Summa Bigpaint 1500 Maintenance Manual

Service Manual BigPaint

CalComp Display Products NV Rochesterlaan 6 8470 Gistel Belgium

Service Manual

SummaPaint

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

SECTION 1 KEYBOARDCONTROL

SECTION 2 REPLACEMENT GUIDELINES

SECTION 3 MAINTENANCE

SECTION 4 CALIBRATION SECTION 5 ERROR CODES - TROUBLESHOOTING 5.1. MOTOR HOT.........................................................................................................5.2 5.2. ERROR IN X-AXIS................................................................................................5.2 5.3. ERROR IN Y-AXIS POSITION..............................................................................5.3 5.4. ERROR IN Y-2 AXIS POSITION...........................................................................5.3 5.5. LOW LINE VOLTAGE...........................................................................................5.4 5.6. HIGH LINE VOLTAGE..........................................................................................5.4 5.7. ILLEGAL PLOT COMMAND.................................................................................5.5 5.8. ILLEGAL CLIP & SCALE SETTINGS..................................................................5.5 5.9. SYNTAX ERROR..................................................................................................5.5 5.10. NVRAM FAILURES AND MESSAGES..............................................................5.6 5.11. RS232 ERROR....................................................................................................5.6 5.12. INTERNAL ERRORS..........................................................................................5.7

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5.13. FLASHING ERRORS AND MESSAGES............................................................5.7 5.14. ROM ERROR......................................................................................................5.8 5.15. RAM ERROR.......................................................................................................5.8 5.16. MACHINE UNABLE TO FIND THE KNIFE HOME POSITION...........................5.8 5.17. MARKERS NOT SENSED PROPERLY.............................................................5.8 5.18. TIMEOUT ERROR ON CONTROL PORT B, CHECK CONNECTION...............5.9 5.19. COULD NOT START INTERNAL TEST, PLEASE RETRY...............................5.9

SECTION 6 FIGURES

6.1 SERVICE STATION...............................................................................................6.2 6.2 PRINTER HEAD.....................................................................................................6.5 6.3 KEYBOARD-LCD SCREEN...................................................................................6.8 6.4 IDLER PULLEY....................................................................................................6.10 6.5 Y-MOTORS..........................................................................................................6.13 6.6 CARRIAGE CUTTERHEAD.................................................................................6.14 6.7 PRINTERHEAD + VOVER..................................................................................6.15 6.8 STANDOFFS RIGHT PLATE...............................................................................6.16 6.9 PRINTER CARRIAGE..........................................................................................6.17 6.10 X-MOTORS-TRANSFO......................................................................................6.18 6.11 PRINTER CONTROL BOX................................................................................6.19

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INTRODUCTION

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INTRODUCTION

1. OVERVIEW This is the CalComp Service Manual for the SummaPaint 1500X Printer Cutter. It provides information for servicing the PC1500X. All repairs are to be made by, or under the direction of, authorised CalComp service personnel. This manual is copyrighted by CalComp 1997. CalComp 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  Figures - part numbers  Appendix A list recommended spare parts

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 come on the LCD screen and the possible solutions

Figures - part numbers: Detailed figures of the various parts and assemblies of the machine.

Appendix A: An overview of all the recommended spare parts, normally only the parts from this list will be provided from CalComp.

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QUICK TOUR AROUND THE MACHINE Introduction

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In order to get acquainted with your SummaPaint PC1500X, read the following description of the machine and components.

FRONT VIEW

1.

Control Panel : - The control panel has 12 keys. All machine activity can be initiated from the control panel. This includes initiating remote mode for computer control, local mode for manual operation and menu mode.

2.

Display : - The 2x16 character display informs the user about the current status of the cutting process or about actions that need to be taken.

3.

Pinch roller lever arm : - This lever is used to raise and lower the pinch rollers.

4.

Pinch rollers : - The pinch rollers (one at each side) hold the media clamped between the rubber rollers and the media drive sleeves. The PC1500X unit is provided with an extra low pressure roller in the middle to keep the media flat.

5.

Media Drive Sleeves : - The media drive sleeves move the media only when the pinch rollers are in the ‘down’ position.

6.

Sensors : - The sensors detect the presence of media to avoid damage to the cutting strip. Upon powering up the machine, they cause the media to move all the way to the front edge of the platen.

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7.

Inkjet Carriage : - The inkjet carriage is the mount for the inkjet head.

8.

Ink Cartridge : - An ink cartridge is a small reservoir of ink on which a print head is mounted.

9.

Safety Cover : - The safety cover prevents the human body from being hit by the moving carriage. Therefore it is advised to close the cover while the unit is working. This cover also prevents dust from falling on the newly printed drawing.

10.

Cutting Carriage : - The cutter carriage is the mount for the tangential cutting head.

11.

Manual cut-off knife : - Upon completing a sign, move the media forward by pressing the key. Use the manual knife to cut the finished sign off the media roll. Leave the loaded media in place ready to start your next cut by pressing the key again.

12.

Stand : - The stand comes standard with the SummaPaint PC1500X.

13.

Cutting strip : - Soft strip to avoid 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.

14.

Pick-up roll : - The pick-up roll makes it possible to roll up the printed material. This way the PC1500X can print unattendedly without damaging a drawing.

15.

Service station : The service station cleans the printing head and prevents the head from drying out when the unit is not working. The service station needs to be cleaned regularly.

16.

Pick-up sensor : - This sensor senses the media. When the media reaches too close to the ground the pick-up roll will be activated. This way, it prevents the pictures from touching the ground.

17.

Power ON/OFF switch : - This rocker switch sets the machine’s 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.

18.

Cartridge compartment : - When a cartridge is not being used, it is advised to place it in a cartridge clamp. These clamps can be placed in the cartridge compartment.

19.

Big ink supply bottles : - The big ink supply bottles can handle 500 ml. ink of each colour. The big ink supply system enables long unattended printing without refilling the ink.

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REAR VIEW

1.

Power Entry Module: - The fuse box and the AC power cord receptacle are located in the power entry module.

2.

Big ink supply system : - The SummaPaint can be upgraded with a second set of ink.

3.

Controller : - For details see further.

4.

Roll Media Guide Bushes : - The two guide bushes serve to keep the media roll in place when media is pulled from the roll.

5.

Media Flanges : - The media flanges ensure proper routing of the media roll.

6.

Media Support Roller : - Rotating support rollers for the media roll.

1.

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1. 2. SUMMAPAINT PC1500X, CONTROLLER

1.

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. This port can only receive cut data.

2.

Parallel Port* : - This printer port provides a unidirectional communication link between the PC1500 and a host computer. The PC1500X can receive print and cut data, but not transmit data via this port. * Note : only one interface can be active at a time. The first port receiving data will be the active interface until the machine is reset.

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Introduction

Keyboard Controls

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`

SECTION 1 Keyboardcontrols SUMMAPAINT CONTROL. The SummaPaint Control Program for Windows is a tool to optimize the overall cutting and printing quality of your PC1500X. For information on the installation or general set-up of this program, refer to the ‘Readme.txt’ file on the installation disk. The SummaPaint Control program basically has the same functions as the control panel. It is up to the user to decide how he will work most efficiently. The users who work with the SummaPaint Control program will notice that it is a very powerful and practical tool. By clicking on the ‘Menu’ button in the main SummaPaint Control window all the machine settings can be changed. Four different user configurations can be saved in the cutter’s memory. The selected configuration number is marked at the bottom of the menu window. These four configurations are maintained independently.

THE CONTROL PANEL Figure 1-1 shows the control panel of the SummaPaint PC1500X. The main functions of the liquid crystal display (LCD) and the control panel keys are explained in the following paragraphs.

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FIGURE 1 SUMMAPAINT PC1500X, CONTROL PANEL

THE LIQUID CRYSTAL DISPLAY The 32-character liquid crystal display (LCD) contains two lines of 16 characters each. The LCD provides cutter status information during operations and displays menu options for the configuration of the cutter. The contrast of the LCD can be adjusted from the control panel in order to ensure optimum readability under varying lighting conditions. Instructions for adjusting the LCD contrast are given in Section 1.. 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. In addition to the status messages and/or menu options displayed on the LCD, arrow symbols representing the , , , jogging keys and the key will tell you which keys to press to go to the next menu item (top line of the display) or to the next value for a given submenu item (bottom line of the display).

