the motor. On the D120 remove the 2 X motors. 6. Remove the belt. 7. Loosen the two setscrews holding the drive drum pulley in place. 8. Pull the pulley out to its full extent. The pulley need not be removed from the unit. 9. Remove the drive drum. 61. Note: 62. Because all the sleeves of the drive drum are accurately matched, it is not possible to replace just one sleeve. To re-install, proceed as follows: 1. Put the drum into the shaft in the correct position. The largest sleeve should be to the side of the keyboard. 2. Put the screws into the blocks but do not tighten them yet. 63. Note: 64. It is very important that the drive drum be stable and stationary to prevent the media from shifting about. To achieve this, proceed as follows: 65. a.Secure the block to the left (or right) of the large sleeve by tightening its screws. Make sure the block is positioned perpendicularly over the holes and that the long sleeve is positioned in the middle of the hole in the base plate. 66. b.Press the block situatedto the right (or left) of the large sleeve firmly against the sleeve and tighten the screws of the block. 3. Now firmly tighten the screws of the other blocks. Make sure they are positioned straight and that they do not have any play. Gently press the blocks against the sleeves when tightening the screws. 4. Thoroughly clean the strip slot. 5. Push the pulley back into its place.

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67. Note: 68. Make sure the setscrew is positioned correctly so that it locks itself into the slot. 6. Firmly tighten the screws of the drive drum pulley. 7. Put the belt back into its original position. 8. Re-install the X-motor. Make sure to properly tighten all screws. 9. Proceed in the reverse order of removal. Make sure to firmly tighten all screws.

69. Caution: 70. Make sure the sensor wire does not touch the drive drum. The rotating drum may damage the wire and cause malfunctioning. 71.

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Replacements Guidelines

SECTION 3 MAINTENANCE

The SummaCut D60 and D120 cutter range has a number of sliding surfaces made of smooth metals and plastics. They are virtually friction-free and require no lubrication. They will, however, collect dust and lint which may affect the performance of the cutter. Keep the cutter as clean as possible by using a dust cover. When necessary, clean the unit with a soft cloth dampened with isopropyl alcohol or mild detergent. Do not use abrasives.

Maintenance and Cleaning

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3.1. 3.2. MAINTENANCE & CLEANING

The SummaCut D60 and D120 has a number of sliding surfaces made of smooth metals and plastics. They are virtually friction-free and require no lubrication. They will, however, collect dust and lint, which may affect the performance of the cutter. Keep the cutter as clean as possible by using a dust cover. When necessary, clean the unit with a soft cloth dampened with isopropyl alcohol or mild detergent. Do not use abrasives.

3.1.1. CLEANING THE DRIVE SYSTEM


After a time, the sleeves of the drive drum may become clogged with accumulated residue from the media. This situation may affect traction, as the media will tend to slip between the pinch rollers and the drive sleeves. 1. 2. To clean the drive sleeves, proceed as follows: First disable the sensors by covering them, or via the configuration menu. Lower the pinch roller arm. Remove the backing from a piece of vinyl. Place the vinyl with the tacky side down between one of the pinch rollers and a drive sleeve. Lower the pinch roller arm.

3.

or jogging keys to move the piece of vinyl backward or forward Use the several times, until all residue is removed from the drive sleeves. Raise the pinch roller arm and remove the piece of vinyl media. Repeat steps 3 through 5 for the other drive sleeves. Set the cutter s power switch to OFF.

4. 5. 6.

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SummaCut D60-D120

CLEANING THE DRIVE SLEEVES

3.1.2. CLEANING THE SENSORS


After a certain time, the sensor may become dirty with accumulated residue from the media. This situation may cause malfunctioning of the cutter. To clean the sensor area, proceed as follows:

1. The sensor is located on the cutter s right side just behind the right big sleeve . 2. To keep the sensor clean, it is sufficient to wipe it out now and then with a cotton swab.

Maintenance and Cleaning

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3.2.

OPERATING VOLTAGE

The power entry module detects the line voltage and switches automatically between 110V and 230V. The fuse is at the back next to the power inlet. The fuse rate is 2.0A Slo-Blo for all voltage ratings.

SAFETY WARNING Before changing the fuse be sure to disconnect the cutter completely.

POWER ENTRY MODULE

1. Power entry module 2. fuse holder 3. fuse

3.3. 3.4.
3.5. 3.6.

3.7. 3.8.
3.9.

3-4

Maintenance and Cleaning

Service Manual 3.10.


3.11.

SummaCut D60-D120

3.12. 3.13. 3.14. 3.15. 3.16. 3.17. 3.18.


3.19. 3.20.

3.21. 3.22. 3.23. 3.24.


3.25.

3.26.

Maintenance and Cleaning

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3.27. 3.28.
3.29.

3.30.
3.31. 3.32.

3.33. 3.34.
3.35. 3.36. 3.37. 3.38.

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3.39.
3.40. 3.41.

Maintenance and Cleaning

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3.42. 3.43.
3.44.

3.45.
3.46. 3.47.

3.48. 3.49. 3.50. 3.51. 3.52.

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3.53. 3.54.

Maintenance and Cleaning

3-9

SECTION 4 Calibration
General
This section contains information on the calibration of replaced parts and on the recalibration of worn down parts. Each time a unit is serviced, check this section to see which calibration has to be or can be done.

Calibration

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4.1.
1.

1.
2.

3.
4.

5.
6.

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Calibration

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4.2.
I.

MEDIA CALIBRATION

1. The unit has to be recalibrated when : a drum has been replaced the camrollers have been replaced the PCB has been replaced or defaulted

!NOTE!
One of the characteristics of a drum driven machine is that different thicknesses of media give different results while calibrating in the xdirection. So if a high accuracy is needed, the unit has to be recalibrated when different thicknesses of material are used. However, recalibrating is not needed for normal usage. 2. Calibration: Load media in the machine (the wider the media, the more accurate the calibration). Start the SummaCutter Control program. Select settings.

Select Calibration.

Calibration

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Measure the test pattern

and enter the measurementsit in the dialogue box.

Switch the machine on and off so that the new calibration parameters will come into effect (the borders will also be corrected).

4-4

Calibration

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SummaCut D60-120

Calibration

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II. 1.

2.

4.3.

HEAD CALIBRATION

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Calibration

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SummaCut D60-120

4.4.
I. KNIFE CALIBRATION ( offset) It is recommended to recalibrate the knife each time it is changed. See section 1.2.4. for the calibration procedure. II. COIL CALIBRATION 1. The coil has to be recalibrated when: the head is changed the PCB is changed when the cut quality is dubious 2. Calibration: Power the machine up when there is no media loaded and while the knife is turned up and the camrollers are down for smallest media. Go to internal system tests - coil set-up. Press the key. The following message is displayed on the LCD : 40 G : 19

On the LCD the desired pressure is displayed and the value that has to be sent to the head to reach the pressure displayed. Press the key. The following message is displayed on the LCD : 400 G : 110

If you have a tension gauge of 400g you can check if the pressure is 400 gr. You can adjust the 400gr pressure with the pot-meter located right besides the connector for the LCD en keyboard on the main PCB. (the max. pressure with a drag machine is 400grs). If you dont have a tension gauge, leave it at 110 . Press the key. The following message is displayed on the LCD : 40 G : 19 If you have a tension gauge of 100g you can check if the pressure is 40 gr. If a value lower than 40 gr. is shown on the tension gauge press the key to

Calibration

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adjust. If a value higher then than 40 gr. is recorded on the tension gauge use key to adjust. the If you dont have a tension gauge leave it at 19. Insert the drag knife holder into the head. Press the key to adjust the drag knife landing pressure. The following message will be displayed : DRAGL : 14 Press the around 2). Press the around 11). Press the key repeatedly until the drag-knife moves upwards (value key repeatedly until the drag knife holder moves down (value key another three times.

Insert the ball-point holder into the head. Press the key to adjust the ball-point pen landing pressure. The following message will be displayed : PENL : 14 Press the around 2). key repeatedly until the ball-point pen moves upwards (value

Press the key repeatedly until the ball-point pen holder moves downwards (value around 11) Press the key another three times.

Insert the knife holder into the head (the knife may not stick out). Press the key to adjust the ball-point pen landing pressure. The following message will be displayed : 40G : 14

! NOTE!
For a good cutting quality, the landing values must be at least 3 less then the 40g pressure

4-8

Calibration

Service Manual

SummaCut D60-120

4.3.