THE RESET/LOAD KEY

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The

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key (RESET/LOAD) is used to move the origin, to initiate a load sequence, to reset

the machine or to abort the job in progress. When the key (RESET/LOAD) is pressed, the unit goes off line, suspends all operations in progress and displays the RESET/LOAD menu. Press the key until SET ORIGIN, LOAD, RESET, ABORT or SPECIAL LOAD is displayed. To confirm RESET, ABORT or SPECIAL LOAD press the SET ORIGIN instruction move the knife origin using the

key (ENTER). To execute the ,

,

,

jogging keys and

press the key (ENTER) to confirm the new origin position. To initiate the LOAD instruction press the 1 or 2 key to initiate a load sequence for a ROLL or SHEET respectively. Upon termination of any of these instructions, the cutter goes on line again. The SET ORIGIN instruction is used to move the knife origin. The LOAD instruction is used to initiate a load sequence. The RESET instruction performs a complete reset of the cutter. The ABORT instruction simply cancels the cut in progress. Aborting a cut will not reset the cutter parameters: the parameters which had been selected for the cut remain in effect. The SPECIAL LOAD instruction activates the OPOS system .

THE ON LINE KEY The key (ON LINE) toggles between on line and off line operation. When the pressed, the selected mode (ON LINE or OFF LINE) is displayed on the LCD.

key is

Selecting OFF LINE will suspend all operations in progress. Pressing the key while the cutter is off line will make the machine go on line again, resuming the suspended operation.

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While the machine is off line, the following operations can be performed: 

or Press the printing mode)



or jogging key to make the media move forward (towards you) or Press the backward (away from you). Moving the media forward will prove to be very practical when you require to cut the finished sign off manually.



key (TOOL UP/DOWN) to lower or raise the active tool of the cutting Press the head. If the tool is not moved for approximately eight seconds, it is raised automatically (disabled in printing mode).

jogging key to move the tool carriage to the left or right. (disabled in

THE MENU KEY The

key (MENU) is used to select one of the menus. Pressing the

key will make the

cutter go off line and suspend all operations in progress. Pressing the key repeatedly will display the different menus one by one. As the menu options are on a loop, pressing the key when the last option is displayed will automatically return you to the first option. The different menus are illustrated in Figure 1-2.

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500

FIGURE 1 SUMMAPAINT PC1500X, CONFIGURATION SUBMENUS To select a menu by scrolling through the different options, press the

jogging key .

To exit the menus and resume the previous on line operation, press the

key (ON LINE).

Under normal conditions, the machine is on line; it may then be selected by the host computer for a printing or cutting operation or deselected by the host computer. Pressing the

,

or

key will make the cutter go off line, in order to initiate another operation.

The contents of the different menus are summarised in Table 1-1.

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MENU

DESCRIPTION

USER CONFIG 1 (->4)

Selects a given active cutter configuration from one of the four sets of configuration parameters stored in the unit's memory

INTERNAL TEST

Activates one of the resident cutting plots provided for informational purposes.

PRINTER SETTINGS

Activates the internal printing tests and printing parameters

TABLE 1-1: CONTENTS OF THE SUMMAPAINT PC1500X MENUS

THE ENTER KEY The

1

key (ENTER) is used to select the item currently displayed on the LCD.

2

THE 1 AND 2 KEYS

The use of the 1 and 2 keys varies according to the operation in progress; their use is displayed on the LCD as appropriate.

THE JOGGING KEYS The use of the jogging keys varies according to the operation in progress. For example, when working in the USER CONFIG menu, the select the new user number and the menu item.

or

or

jogging key is used to

jogging key is used to go to the previous or next

THE TOOL UP/DOWN KEY The

key (TOOL UP/DOWN) is used while the cutter is off line to raise or lower the tool.

Pressing the raise the tool.

key once will lower the tool onto the media. Pressing the

key again will

key is pressed while the unit is online, the print carriage will move to the origin, away If the from the capping station. Pressing any key will move the print carriage back.

THE TOOL SELECT KEY

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The key (TOOL SELECT) is used to select one of the following tools : a tangential knife a drag knife a ballpoint pen To temporarily change the tool, press the

key, then press the

or

jogging key until

the desired tool appears on the second line o the LCD. Press the key to confirm the tool. An asterisk * appears next to the selected tool. When the cutter is powered on the next time, the default tool will be selected. For setting up the default tool see Section 1..

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NORMAL OPERATION The term "normal operation" covers on line operation, off line operation and local operation, i.e. the three types of operation for actual cutting or plotting. They are explained in further detail in the following paragraphs.

ON LINE AND OFF LINE On line and off line are two important concepts when using the SummaPaint PC1500X. The cutter is on line only when one of the following messages is displayed on the LCD : Online in printing mode:

Online in cutting mode: 500mm/s 120 g .45mm(1) *ON LINE

K 1

PRINT MODE *ON LINE

K 1

This display message should be read as follows :

This display message should be read as follows :

500 mm/s 120 g

PRINT MODE = indicates that the machine is in print mode. K = knife operation (K) or pen operation (P) *ON LINE = printer is ready to receive data 1 = user number

K .45 mm(1)

ON LINE 1

= =

velocity knife pressure or pen pressure = knife operation (K) or pen operation (P) = knife offset - only displayed when in drag knife mode = cutter is ready to receive data = user number

In all other cases, the cutter is off line. When on line, the cutter can be addressed by the host computer, which means that the cutter will execute cutting or plotting instructions issued by the host computer's application software. For normal operations, the cutter MUST be on line, so that it can receive instructions from the host computer and the printing/cutting software.

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When the machine is on line, the following conditions must be met: 

The machine must be powered ON.



Media must be loaded.



The proper tool must be installed.



The unit must be connected to the host computer via the parallel interface and / or the RS-232-C link.



The unit must be configured for the scheduled operation.

To put the cutter off line, press the , or key. Pressing any of these keys will suspend the current printing / cutting operation until the PC1500X is put on line again.

LOCAL OPERATION Local operation is only possible while the machine is off line. Local operation means that the machine is operated directly by the operator via instructions entered on the control panel. 

To work in local operation mode, proceed as follows:

1.

If the machine is still on line, press the move forward over a certain distance.

2.

To move the carriage to the left or right, press the print mode)

3.

To make the media move forwards (towards you) or backwards (away from you), press the

or

key once to select off line. The media will

or

jogging key. (Disabled in

jogging key.

4.

To move the tool head up or down, press the

5.

To end local mode and put the cutter on line again, press the

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key. (Disabled in print mode) key.

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THE USER CONFIG MENU The USER CONFIG(uration) menu gives access to different submenus which allow you to configure the cutter's operating parameters. It should be taken into account that access to some of the submenus will be determined by the plotting language you are using. Four different user configurations can be saved. The selected configuration number is displayed on the LCD next to the USER CONFIG message. These four USER CONFIG 1(->4) menus are maintained independently. 

To select another configuration number, proceed as follows:

1.

Power on the cutter.

2.

Press the

3.

or Press the to USER CONFIG.

key until USER CONFIG 1(->4) is displayed. jogging key until the desired configuration number is displayed next

NOTE Before altering any of the items in the USER CONFIG menu, make sure that you have previously selected the right configuration number in the USER CONFIG 1(>4) menu.

Figure 2-3 shows the USER CONFIG submenus. 

To select and alter a configuration parameter, proceed as follows:

1.

Power on the cutter.

2.

Press the

key until USER CONFIG 1(->4) is displayed.

3.

Press the, of the LCD.

or

4.

Press the

5.

Press the key to confirm the selection, an * will be displayed next to the selected setting. (An * is always displayed next to the active value. )

1-10

or

jogging key until the desired submenu is displayed on the first line

jogging key until the desired value is displayed on the second line.

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* = in DM/PL ONLY ** = IN HP/GL and HP/GL/2 ONLY

FIGURE 1 FLOWCHART SHOWING FACTORY PRESET MENU SETTINGS

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KNIFE PRESSURE The KNIFE PRESSURE submenu is used to set or modify the cutting pressure of the knife. The default knife pressure value is 120 grams. The knife pressure can be set between 0 and 600 grams. The knife pressure value is set in 5 gram increments. On the LCD, the active knife pressure value is marked with an *.

PEN PRESSURE The PEN PRESSURE submenu is used to set or modify the pressure of the ball point pen. The default ball point pressure value is 80 grams. The pressure can be set between 0 and 600 grams in 5 gram increments. On the LCD, the active pen pressure value is marked with an *.

KNIFE OFFSET The KNIFE OFFSET submenu is used to set or modify the distance between the DRAG knife blade tip and the centre axis. This routine applies to a drag knife only. The default drag knife offset value is .45 mm. 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 the 1 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.