MACHINE TYPE

The machine type has to be reset when: The pcb has been changed a special init has been done 1.Configuration of the pcb: via keyboard: 1. Initiate a start-up in Factory Set-up Mode (FSM mode or 3-key mode). Do this by switching on the unit while simultaneously pressing the key and the key

key until the message "Standard init" appears on the LCD.

7.
8.
OUT.

Caution:

WHEN STARTING IN 3-KEY MODE, NO LOAD PROCEDURE IS CARRIED TO MAKE THE UNIT OPERATIONAL, A LOAD PROCEDURE HAS TO BE CARRIED OUT (SEE USERS MANUAL). IF THIS LOAD PROCEDURE IS NOT CARRIED OUT, THE UNIT MAY CRASH.

key or key to select "Standard init" or "Special init". If you 2.Use the select "Special init" the default values are put into the NVRAM. It is advisable to use "Special init" if the unit does not start with "Standard init" or if the unit is completely disordered.

9.

Caution:
THEN

10. WHEN THE MACHINE HAS BEEN STARTED UP IN SPECIAL INIT EVERY PARAMETER IN THE MACHINE HAS BEEN DEFAULTED.

In 3-key mode the following extra items appear under system tests (along with several others, such as "Coil set-up", which are always available).: a. Vel Override b. Burn in: only used in factory c. select Machine: to set the unit type d. System reg: only used in factory e. Rom to flash f. DMPL Errors g. Bundling

11.
12.

Caution:
DO NOT USE THE SYSTEM TESTS MARKED

FACTORY

USE ONLY.

BE

EXTREMELY CAREFUL WHILE IN THAT MODE AND FOLLOW GIVEN GUIDELINES TO

Calibration

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THE LETTER.

YOU

CAN INFLICT SERIOUS DAMAGE BEYOND REPAIR TO THE

MACHINE IF THE WRONG PARAMETERS ARE CHANGED.

3.Select "Setup machine" in the list of system tests and choose the correct model type. via computer: 1. Start the summa cutter control program 2. press Alt, Ctrl, Shift and m 3. Choose the right machine type and click OK.

4-10

Calibration

Service Manual

SummaCut D60-120

4.5.

4.6. 4.7.
I.

4. Press the

Press the

Weed carefully with tweezers the rectangle cut and press the

Calibration

4-11

SummaCut D60-120

Service Manual

4.8. 4.9.

SENSOR TEST

The front and rear media sensors can be tested with internal test as described in section 1.6.4. . To test the media sensors just follow the guidelines on the LCD screen . --------------------------------> is shown when the sensor is covered.

>

is shown when the sensor is uncovered. The bottom arrow has to be at least 2 positions further than the top arrow for the unit to function properly.

There is a possibility to change the positions of the bottom arrow with the left and right arrow on the keyboard. With Summa Cutter control the sensor test can also be done. Go to test then to rear sensor.

4-12

Calibration

Service Manual

SummaCut D60-120

Load the media half way the sensor.

1.

4.10. AUTOMATIC TEST


The SummaCut D60 and D120 has an automatic test build in. IT test the complete unit keyboard, motor, coil, interface etc.

Calibration

4-13

SummaCut D60-120

Service Manual

To activate this test press during the power up. Continue pressing following message on the display. HARDWARE TEST X

till you get the

1. Since the RS-232-C is tested use a loopback test cable to connect pin 2 of the cutters connector to pin 3 and pin 7to pin 8. 2. On the D60 the parallel input is tested following loopback cable needs to be used. Connect pin 1 to pin 32, connect pins 2,4,6,8 and 12 together, connect following pins together 3,5,7,9 and 13, connect pin 10 with pin 14 and connect pin 11 with pin 13. 3. For the D120 the USB needs to be connected to the USB of a computer. When the test is running following message will been displayed on the display. PRESS MENU key When the key is pressed the following message is displayed on the display. PRESS TEST key When the key is pressed the following message is displayed on the display. PRESS up arrow When the key is pressed the following message is displayed on the display. PRESS LEFT

When the

key is pressed the following message is displayed on the display. PRESS RIGHT

When the

key is pressed the following message is displayed on the display. PRESS DOWN

When the

key is pressed the following message is displayed on the display. PRESS X key

When the

key is pressed the following message is displayed on the display. PRESS V key

4-14

Calibration

Service Manual

SummaCut D60-120

When the

key is pressed the following message is displayed on the display. OPEN CAM SWITCH

When the handle is opened the following message is displayed and the cam switch is tested.
CLOSE CAM SWITCH

When the handle is closed the following message is displayed . DAC TEST At this moment the cutter is testing the DAC. COIL TEST During this moment the coil is tested. MOTOR TEST The X and the Y motor are moving and the motors are tested. X2 TEST This test is only possible with the D120 and not with the D60. When pressing the or the additional motor in the X axis is rotating and tested to . Then following message will be displayed. cover back sensor When the sensor is activated the sensor is tested and following message will be displayed. Baud rate 2400 Be sure that the plotter has a loop installed on the RS-232-C connector. If this loop is not connected the plotter will display an RS-232-C error. When the loop back is installed all the different Baud rates will be displayed and tested. When the test was successful following message will be displayed on the D60 with a Parallel port. RAR. TEST When the connections are been made on the parallel port this port will be tested. On the D120 with the USB port following message will be displayed. USB TEST When the cutter is connected with a USB port on the computer the USB port will be tested. When the test was successful the following message will be diplayed.

continuing the test press

Calibration

4-15

SummaCut D60-120

Service Manual

USB TEST PASSED

13.

4-16

Calibration

SECTION 5 Troubleshooting - Error codes


General
This section contains information on the error codes which can appear on the LCD screen. A step-by-step procedure is provided in this section to prevent this error.

Troubleshooting-Error Codes

5-1

SummaCut D60-D120

Service Manual

5.1.
Cause:

ERROR IN X-AXIS

The drum motor cannot move to the required position. This is a fatal error. It can only be solved by turning the power off and then on again. This error is usually caused by a media crash in the machine. Action: 1. Remove the crashed media and restart the machine. Should this happen rather frequently, the cause can be : knife depth or pressure is not well set. bad tracking because an unstabilised media type is used. bad tracking because the humidity is too high or too low. bad tracking because an unapproved type of media is used. the media hit something on the floor while cutting. the media shows already different tracks, so that the media does not know which track to follow. 2. Lower the speed of the media. 3. Check whether the drive drum turns smoothly (first turn the power off and place the cam rollers in the up-position). 4. If the error in the x-axis happens at start-up, check the x-axis motor, the encoder connectors and the cables. 5. Replace the X-motor encoder. 6. Replace the PCB.

5-2

Troubleshooting-Error Codes

Service Manual

SummaSign

5.2.
Cause:

ERROR IN Y-AXIS POSITION

The motor driving the machine head cannot move to the position wanted. This is a fatal error. It can only be solved by turning the power off and then on again. This error is usually caused by a media crash. Action: 1. Remove the crashed media and restart the machine. 2. Lower the speed and/or the knife pressure. 3. Check whether the head moves smoothly (first turn the power off and position the cam rollers on the outer edges of the media). 4. Check the y-axis motor and the encoder cables. 5. Replace the Y-motor. 6. Replace the PCB.

5.3.
Cause:

SYNTAX ERROR

Syntax errors occur when an incorrect HPGL command is received by the machine. The next table gives an overview: Error Number 1 2 3 5 7 10-18 Action: 1. Change the data sent to the machine. 2. Refer to the HPGL supported commands. Meaning Instruction is not recognised. Wrong number of parameters. Parameter is out of range or illegal character. Unknown character set. Buffer overflow for polygons or downloadable characters. Problems with Device Control Instruction.

5.4.

NVRAM FAILURES AND MESSAGES

Non fatal errors:

Troubleshooting-Error Codes

5-3

SummaCut D60-D120

Service Manual

WARNING: SOME SYSTEM SETTINGS HAVE BEEN DAFAULTED DUE TO OPGRADE, SOME USER SETTINGS HAVE BEEN DEFAULTED DUE TO UPGRADE. Action: 1. Message appears when rebooting the machine for the first time after an upgrade of the ROMs. The configuration of the machine will be defaulted. After answering the questions on the display, this message should no longer appear when the machine is switched on. 2. If it does replace PCB. Fatal errors: WARNING: SYSTEM NVRAM CHECKSUM FAILURE - SYSTEM NVRAM HAS BEEN DEFAULTED TRY TO REBOOT MACHINE, WARNING: USER NVRAM CHECKSUM FAILURE, SYSTEM NVRAM WOULD NOT ACCEPT VALUE WRITTEN TO IT, USER NVRAM WOULD NOT ACCEPT VALUE WRITTEN TO IT. Action: 1. The preceding messages warn for a problem with the (NV)RAM. Important information can be lost, such as calibration, landing pressure. 2. Replace the main PCB.