FIRING RATE The firing rate submenu is used to set the speed of printing. When using ink types with a high viscosity it is advised to lower the firing rate to obtain a better print quality and a longer life time of the ink cartridges. Lowering the firing increases the time of printing. The default firing rate is high. The firing rate can be set to LOW, MEDIUM and High.

VELOCITY The VELOCITY submenu is used to set or modify the velocity of the tool. The default velocity is 500 mm/s (20 ips). The velocity can be set between 50 mm/s (2 ips) and 600 mm/s (24 ips).

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OVERCUT The OVERCUT submenu enables you to generate an overcut in order to facilitate weeding the cut. 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 *.

SYSTEM SETUP The SYSTEM SETUP submenu covers the menu items you normally only need when establishing the initial setup e.g. when you install the cutter in combination with the software you use. Press the

key to access the different submenu items, which are explained in section 1.5.

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SYSTEM SET UP Refer to Figure 1-3.

CONCATENATION The CONCATENATION feature increases the speed and quality with which cut data having a very high resolution is cut. However when changing over to normal characters again, deactivate concatenation by setting this parameter to 0. On the LCD, the active concatenation value is marked with an *.

SMOOTHING The SMOOTHING feature helps to cut smoother curves when curve data with many short vectors is received from the computer. The default setting is OFF. On the LCD, the active setting is marked with an *.

EMULATE The EMULATE submenu is used to select the active cutting/plotting language for the cutter. The SummaPaint PC1500X supports HP/GL, HP/GL/2 and DM/PL. 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 which is supported by the host computer's cutting software.

Select the HP/GL menu option to set the active cutting/plotting language to HP/GL. The cutter will emulate an HP model 758xB plotter (with selectable origin, see 1.4.12). 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.

TOOL The TOOL sub-menu is used to select the default tool at power up. To configure the cutter for TANGENTIAL KNIFE cutting operations, select the TANG. KNIFE option. To configure the cutter for PLOTTING operations, select the BALL POINT option. To configure the cutter for DRAG KNIFE cutting operations, select the DRAG KNIFE option. To select a tool other than the default one temporarily, see section 1..

HPGL RESOLUTION

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The HPGL RESOLUTION sub-menu is used to select the cutter's default HPGL useraddressable cutting resolution. The default addressing resolution is HIGH (0.01 mm) . The user-addressable resolution can be set to NORMAL (0.025 mm) or HIGH (0.01 mm). On the LCD, the active resolution value is marked with an *

MENU UNITS The MENU UNITS submenu allows you to select English or metric menu units for DM/PL. For models sold in the US, English units are the default setting. For models sold in Europe, metric units are the default setting. On the LCD, the active menu units setting is marked with an *.

ADDRESSING The ADDRESSING submenu is used to select the cutter's default DM/PL user-addressable cutting resolution. The default addressing resolution is 0.025 mm (Europe) or 0.001" (US). The user-addressable resolution can be set to 0.025 mm or 0.001" or 0.1 mm or 0.005". On the LCD, the active resolution value is marked with an *

BAUD RATE The BAUD RATE submenu is used to set or modify the operating baud rate for RS-232-C serial communications between your cutter and the host computer. The default baud rate is 9600 bps. 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.

PARITY The PARITY sub-menu is used to set or modify the byte format and parity type for RS-232-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

Keyboard Controls

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

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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.

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. RTS/DTR can be set to TOGGLE (hardware handshaking) or HIGH (software handshaking). On the LCD, the active handshaking setting is marked with an *.

SPECIAL LOAD The special load submenu is used to determine which alignment procedure is used when activating the special load procedure (see section 1). By using the the special load procedure, a contour cut can be done on a preprinted sign. On the LCD the active value is marked with an *. The default setting is OPOS. The SPECIAL LOAD can be set to X-AXIS ALIGN, XY-AXIS ALIGN, XY-ADJUSTMENT and OPOS.

MEDIA SENSOR The MEDIA SENSOR sub-menu is used to activate or deactivate the media sensors. On the LCD, the active setting is marked with an *. The sensors detect whether media is loaded or detect the end of media. The sensors prevent damage to the cutting strip and knife tip.

FRONT SENSOR The FRONT SENSOR sub-menu is used to activate or deactivate the front media sensors. On the LCD, the active setting is marked with an *. The front sensors detects the front edge of the media. Disabling the front sensors prevent that the media is pulled back in the loading sequence. This is necessary when the pick-up roll is used.

PICK-UP ROLL The PICK-UP ROLL sub-menu is used to activate or deactivate the pick-up roll. When using sheets or when you simply do not want to use the pick-up roll you can switch it off. The default setting is ON. On the LCD display, the active setting is marked with an *.

AUTOLOAD

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The AUTOLOAD option enables the user to the change the vinyl unroll proceedings. When AUTOLOAD is ON , the PC1500X will automatically unroll the media when needed. When the AUTOLOAD option is OFF, the operator himself should unroll enough media before starting to cut. The default setting is ON. Best results and performance are usually guaranteed when using this setting. On the LCD display, the active setting is marked with an *. When using weak or soft materials, e.g. canvas, better results are achieved when autoload is off.

CLEANING The CLEANING sub-menu is used to set the cleaning frequency of the cleaning procedure. While printing the print-carriage moves periodically to the service station to clean the print heads and to spit some ink out of all its nozzles to prevent blocking of the nozzles. It is advised to set the cleaning as low as possible to work faster and save some ink. In this way the reservoirs of the service station can be used longer before they need to be cleaned (see section 3). However if the cleaning frequency is to low, nozzles will block. The default setting is MEDIUM. Cleaning can be set to OFF, LOW, MEDIUM and HIGH.

TOOL COMMAND The TOOL COMMAND is used to determine whether the DM/PL and HP/GL pen/knife-select commands (the P and SP commands respectively) are ignored or accepted. When the TOOL COMMAND option is set to “ACCEPT”, the P or SP commands will change the selected tool in the cutter according to the suffix that follows the pen/knife command. The cutter’s LCD will, e.g. prompt the user with the following message: “INSERT PEN” when a P2 command is sent. When the TOOL COMMAND option is set to “IGNORE”, the pen/knife commands are ignored. On the LCD, the active setting is marked with an *. The default setting is “ACCEPT”.

LOAD ON W COMMAND The LOAD ON W CMD submenu will only be displayed if the PLOT LANGUAGE is set to DM/PL (See Paragraph 1..). The LOAD ON W CMD determines, when receiving the DM/PL Window-command (W-command), whether aside from the scaling function, media is loaded or not. Besides scaling, the W-command is also very useful when cutting long signs. With the Wcommand, media loading will go smoother. Sufficient media will be pulled off the roll at once. Even when AUTOLOAD is off, there is no need anymore to unroll the media manually.

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. 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

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stops at every change of pressure. Pressing the 1 key will activate the configuration menu, which allows you to set the cutting pressure and the cut length. 1. CUT LENGTH This parameter determines the length that is cut with full pressure. By pressing the 1 key, the FLEX-CUT test pattern will be cut. 2. FLEX-CUT LENGTH This parameter determines the length that will be cut with reduced pressure or without pressure. By pressing the 1 key, the FLEX-CUT pattern will be cut. 3. FLEX PRESSURE This parameter determines the pressure of the FLEX-CUT LENGTH. By pressing the 1 key, the FLEX-CUT test pattern is cut.

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INTERNAL TEST MENU 

To access any internal test, proceed as follows:

1.

Power the machine on.

2.

Load cutting or printing media.

3.

Install a knife or a pen.

4.

Press the

5.

Press the

6.

To perform the test, press the

key until INTERNAL TEST is displayed and press the or

jogging key.

jogging key until the desired internal test is displayed. key.

To exit from this menu and go to another menu, press the displayed. To exit from the menus and put the cutter on line again, press the

key until the desired menu is key.

Figure 1 - shows the different INTERNAL TEST submenus.

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FIGURE 1 INTERNAL TESTS SUBMENUS

TANG. KNIFE CALIBRATION The purpose of the knife calibration routine is to detect and, if need be, to correct problems related with the concentricity of the TANGENTIAL knife blade. This routine should only be run when required. When noticing cut quality problems with a new knife, perform a knife calibration test as described in the following paragraphs.

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During the knife calibration routine, the cutter will cut a series of test patterns which will allow you to identify errors in knife rotation and concentricity. Corrective measures can be taken using the control panel keys. Knife calibration errors may be due to any of the following causes (see Fig. 1-5): 

Concentricity misalignment. The knife tip is slightly rotated in relation to its theoretical 0 angle. This error can be corrected by means of the ADJUST ORIGIN test routine.