5.5.
Cause:

RS232 ERROR

These errors can only happen when the RS232 test is being executed. A special loopback test cable is necessary to do this test. (This cable connects pin 2 to pin 3 and pin 7 to pin 8). Possible errors: COULD NOT TRANSMIT DATA COULD NOT RECEIVE DATA DATA RECEIVED DID NOT MATCH DATA TRANSMITTED PARITY/FRAMING/OVERRUN ERROR COULD NOT TOGGLE RTS HARDWARE HANDSHAKE LINE. Action: 1. Make sure that the loopback connections have been made. 2. Check for bad contacts in the RS232 area on the PCB. 3. Replace the main PCB.

5.6.
Cause:

INTERNAL ERRORS

Happens when there is a Firmware problem or a problem with the main board (address bus or data bus), the following list gives an overview:

5-4

Troubleshooting-Error Codes

Service Manual

SummaSign

Error Number 1 2 3 4 5 6 7 8 Action:

Meaning bus error address error illegal instruction zero division chk instruction trapv instruction line 1010 line 1111

1. This is an internal error. The cause of this error may be an unknown firmware problem in the machine's EPROMs. Do the internal confidence test. If this test is OK, check the data sent to the machine. 2. Reflash the ROMs on the main board. (change the ROMs on the old type PCB) 3. Replace the main PCB.

Troubleshooting-Error Codes

5-5

SummaCut D60-D120

Service Manual

5.7.

FLASHING ERRORS AND MESSAGES

Non errors: ERASING FLASH, PROGRAMMING,READING DATA Action: Message appears when the internal ROMs are being reflashed. Just wait untill the operation is done.

Errors: UPGRADE ERROR: SET JUMPERS TO COPY MODE (ONLY POSSIBLE IN ROM TO FLASH TEST) Fatal errors: ORDER ROM COULD NOT ERASE FLASH COULD NOT PROGRAM FLASH COULD NOT DETECT FLASH UPGRADE ERROR: CORRUPTED FILE OR COMMUNICATION PROBLEM REBOOT Action: 1. Those are fatal errors. The information in the internal ROMs is not reliable any more. 2. Order ROMs and do an internal reflash. 3. Change main PCB. COULD NOTDETECT FLASH: POWER OFF- VERIFY JUMPER SETTINGSRESTART REBOOT MACHINE BEFORE FLASHING UPGRADE ERROR: UPGRADE FILE DOES NOT MATH MACHINE TYPE, REBOOT CUTTER

5.8.
Cause:

RAM ERROR

RAMs are going bad. Action: Replace the main PCB.

5-6

Troubleshooting-Error Codes

Service Manual

SummaSign

Troubleshooting-Error Codes

5-7

6. FIGURES
This section contains the detailed drawings of several assys of the SummaSign. There are no detailed drawings of the base, since the base (containing baseplate assys and the top beam assys) are considered as a whole and may never be disassembled. If they should ever be taken apart (e.g. heavy transport damage), then the base has to be reassembled in the factory or by a Summa technician).

Figures

6-1

SummaCut D60-D120

Service Manual

1 2 3 4 5 6 7 8 9

399-001 399-620 399-028 399-019 399-618 399-002 399-050 399-085 391-386 391-886 398-611 399-635 398-515 398-516 398-530

Cover left/right Assy D-head Cover head Molded lever Assy top cover D120 Top cover D60 Stand D60 Stand D120 Cutting strip +tape D60 Cutter strip + tape D120 Drive drum D60 Drive drum D120 Assy media select left Assy media select right Assy media select middle(not shown)

6-2

Figures

Service Manual

SummaCut D60-D120

1 2 3 4 5

398-516 398-515 398-530 399-019 399-925 399-024 399-034

Assy media select right Assy media select left Assy media select middle(not shown) Molded lever Assy Power entry Roll D60 Roll D120

Figures

6-3

SummaCut D60-D120

Service Manual

1 2 3 4

398-611 399-635 391-809 398-224 399-013

Drive drum assy D60 Drive drum assy D120 Assy motor without encoder Assy motor Roller Guiding

6-4

Figures

Service Manual

SummaCut D60-D120

1 2 3 4

399-011 ND5000-9881 ND5000-9879 399-013

Brake Spring brake O ring Roller Guiding

Figures

6-5

SummaCut D60-D120

Service Manual

1 2

399-002 399-033 399-985

Top Cover D60 Top cover D120 Assy, PCB keypad and LCD

6-6

Figures

Service Manual

SummaCut D60-D120

1 2 3

399-016 399-025 399-985

Keyboard insert D120 only Keypad Assy, PCB keypad and LCD

Figures

6-7

SummaCut D60-D120

Service Manual

1 2 3 4 5

398-529 399-921 399-905 399-975 399-925 399-906

Assy Fan Power supply Assy main PCB Parallel Assy main PCB USB Assy power entry Cable RS232 Internal(not on USB)

6-8

Figures

Service Manual

SummaCut D60-D120

1 2 3 4 5 6 7

399-986 399-639 MB9129 398-224 399-617 399-019 ND5000-9439

Cable keypad and LCD Assy dbl pulley 120/60T Belt Assy motor Assy switch pinch roller Molded lever Spring

Figures

6-9

SummaCut D60-D120

Service Manual

1 2 3 4 5 6 7 8

399-631 399-634 421-165 421-600 MB9124 398-224 391-198 421-567 399-957 399-956

Assy Y belt D60 Assy Y belt D120 Assy idler Y-axis Pulley Idler Belt Assy Motor Pulley with screw Pulley Cable head D120 Cable head D60

6-10

Figures

Service Manual

SummaCut D60-D120

1 2 3 4 5

398-611 399-635 399-965 391-759 421-198 MB0389

Drive drum assy D60 Drive drum assy D120 Assy pCB media sensor Anti-static brush Bearing block Bearing

Figures

6-11

SummaCut D60-D120

Service Manual

1 2 3

398-611 399-635 421-198 398-224

Drive drum assy D60 Drive drum assy D120 Bearing block Assy Motor

6-12

Figures

Service Manual

SummaCut D60-D120

1 2 3 4 5 6

398-611 399-635 399-965 391-759 399-024 399-034 421-198 398-224

Drive drum assy D60 Drive drum assy D120 Assy, PCB media sensor Anti static brush Roll D60 Roll D120 Bearing block Assy motor

Figures

6-13

SummaCut D60-D120

Service Manual

1 2 3 4

399-011 ND5000-9881 ND5000-9879 399-013

Brake Spring brake O ring Roller Guiding

6-14

Figures

Service Manual

SummaCut D60-D120

1 2 3 4 5 6 7

391-365 391-386 391-886 391-326 399-029 391-313 399-631 399-634 391-956 399-957

Assy exc. Shaft Cutting strip with tape D60 Cutting strip with tape D120 Assy pinch roller Belt attachement plate Assy conc.Shaft Belt assy D60 Belt assy D120 Cable head D60 Cable head D120

Figures

6-15

SummaCut D60-D120

Service Manual

1 399-019 2 398-611 399-635 3 399-620 4 399-025 5 399-985 6 399-965 7 391-326 8 391-386 391-886 9 399-031 10 399-009

Molded lever Drive Drum Assy D60 Drive Drum Assy D120 Assy D-Head Keypad Assy PCB Keypad +LCD Assy PCB Media sensor Assy Pinch Roller Cutting strip + tape D60 Cutting strip + tape D120 Alingment strip Vinyl Guiding strip only on D60

6-16

Figures

Service Manual

SummaCut D60-D120

1 2 3 4 5 6

399-925 399-906

399-921 399-905 399-975

Assy Power entry Cable RS-232-C Internal only on D60 NUT Screw Power Supply Assy Main PCB D60 RS-232 Assy Main PCB D120 USB

Figures

6-17

SummaCut D60-D120

Service Manual

1 399-002 399-033 2 399-001 3 399-001 4 ND5000-9556 5 ND5000-9639

Top Cover D60 Top Cover D120 Cover left/right Cover left/right Screw Ring

6-18

Figures

Service Manual

SummaCut D60-D120

1 2 3 4 5 6 7 8 9 10 11 12

399-027 391-365 391-313 391-314 391-182 ND5000-9667 ND5000-9267 ND5000-9540 ND5000-9231 ND5000-9620 ND5000-9602 399-631 399-634 13 ND5000-9587 ND5000-9604

carriage plate assy, excentric shaft assy concentric shaft assy flatcable holder flatcable clamp screw M2x4 flatwasher M2 hexnut M4 lockwasher M4 washer 8x4.1x.3 screw M2x6 Assy Belt D60 Assy Belt D120 lockwasher M3 screw M3