Horizontal misalignment. The knife tip deviates from its theoretical longitudinal centre. This error can be corrected by means of the ADJUST LONG. test routine.



Vertical misalignment. The knife tip deviates from its theoretical lateral centre. This error can be corrected by means of the ADJUST LAT. test routine.

ORIGIN deviation

LONGITUDINAL deviation

Theoretical 0º angle of the knife

Theoretical centre of the knife LATERAL deviation

FIGURE 1 POSSIBLE KNIFE CALIBRATION GROUNDS

The calibration settings entered during the knife calibration routine are automatically stored in the machine’s memory and will be maintained after power down.

NOTE Prior to knife calibration, load vinyl and install a knife to avoid damage to the cutting strip.

ADJUST ORIGIN TEST ROUTINE 

Press

INTERNAL TESTS CALIBRATE KNIFE to select the ORIGIN test.

ADJUST ORIGIN

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 0 Press

to execute the ORIGIN test.

This is the correctly cut test pattern.

Weed out the ring and compare the circle pattern cut in the vinyl with the circle pattern illustrated above. If you obtained this kind of pattern, increase the value displayed on the LCD by pressing the the

jogging key to correct closing of the circles cut. To repeat the test, press

key.

Press the

key to go to the next step of the calibration procedure

However if you obtained the kind of pattern illustrated above, then, decrease the value jogging key to correct closing of the circles cut.

displayed on the LCD by pressing the To repeat the test, press the Press the

key.

key to go to the next step of the calibration procedure

ADJUST LAT. test routine ADJUST LAT  0 Press

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1

to execute the LAT test.

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1 runs from the horizontal line at the bottom to the centre. 2 runs from the horizontal line at the top to the centre. 3 runs from the centre to the horizontal line at the top. 4 runs from the centre to the horizontal line at the bottom. Carefully check the alignment of the different cuts: the two vertical lines should meet seamlessly precisely in the middle, without any gaps.

Weed out the rectangle and if you obtained the kind of pattern illustrated above, decrease the value displayed on the LCD by pressing the To repeat the test, press the Press the

jogging key to correct closing of the lines cut.

key.

key to go to the next step of the procedure.

However, in case your cut resembles the pattern illustrated above, increase the value displayed on the LCD by pressing the

jogging key to correct closing of the lines cut.

To repeat the test, press the

key.

A complementary test has been added to fine tune the LAT. adjustment. Press the 2 key to perform the vertical test shown above. All the squares should be identical. Press the

key to go to the next step of the procedure.

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ADJUST LONG. TEST ROUTINE ADJUST LONG 0 Press

1

to execute the LONG test.

The test pattern is similar to the LAT-test. Check the quality of the cuts: the end of the vertical cuts should coincide precisely with the horizontal cuts, without any gaps.

Weed out the rectangle and if you obtained a pattern as illustrated above, decrease the value displayed on the LCD by pressing the To repeat the test, press the Press the routine.

jogging key to correct closing of the lines cut.

key.

key to repeat the calibration procedure or press the

key to interrupt the

However, if you obtained a pattern as illustrated above, increase the value displayed on the LCD by pressing the

jogging key to correct closing of the lines cut.

To repeat the test, press the Press the routine.

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key.

key to repeat the calibration procedure or press the

key to interrupt the

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A complementary test has been added to fine tune the LONG. adjustment. Press the 1 key to perform the horizontal test; all the squares should be identical.

CUT BORDER The CUT BORDER sub-menu is used to cut the border of the media area which was defined during the load sequence. This function is particularly useful if you want to verify the exact cutting area.

MENU PLOT The MENU PLOT is a hard copy of the present machines configuration, i.e. the items selected in the USER CONFIG sub-menus described in Section 1.3. The plot is organised by menu categories to show the current values for the various USER CONFIG 1(->4) configurations. To run this plot, load a sheet of plotting paper and install a pen.

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NOTE It is strongly recommended to produce a MENU PLOT hard copy each time you alter the cutter configuration. The resulting plot should be kept with the machine’s documentation in order to provide other users with details of the actual configurations of the unit.

CONFIDENCE CUT 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.

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.

CALIBRATION OPOS. The CALIBRATION OPOS sub-menu is used to calibrate the OPOS (Optical positioning system). This calibration is normally done in the factory. When the system is no longer working precisely a calibration test must be performed. Calibration allows to fix the exact distance between the knife tip and the sensor.  To calibrate the optical system, proceed as follows: 1. Power up the unit and load a piece of black vinyl with a white backing. The load procedure is described in section 1. 2. Set the origin on a clean, blank part of the vinyl. 3. Press the LCD.

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key (MENU) key until the message ‘INTERNAL TEST’ is displayed on the

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 INTERNAL TESTS

4. Press the

jogging key until the message ‘ CAL OPOS’ is displayed.

 INTERNAL TESTS  CAL. OPOS

Press the

key to confirm the selection.

The cutter will now cut out a rectangle.

5. The message ‘WEED RECTANGLE’ will appear on the display: WEED RECTANGLE PRESS MENU Weed carefully with tweezers the rectangle cut and press the

key.

The cutter will now measure the rectangle and set its calibration parameters.

OPTICAL SENSOR The OPTICAL SENSOR option is a useful routine to check whether or not the OPOS sensor is functioning properly. If the sensor is placed above black the sensor output should be High (above 1500). If the sensor is placed above white the sensor output should be low (below 700).

MEDIA CALIBRATION. The OPOS is calibrated to work on a wide range of materials. However certain material will not work with the default setup (high glossy materials). The media calibration test will change the sensor value in such way that it is most reliable to sense the markers.  To calibrate the media, proceed as follows:  Print on the media and with the ink that will be used with OPOS a black square of at least 4x4cm.  Power up the cutter and load that piece of media. The load procedure is described in the SummaSign User’s Manual.  Press the LCD. 

key (MENU) key until the message ‘INTERNAL TESTS’ is displayed on the

INTERNAL TESTS

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 Press the 

jogging key until the message ‘ CAL MEDIA’ is displayed.

INTERNAL TESTS CAL. MEDIA

 Press the

1 2

Service Manual



key to confirm the selection. The following message is displayed.

= SET = MEASURE

 The 1 Option is to set the value manually. This is handy when you have already calibrated this kind of media and you know the value. Or to set the default value back again. Otherwise choose 2 to proceed.

PUT ON WHITE AREA  Click the sensor down and use the arrows to place the sensor on top of a white area. Press on the

key. The cutter will now sense the white area and display following message:

PUT ON BLACK PRINTED AREA  use the arrows to place the sensor in the lower right part of the black printed square. Press on the key. The cutter will now sense the black area.  Normally a value will be displayed on the LCD:

VALUE : 38

This value is a specific value for this kind of media. It is advisable to memorise this value. Later you can calibrate the media quickly by setting this value manually in stead of measuring it.  It may happen that an error message appears. In this case the sensor is not able to differentiate black and white. Make sure that the test has been performed correctly. If OPOS in not able to sense the markers the manual alignment methods can be used.

SYSTEM TESTS The SYSTEM TESTS sub-menu covers the menu items you only occasionally need to adjust. Press the ENTER key to access the different sub-menu items which are explained in section 1.6 below.

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SYSTEM TESTS The SYSTEM TESTS menu is a special set of procedures which are not required for normal cutter operation. Field service personnel, however, will use the SYSTEM TESTS menu occasionally. When in SYSTEM TESTS, the cutter is fully operational and performs as described in this manual.

LANGUAGE The MENU LANGUAGE sub-menu is used to set or modify the dialogue language on the LCD. Press the

or

jogging key until the desired language is displayed on the LCD and press

to confirm. The information on the LCD can be displayed in English, French, German, Dutch, Spanish or Italian.

ROM REVISION Selecting the ROM REVISION option, by pressing the key will furnish the details on the cutter’s ROM revision. This information is often helpful to technicians when diagnosing problems over the telephone.

SERVICE PLOT The SERVICE PLOT provides information about the cutter, which is helpful when requesting service for your cutter. The SERVICE PLOT is always plotted at the same size and should be performed with a pen on paper. The plot shows the cutter model number, the revision numbers of the installed ROM (Read Only Memory) circuits, the selected baud rate, the resolution and buffer (memory) size.

CAUTION The following test routines are normally restricted to CalComp’s Field Service Personnel.

SENSOR SETUP The SENSOR SETUP option is a useful routine to check whether or not the front and rear media sensor are functioning properly and whether the switching levels of these sensors are correctly set.

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CAM SENSOR The OPTICAL SENSOR option is a useful routine to check whether or not the cam sensor is functioning properly. The cam sensor is the sensor mounted to the cut carriage. This sensor senses the location of the pinch rollers.

CALIBRATION CALIBRATION allows to adjust the length of the lines cut, within the specifications. For instance, if a cut line should measure 100 mm exactly, the cutter can be adjusted for any discrepancy.

ROLL TEST The ROLL TEST option is a useful routine to check whether or not the pick-up roll and the pickup sensor are functioning properly. The pick-up roll can be activated by means of the arrow keys.

RS232 TEST The RS232 TEST routine verifies the unit’s 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.

RAM TEST This test completely checks the RAM bit by bit. When running this test the unit will not respond. After this test, power the unit off, then on again.

INSTALL MENU The INSTALL MENU routine restores the factory-defined menu settings in all four USER CONFIG menus. This test routine can be performed without a tool and without media.

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 system’s 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).

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LCD CONTRAST The LCD CONTRAST submenu is used to adjust the contrast (or intensity) of the liquid crystal display on the control panel. Press the

or

jogging key to increase or reduce the contrast and press

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to confirm.

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PRINTER SETTINGS 

To access any printer setting, proceed as follows:

1.

Power the machine on.

2.

Load printing media.

3.

Install the ink cartridges and a knife or a pen .

4.

Press the

5.

Press the

6.

To perform the test (if available) press the

7.

To change parameters (if available), press the

key until PRINTER SETTINGS is displayed and press the or

jogging key.

jogging key until the desired printer setting is displayed.

1 key. key.

To exit from this menu and go to another menu, press the displayed.

key until the desired menu is

To exit from the menus and put the machine on line again, press the

key.

Figure 1-6 shows the different PRINTER SETTINGS sub-menus.

NOTE The printer settings are not stored in the user configurations.

NOTE All the tests described further in this section can also be activated through the SummaPaint Control program. To install this program read the readme.txt file on the installation disk.

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FIGURE 1 PRINTER SETTINGS

NOZZLE TEST To make sure that all nozzles of the 4 cartridges are working properly, do the NOZZLE TEST. Press the 1 key to perform a nozzle test as illustrated in the figure below.

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NOZZLE TEST PATTERN When all nozzles are working fine, the four slanting lines will be continuous. If one color line is interrupted, one ore more nozzles will be blocked. Repeat this test a second time. If some nozzles are still blocked, the cartridge needs to be cleaned (see section 2).

CARTRIDGE CAL. The CARTRIDES CAL(ibration) aligns the cartridges. Press the 1 Key to perform a color calibration test as illustrated below:

After printing the color calibration test you can change the values for the horizontal and vertical offset of the printed color with reference to the black. Select again ‘COLOR CAL.’ key to change the color calibration parameters.

Press the 

CYAN HORZ.  *0



Examine the horizontal and vertical tests carefully. Verify per row in which square the colored lines are in a direct line with the black lines. The value figuring on top of the corresponding column is the value that has to be entered. Press the value. Press the and

and

jogging keys to change the

key to confirm the selection (an * appears in front of the value). Press the

jogging keys to switch between the different parameters. After changing the

values a final test can be done by pressing the 1 Key.

PRINT MODE The PRINT MODE sub-menu is used to set print mode. The PRINT MODE default value is ENHANCED. PRINT MODE can be set to ENHANCED or DRAFT. The draft mode is fast but can only be used for line drawings or technical drawings. For printing pictures the enhanced mode should always be used.

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DIRECTION The DIRECTION sub-menu determines during which print-carriage movement the machine actually prints. The default setting is UNI-LEFT. DIRECTION can be set to UNI-LEFT, UNI-RIGHT and BI-DIRECTIONAL. UNI-LEFT : Printing takes place while the carriage moves to the left. UNI-RIGH : Printing takes place while the carriage moves to the right. BI-DIRECTIONAL: Printing takes place while the carriage moves to the left and also when it moves to the right. The BI-DIRECTIONAL mode is fast but requires an additional calibration (see 1.).

BI-DIR CAL The BI-DIR(ectional) CAL(ibration) aligns the left and right printing movements to each other in order to print bi-directional. In line drawings the result of the bi-directional calibration can easily be seen. Examine whether the lines are smooth. If the lines are not in a direct line then the bi-directional value has to be changed. and

The values can be changed by pressing the

jogging keys. Press the

key to

confirm the selection (an * appears in front of the value).

NOTE When using the SummaPaint Control program, a special test can be activated to do the bi-directional calibrating test.

PRINT / CUT CAL. The PRINT / CUT CAL. calibrates the position of the four cartridges in relation to the cutting head. Press the 1 Key to perform a Print and Cut calibration test as illustrated below:

Result : After printing the Print and Cut calibration test you can change the values for horizontal and vertical offset. Select again ‘PRINT / CUT CAL.’ key to change the horizontal offset.

Press the 

HORZ. OFFSET

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SummaPaint  Press the

and

Service Manual *0



jogging keys to change the value. The value must correspond with the

number of dots the printed part has to move so that printed and cut lines are exactly the same. Moving to the left increases the parameter, moving to the right decreases the parameter. Press key to confirm the selection (an * appears in front of the value). Press the

the

and

jogging keys to switch to the vertical offset. Press the

and

jogging keys to change the value. The value must correspond with the

number of dots the printed part has to move so that printed and cut lines are exactly the same. Moving upwards increases the parameter, moving downwards decreases the parameter. Press key to confirm the selection (an * appears in front of the value). the After changing the values a final test can be done by pressing the 1 Key.

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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. Use the last section of this manual for detailed assembly pictures.

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

    

Do not wipe or touch the cartridge head. The ink nozzles can be damaged. If the contacts of either the cartridge or flex are touched, then isopropyl alcohol is the proper cleaning fluid, because it doesn’t leave residues. 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 SIDE PLATES NOR THE Y-GUIDING. Unplug the line cord 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 and reflection plates free of scratches and dirt.



Keep the guiding, at least dirtfree where the wheels of the carriage pass.

Replacements Guidelines

2-1

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Service Manual

1 2 3 4 5

2-2

left end cover right end cover screws + washers screws + washers body

400-547 400-548 ND5000-9650+ND5000-9639 ND5000-9650+ND5000-9639

6 (3 +2+1) 6 (3 +2+1)

Replacements Guidelines

Service Manual

2.1.

SummaPaint

REMOVING THE LEFT-HAND COVER

To remove the left-hand cover, proceed as follows: 1. Remove the six screws holding the left-hand cover in place. Two are located at the front, one at the rear and three on the bottom. 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 six screws holding the right-hand cover in place. Two are located at the front, one at the rear and three on the bottom. Pay close attention to where each of the screws goes. They should be returned to their original location when re-installed.

! Note ! The rear screw is located in the top corner of the plate, to the left of the three vertically-aligned screws. Remove only the screw in the top corner because the others serve to hold the PCB in place.

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.

!

CAUTION 1. 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. Protruding parts inside the cover can partly unconnect the flat cables and inflict serious damage to several pcb’s 5.

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Service Manual

2.3.

1 2 3 4

2-4

2 screws on each side keyboard and LCD safety cover top cover

ND5000-9277 400-541 400-204 400-147

Replacements Guidelines

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2.4.

SummaPaint

REMOVING THE SAFETY COVER

To remove the safety cover, proceed as follows: 1. Open the topcover by pushing it upward with one hand from underneath the safety cover. 2. Remove the two screws at each side of the safety cover. 3. Remove the safety cover. 4. Be careful not to lose any of the loose parts in the side plate. If the safety covers stays of for a long times, keep them apart. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all the screws.

2.5.

REMOVING THE KEYBOARD - LCD

To remove the keyboard-LCD, proceed as follows: 1. Remove the right-hand cover (see Chapter 2.2. Removing the right-hand cover ). 2. Unplug the keyboard connectors. 3. Remove the two screws holding the keyboard plate. 4. Remove the nut holding the grounding wire. 5. Remove the other three nuts from the bottom of the plate. 6. Remove the keyboard and LCD assy ( fig6.3 page 6-8). 7. Remover the four nuts holding the LCD in place. 8. Remove the LCD . To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

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2.6. 1 2 3 4 5 6 7

2-6

bottom plate fan assy fan guard washer M4 screw M4 x 45 base screw ST4.2 x 9

400-148 400-544 MF0067 ND5000-9315 ND5000-9606

4x 4x secure with loctite 242

ND5000-9795

20x

Replacements Guidelines

Service Manual

2.7.