Figures

6-19

SummaCut D60-D120

Service Manual

1 2 3 4 5 6 7

motor encoder red on + black on connector 5pin tie-wrap holder tie-wrap capacitor MC1697

6-20

Figures

Service Manual

SummaCut D60-D120

1 2 3 4 5 6 7 8 9 10 11 12

398-451 391-115 391-121 398-440 ND5000-9621 ND5000-9607 390-142 ND5000-9196 391-326 ND5000-9244 391-116 391-117

carriage media select right pinch roller mount base eccentric cam connecting pin setscrew M3x12 truarc dia. 4 shaft camroller setscrew M3x5 assy, pinch roller spring plunger dia 4 adjustable springholder Spring

Blank page

remark: for the assy media select left the partnumber for the molded part (1) is 398-450.

Figures

6-21

Spare Parts List

7-1

SummaCut D60 SPARE PARTS


Part no Description

391-198 391-313 391-326 391-365 391-386 391-500 398-224 398-515 398-516 398-529 398-611 399-002 399-008 399-011 399-019 399-024 399-025 399-031 399-617 399-620 399-621 399-622 399-623 399-624 399-630 399-631 399-639 399-905 399-906 399-921 399-925 399-927 399-956 399-965 399-985 399-986 421-198 421-567 MB0389 MB9124

Pulley Motor Concentric shaft assy Assy, pinch roller Assy,exentric shaft Strip + tape Core holder assy Assy motor Assy, Media select left Assy,Media select right Assy, Fan Summacut Drive Drum Assy Top Cover Cam Detection part Brake Dia .30 Molded lever Roll D60 Key pad Aligment strip Assy,switch pinch rol D60 Assy,D-Head D60 X-Motor cable D60 Y-motor cable D60 X-encoder cable D60 Y-Encoder cable D60 Assy Carriage head Assy, Y-belt Assy DBL Pulley 120/60T Assy, Main PCB Cable RS-232 internal Assy Power supply Assy,power entry Assy, DC Power cable Cable head Assy, PCB Media sensor Assy,PCB Keypad+LCD Cable keypad+LCD Bearing Block Pulley 72 T Bearing Belt X motor 110T

Spare Parts List

7-1

Summasign
MB9129 ND5000-9879 ND5000-9881 Belt X-motor O ring Spring

Service Manual

7-2

Spare Parts List

Spare Parts List

7-3

SummaCut D120 SPARE PARTS


Part no Description

384-478 391-014 391-198 391-312 391-313 391-326 391-365 391-500 391-759 391-809 391-886 398-224 398-515 398-516 398-529 398-530 399-001 399-008 399-011 399-016 399-019 399-025 399-026 399-028 399-031 399-034 399-617 399-620 399-622 399-624 399-629 399-630 399-634 399-639 399-921 399-925 399-927 399-957 399-965 399-975 399-985

Pulley Steel strip flatcable Pulley Motor Roller assy Concentric shaft assy Assy, pinch roller Assy,exentric shaft Core holder assy Anti-static brush Assy Motor without encoder CuttingStrip with tape Assy motor Assy, Media select left Assy,Media select right Assy, Fan Summacut Assy, Media select Middle Cover left /right Cam Detection part Brake Dia .30 Keyboard insert Molded lever Key pad Spring key pad Cover head Aligment strip Roll D120 Assy,switch pinch rol D60 Assy,D-Head D60 Y-motor cable D120 Y-encoder cable D120 X-Motor cable D120 Assy Carriage head Assy, Y-belt Assy DBL Pulley 120/60T Assy Power supply Assy,power entry Assy, DC Power cable Cable head D120 Assy, PCB Media sensor Assy,main PCB USB Assy,PCB Keypad+LCD

Spare Parts List

7-3

Summasign
421-139 421-198 421-567 MB0313 MB0389 MB9124 MB9129 MF-0067 ND5000-9879 ND5000-9881 Pulley dbl 120+60T Bearing Block Pulley 72 T Bumper Bearing Belt X motor 110T Belt X-motor Guard fan O ring Spring

Service Manual

7-4

Spare Parts List