SummaPaint

REMOVING THE BOTTOM PLATE

To remove the bottom plate, proceed as follows: 1. Remove the right-hand cover (see Chapter 2.2. Removing the right-hand cover ). 2. Disconnect the connectors of the fan. 3. Remove all the tie-wraps of the wires of the fan. 4. Remove the 20 screws holding the bottom plate in place.

6.

! NOTE !

7. 8. Do not pull at the wires of the fans, but guide them gently through the hole. 9. 10. Mind the vacuum baffle (piece of cardboard which separates the service station from the rest of the bottom cavity). 11. 5. Gently pull the bottom cover from under the unit while holding it parallel between the side plates.

To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

!

CAUTION 12. 13. 14. Do not forget to reconnect the fan and make sure the wires cannot touch moving parts. Also tie-wrap them in the same way as they were. 15. Removing or misplacing of the vacuum baffle results in soiling the service station when cleaning of the printhead happens.

2.8.

REPLACING THE FAN MOTOR

To replace the fan motor, proceed as follows: 1. Remove the bottom plate (see Chapter 2.5. Removing the bottom plate). 2. Remove the four screws holding the fan motor in place. 3. Remove the fan motor. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all the screws.

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The wire colour are only as a reference they are subject to change without notice. They are summed up from left to right looking from there rear towards the PCB. Between 7 and 8 are two 2pins connectors unused. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14b 15 16 17 18 19 20

x-motor 1 x-motor 2 y-motor 1 (cuttercarr.) power supply (30V DC) ultrasonic sensor x-encoder y-encoder 1 (cuttercarr.) cam switch media sensors LCD control panel cutter carriage power supply (30V DC) printerhead printerhead fans y-encoder 2 (printer carr.) y-motor 2 (printer carr.) motor pick up roll serial port parallel port

3pins -red blank black 3pins -red blank black 3pins -red blank black 3pins -blank red black 4pins -red orange brown black 4pins -black brown orange red 4pins -black brown orange red 2pins - orange red 5pins -yellow green red brown orange 14pins 15pins 15pins -no label on flatcable 3pins -black red blank 15 pins flatcable labeled front 15 pins flatcable labeled rear 2x2pins -black red 4pins -red orange brown black 3pins -black blank red 3pins -black black red

2.9.

2-8

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2.10. REPLACING THE MAIN PCB To replace the PCB, proceed as follows: 1. Disconnect the power cord, the serial cable and the parallel cable. 2. Remove the right-hand cover (see Chapter 2.2. Removing the right-hand cover). 3. Remove the flat cables from the heads by gently pulling the flat cable out of the connector. 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. Disconnect the various connectors at the top and bottom of the PCB’s. Pay close attention to the position of the connectors. They should be returned to their original location when re-installed. If necessary, mark them 5. Remove the flat cables from the keyboard. 6. Remove the three screws in the side plate which hold the PCB. Pay close attention to the position of the screws. They should be returned to their original location when re-installed. 7. Loosen the earthing clamp(s) so that the earthing wires can be removed. Take the cables, running towards the leg of the stand, out of their cable holders To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all the screws and nuts.

!

16. CAUTION 17. 18. When re-installing, pay close attention to plug the connectors into the correct places. 19. Once the new PCB has been has been installed, it is very important that the data (x and y calibration factors, and the tuning of the heads) stored on the old PCB be brought back in the new one. See further in the manual for how to do this.

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2.11.

1 2 3 4

2-10

motor encoder screws holding motor pulley setscrew pulley

400-526 ND5000-9694 391-198 ND5000-9380

3x (with setscrew)

Replacements Guidelines

Service Manual

SummaPaint

2.12. REPLACING THE X-MOTOR WITH THE ENCODER To replace the X-motor, proceed as follows: 1. Remove the right-hand cover ( see Chapter 2.2. Removing the right-hand cover ). 2. Remove all the tie-wraps leading from the motor to the PCB board, open the ferrite core and disconnect the connectors. 3. Remove the Keyboard ( see Chapter 2.4 Removing the keyboard LCD from 1.  4. ) 4. Remove the three screws holding the x-motor.

!NOTE! As the motor is mounted springloaded, make sure to hold the motor firm, whilst unscrewing the last screw

5. Leave the belt over the big x-pulley as it is. 6. Take the small pulley from the x-motor by unscrewing the setscrew. 7. Solder off the black and red wires and the capacitor. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all the screws and setscrews.

!

CAUTION

Make sure to weld 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 label. Make sure the setscrew of the small pulley is on the flat part of the axis.

Replacement Guidelines

2-11

SummaPaint

Service Manual

2.13.

1 2 3 4

2-12

motor without encoder screws which hold motor pulley setscrew pulley

391-809 ND5000-9694 391-198 ND5000-9711

3x

Replacements Guidelines

Service Manual

SummaPaint

2.14. REPLACING THE X-MOTOR WITHOUT THE ENCODER To replace the X-motor, proceed as follows: 1. Remove the right-hand cover ( see Chapter 2.2. Removing the right-hand cover ). 2. Remove the Keyboard ( see Chapter 2.4 Removing the keyboard LCD from 1.  4. ) 3. Remove the three screws holding the x-motor

!NOTE! As the motor is mounted springloaded, make sure to hold the motor firm, whilst unscrewing the last screw.

4. Leave the belt over the big x-pulley. 5. Take the small pulley from the x-motor by unscrewing the setscrew. 6. Solder off the black and red wires and the capacitor. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws and setscrews.

!

CAUTION

Make sure to weld 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 label. Make sure the setscrew of the small pulley is on the flat part of the axis.

Replacement Guidelines

2-13

SummaPaint

1 2 3 4 5 6

2-14

motor printer head screws holding motor on spacers pulley spacers nuts and washers to hold spacers setscrew pulley

Service Manual

400-526 MH0899 391-198 391-503 MH071 and MH0291 ND5000-9380

3x 3x 3x + 3x

Replacements Guidelines

Service Manual

SummaPaint

2.15. REPLACING THE Y-MOTOR FROM THE PRINTERHEAD To replace the Y-motor proceed as follows: 1. Remove the right-hand cover ( see Chapter 2.2. Removing the right-hand cover ). 2. Remove all the tie-wraps leading from the motor to the PCB board, open the ferrite core and disconnect the connectors. 3. Disconnect the flatcables from the keyboard. 4. Remove the tie-wraps holding the tubes and flatcables to the tie-wrap feet to expose the nuts underneath. 5. Unscrew the three nuts holding the y-motor with the long spacers. 6. Remove the motor with the long spacers. 7. Solder off the black and the red wire and the capacitor from the Y-motor. 8. Remove the three screws from the spacers. 9. Take the small pulley from the x-motor by unscrewing the setscrew. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws and setscrews.

!

CAUTION

Make sure to weld 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 label. Make sure the setscrew of the small pulley is on the flat part of the axis.

Replacement Guidelines

2-15

SummaPaint

1 2 3 4 5 6

2-16

motor printer head screws to hold motor on spacers pulley spacers nuts and washers to hold spacers setscrew pulley

Service Manual

400-526 MH0899 391-198 391-502 MH071 and MH0291 ND5000-9380

3x 3x 3x + 3x

Replacements Guidelines

Service Manual

SummaPaint

2.16. REPLACING THE Y-MOTOR FROM THE CUTTERHEAD To replace the Y-motor proceed as follows: 1. Remove the right-hand cover ( see Chapter 2.2. Removing the right-hand cover ). 2. Remove all the tie-wraps leading from the motor to the PCB board, open the ferrite core and disconnect the connectors. 3. Disconnect the flatcables from the keyboard. 4. Remove the tie-wraps which hold the tubes and flatcables to the tie-wrap feet to expose the nuts underneath. 5. Unscrew the three nuts holding the y-motor with the long spacers. 6. Remove the motor with the long spacers. Keep it aside. 7. Unscrew the three nuts holding the y-motor with the short spacers. 8. Remove the motor with the short spacers 9. Solder the black and the red wire and the capacitor off from the Y-motor. 10.Remove the three screws from the spacers. 11.Take the small pulley from the x-motor by unscrewing the setscrew. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all the screws and setscrews.

!

CAUTION

Make sure to weld 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 label. Make sure the setscrew of the small pulley is on the flat part of the axis.

Replacement Guidelines

2-17

SummaPaint

1 2 3 4 5 6 7 8 9 10 11

2-18

screws holding the cover cover cutter head cutter head mounting screws for cutterhead flat cable connector flatcable connector motor connector encoder connector width sensor connector OPOS system connector coil

Service Manual

ND5000-9160 391-601 400-600 ND5000-9693 400-162

Replacements Guidelines

Service Manual

SummaPaint

2.17. REPLACING THE CUTTERHEAD To replace the cutterhead, proceed as follows: 1. Raise the inserted tool by turning to make sure it does not protrude! 2. Remove the cover of the cutter head by loosening the two screws . 3. Gently pull the flat cable out of the connector . 4. 5. 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 cutterhead, proceed as follows: 1. Place the head back onto the screws. 2. 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. 3. Adjust the height and position of the head. The height must be between 2.7mm and 3mm and the head must be positioned perpendicular to the cutting strip. To do this one can use the adjustments tools, Partnumber are 391-635 and 391-636. The positioning of the head has to be checked or done while the unit powered on without media in it.

! NOTE ! Aside from the standard adjustment tools used in the standard operating procedure, you can use an ordinary 3.1/2” disk to adjust the height and the position of the head. To do this proceed as follows: 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 perpendicular to the cutting surface. Slide the disk under the knife holder. If the disk touches the knife holder the head is mounted too low. 4. Firmly tighten the screws once the cutter head is properly positioned. 5. Put the flat cable back into the connector. To ensure good contact, the flat cable must be positioned as deeply as possible in the middle of the connector. 6. Remount the front cover of the head and firmly tighten the screws.

!

CAUTION 20. 21. 22. Now that the head is replaced, it is extremely important to bring the data stored on the PCB in line with the head and vice-versa. See further .

Replacement Guidelines

2-19

SummaPaint

1 2 3 4 5 6 7

cover printer head screws to hold cover screws to hold the printer head printer head upper screw to tilt the head connector for flatcables connector linear encoder

Service Manual

400-155 ND5000-9785 ND5000-9693 400-550 ND5000-9272

2 on each side the 4 outer ones

CHECK THE LABELS ON IT

1: 6.7mm between carriage and base = 9.7mm from base plate till top of plate printerhead (3) 2: 6.8mm between carriage and base = 9.8mm from base plate till top of plate printerhead (3)

2.18.

2-20

Replacements Guidelines

Service Manual

SummaPaint

2.19. REPLACING THE PRINTHEAD To replace the printhead proceed as follows: 1. Remove the safety cover (see Chapter 2.4. Removing the safety cover ). 2. Close the tubes near to the filling bottles with the attached clamp. 3. Remove the cartridges from the head and put the cartridge clamp on the cartridge. Put the cartridge aside..

! NOTE ! DO NOT LOOSEN THE TUBE CONNECTION. If you do, you’ll have to go through the filling procedure again

4. Remove the cover by unscrewing the four screws at the side. 5. Remove the two flat cables from the PCB. 6. Remove the connector from the encoder. 7. Remove the printer head by unscrewing the four outer most screws holding the plate from the printer head to the carriage.

To re-install the cutterhead, proceed as follows: 1. Put the carriage right beside the capping station. 2. Screw the printhead on the printer carriage with four screws. 3. Measure the distance between the carriage and the plate. It should be 6.8 (0.15)mm at the front and 6.7(0.15)mm at the back. This can easily be measured with a vernier calipers taking into account that the thickness of the plate is 3mm (9.8 and 9.9mm). 4. If the carriage isn’t tilted for .0.1mm upwards, then this can be adjusted with the two mounting blocks at each side of the carriage (unscrew the top screw and adjust with the slotted special screw inside the block). 5. If the printhead is mounted correctly, then continue in the reverse order of removing it starting at 6.

Replacement Guidelines

2-21

SummaPaint

Service Manual

2.20.

1 2 3

det1 det2

2-22

drive drum screws to hold the drum x-pulley

400-511 ND5000-9695 391-152

22x

push all the bearing blocks in the same direction equal distances

Replacements Guidelines

Service Manual

SummaPaint

2.21. REPLACING THE DRIVE DRUM To change the drum-drive proceed as follows:

! NOTE ! Because all the sleeves of the drive drum are accurately matched, it is not possible to replace just one sleeve.

1. Disconnect the power cord and the various cables. Pay close attention to the position of the cables. They should be returned to their original location when re-installed. 2. Remove the right-hand cover (see Chapter 2.2. Removing the right-hand cover). 3. Disconnect the connectors of the fan (at the bottom of the PCB). 4. Remove all the tie-wraps of the wires of the fan. 5. Unscrew the four wingnuts fixing the machine to the stand. 6. Remove the unit from the stand and turn it upside down. 7. Remove the 20 screws holding the bottom plate in place, remove the bottom plate.

23. 25.

! NOTE !

24. Do not pull at the wires of the fans, but guide them gently through the hole.

8. Gently take the belts from the big pulley (do this by pushing the respective motor to the drum and turn the pulley while gently guiding the belt to one side of the big pulley). Put one belt in front of and one behind the big pulley. 9. Remove the pulley by unscrewing the setscrews. 10.Remove the 22 screws from the bearing blocks. 11.Disconnect the front sensor from the rear sensor and cut the tie-wraps, if any. 12.Take the drum out of the unit.

To re-install, proceed as follows: 1. Place the drum in the base plate. 2. Put the screws into the blocks but do not tighten them yet.

Replacement Guidelines

2-23

SummaPaint

1 2 3

det1 det2 det3

2-24

Service Manual

drive drum screws to hold the drum x-pulley

22x

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

Replacements Guidelines

Service Manual

SummaPaint

!

26. CAUTION 27. 28. 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: 29. 1. Secure the block to the left (or right) of the large sleeve by tightening its screws. Make sure the block is positioned perpendicular over the holes and that the long sleeve is situated in the middle of the hole of the base plate. 2. Press the block to the right (or left) of the large sleeve firmly against the sleeve and tighten the screws of the block. 30. 31. Also make sure all the blocks are pushed in the same direction while being fastened (either up or down). 32. 3. Now firmly tighten the screws of the other blocks. Make sure they are positioned straight and that they do not have any play. 4. Proceed in the reverse order of removal. Make sure to firmly tighten all the screws.

Replacement Guidelines

2-25

SummaPaint

Service Manual

2.22. 1 2 3 4 5 6

2-26

rear sensor spacer screw front sensor screw spacer

400-513 ND5000-9617 ND5000-9694 400-515 ND5000-9694 ND5000-9617

Replacements Guidelines

Service Manual

SummaPaint

2.23. REPACING THE MEDIA SENSORS The unit is equipped with two media sensors. One is located at the front and the other one at the rear of the machine.

! NOTE ! When one sensor is malfunctioning it is advisable to replace both sensors. Experience shows that soon after replacing the broken sensor, the other sensor tends to start malfunctioning as well. Therefore, to avoid having to perform the same repair twice within a short span of time, it is advisable to replace both sensors at the same time.

To replace the media sensors proceed as follows: 1. Remove the right-hand cover (see Chapter 2.2. Removing the right-hand cover). 2. Remove the bottom plate (see Chapter 2.5. Removing the bottom plate). 3. Remove all the tie-wrap from the media sensor cable and disconnect the cable from the PCB. 4. Remove the screws holding the two sensors in place. Pay close attention to the position of the spacers. They should be returned to their original location when re-installed. 5. Disconnect the other end of the sensor wire from the PCB. 6. Remove the sensors. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

!

CAUTION 33. 34. 35. Make sure the sensor wire does not touch the drum. The rotating drum may damage the wire and cause malfunctioning. 36. 37. Also check whether the sensors aren’t sticking out. 38.

Replacement Guidelines

2-27

SummaPaint

1 2 3 4 5 6

2-28

screw for reflection part reflection part camroller setscrew shaft camroller camroller start here to peel of pink strip

Service Manual

ND5000-9780 400-102 ND5000-9196 390-142 391-326

2x

Replacements Guidelines

Service Manual

SummaPaint

2.24. 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. Clear all the debris out of the cutting strip slit and degrease it. 4. Cut the new cutting strip to the correct length and stick it onto the unit.

Replacement Guidelines

2-29

SummaPaint

Service Manual

2.25. REPLACING THE CAMROLLERS To replace the camrollers, proceed as follows: 1. Remove the safety cover. (see Chapter 2.4. Removing the safety cover ). 2. Remove the reflector block from the camroller assy. 3. Remove the setscrew on both sides of the camroller. 4. Remove the pin (push on the left side of the shaft). 5. Remove the camroller.

! NOTE ! Camrollers come in pairs. When one is malfunctioning or broken, both the outer camrollers need to be replaced. The centre camroller does not matched with the two edge camrollers and can be installed independently.

To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all the screws.

!

CAUTION 39. 40. 41. It is extremely important that the camroller be stable and stationary. To achieve this, press one side of the camroll shaft while tightening the setscrews. 42.

2-30

Replacements Guidelines

Service Manual

1 2 3 4

SummaPaint

cover cutterhead screws and washers which hold steel strip screws which hold flatcable holder flatcable and steel strip glued along here

Replacement Guidelines

2-31

SummaPaint

Service Manual

2.26. REPLACING THE FLATCABLE OR STEEL STRIP FOR THE CUTTER HEAD To replace the flat cable or steel strip, 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. Open the top cover. 4. Loosen one end of the flatcable (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. 5. Pull the flatcable free as far as the side plate. 6. Remove the two screws holding the steel strip (Mind the order of washers !). 7. Loosen the flat cable and steel strip which has been glued along the length of the top beam. 8. Remove the screws of the cover of the head. 9. Remove the cover. 10.Loosen the end of the flat cable attached to the head. Follow the same procedure as before (see point 5). 11.Remove two screws from flatcable holder. 12.Remove the two screws holding the flatcable and steel strip in place.

! NOTE ! Pay close attention to the way the flatcable has been folded. The flat cable will need to be folded exactly the same way when re-installed.

To re-install, proceed as follows: 1. Put the flatcable and steel strip in the flatcable holder . 2. Mount the flatcable clamp back on the carriage. Make sure that the flatcable and steel strip runs parallel to the top beam . 3. Slide the carriage a couple of times from left to right to see if the flatcable and steel strip run smoothly. 4. Proceed in the reverse order of removal starting at 10 .

!

CAUTION 43. 44. 45. 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.

2-32

Replacements Guidelines

Service Manual

1 2 3 4 5

SummaPaint

hole feeding the tubes to the outside nut holding shielding strip chain lift 3 screws between the tubes screws chain lift

1 2 3 4 5 6

tubes grey tube steel strip flatcables chain assy tubes

Replacement Guidelines

400-146

MH0071 400-179 ND5000-9693 ND5000-9786

2.27.

400-178 400-162 400-144 400-556

2-33

SummaPaint

Service Manual

2.28. REPLACING THE TUBE ASSY FOR THE PRINTER HEAD To replace the flat cable or steel strip, proceed as follows: 1. Remove all the ink from the tubes. Close the clips on the tubes of the bottles 2. Disconnect the tubes from under the tray . 3. Remove the right-hand cover (see Chapter 2.2. Removing the right-hand cover). 4. Remove the safety cover (see Chapter 2.5. Removing the safety cover). 5. Remove all the tie-wraps from around the tubes. 6. Disconnect the three flatcables on the PCB board. 7. Unscrew the nut holding the big washer holding the steel strip. 8. Put the flatcable of the cutter head aside. 9. Remove the chain lifts. 10.Unscrew the chain from the top beam (small screw is at the front). 11.Remove the assy from the printer head carriage (3 screws between tubes). 12.Remove the ferrite cores from the flatcables. 13.Gently pull the cables and tubes and steel strip out of the chain.

! NOTE ! Pay close attention to the way everything has been folded. Everything will need to be folded exactly the same way when re-installed. On older models, the steel strip is between side plate and upper pulley holder, just pull it from between or cut it real close to the upper pulley holder.

To re-install, proceed as follows: 1. Gently lead the flatcables, tubes and steel strip through the chain . 2. Proceed in the reverse order of removal starting at 12.

46. ! NOTE ! 47. Before refitting the steel strip to the upper pulley holder, cut it the same way the old one was. 48. If the tubes or flatcables are changed separately, the same procedure can be used, however it advisable to change them all at the same time. 49.

2-34

Replacements Guidelines

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SummaPaint

2.29.

Blank page

Replacement Guidelines

2-35

SECTION 3 GENERAL INFORMATION 3.1.

MAINTENANCE & CLEANING

The SummaPaint PC1500X 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, which may affect the performance of the machine. Keep the SummaPaint PC1500X 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 SERVICE STATION.

NOTE When the machine is used intensively the service station must be cleaned daily.

The service station contains ink reservoirs. The head will spit in these reservoirs periodically to prevent the nozzles from blocking. If the service station is not cleaned regularly, the ink will overflow and cause difficulties. 

To clean the service station, proceed as follows:

1. Set the cutter's power switch to OFF. 2. Move the two carriages manually away from the service station.

Maintenance and Cleaning

3-1

SummaPaint

Service Manual

FIGURE 3 CLEANING THE SERVICE STATION

3. Lift the service station moving it a little to the side so that it comes free from the machine body. 4. First hold the complete service station under water allowing most ink to flow away, then clean it more carefully with a soft dampened cloth. 5. Dry the service station as well as you can to prevent corrosion. 6. Place the service station back in place. 7. Move the service station as far as possible to the left.

3.1.2

CLEANING CARTRIDGES

When a cartridge has blocked nozzles, try the following suggestions to make them work again. Repeat the first suggestion a few times before trying the other suggestions.

3-2

Maintenance and Cleaning

Service Manual

SummaPaint

Copper Contacs

Print nozzles FIGURE 3 CLEANING INK CARTRIDGE

 Clean the nozzles with a soft dampened cloth. Pressing the sides of the cartridge will force ink to come out of the nozzles. Do this while holding the print nozzles downwards.  Clean the copper contacts of the cartridge with a soft cloth.  Clean the copper contacts of the print carriage with a soft cloth.  To find out whether a cartridge is not working properly anymore due to blocked nozzles or bad contacts, switch two cartridges from place and repeat the prime test.  If the cartridge is still not working fine, force some ink to come by pumping air in the ink bottles with the priming bulb while printing. However, do not do this when printing final pictures. The cartridge could start leaking for a while.  If the cartridge is still not working fine, place it on top of a wet (destilled water)cloth during a few minutes so that the water has time to dissolve the blocked nozzles.

3.1.3

CLEANING THE DRIVE SLEEVES

After a time, the sleeves of the drive drum may become clogged with accumulated residue from the media. This situation may affect the traction as the media will tend to slip between the pinch rollers and the drive sleeves. 

To clean the drive sleeves, proceed as follows:

1.

First disable the sensors by covering them, or via the configuration menu .

2.

Place the cutter in local operation. (See Section 1.2.2.) Local operation will allow you to use the control panel jogging keys, even when no media is loaded.

3.

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.

Maintenance and Cleaning

3-3

SummaPaint

Service Manual

4.

Use the and jogging keys to move the piece of vinyl backward and forward several times until all residue is removed from the drive sleeves.

5.

Raise the pinch roller arm and remove the piece of vinyl.

6. Repeat steps 3 through 5 for the other drive sleeves. 7.

Set the machine’s power switch to OFF.

VINYL STRIP

PINCH ROLLER

TACKY SIDE ON BOTTOM

SLEEVE

FIGURE 3 -

CLEANING OF THE DRIVE SLEEVES

3.1.4

CLEANING THE SENSORS.

3.1.5 After a certain time, the sensor may become dirty with accumulated residue from the media. This situation may cause malfunctioning of the unit. 

To clean the sensor area, proceed as follows:

1.

The sensors are located on the machine’s right side. One sensor is located on the front platen, the other sensor is located on the rear platen.

3-4

Maintenance and Cleaning

Service Manual

SummaPaint

FIGURE 3 -

LOCATION OF THE SENSORS

2.

To keep the sensors clean, it is sufficient to wipe them out now and then with a cotton swab.

3.1.6

CLEANING THE NOSE PIECE.

3.1.7 The nose piece may become dirty with accumulated residue from the vinyl, which will result in poor cut quality. 

To clean the nose piece, proceed as follows:

1.

Gently take out the knife or ball-point pen by turning the knife holder anticlockwise.

2.

Observe the orientation of the nose piece first and then push it out of its holder.

3.

Remove any remaining vinyl residue using a brush or a pair of tweezers.

4.

Place the nose piece back.

5.

Install the knife or ball-point pen holder.

Maintenance and Cleaning

3-5

SummaPaint

3.1.8

Service Manual

CLEANING THE Y-GUIDING.

After a certain time, the y-guiding may become dirty with dust and accumulated residue from the carriage wheels. This may lead to bad printing and bad cutting quality. 

To clean the y-guiding, proceed as follows:

1. Set the machine’s power switch to OFF, and open the safety cover. 2. The Y-guiding is the guiding on which the two carriages (print en cut carriages) are moving.

FIGURE 3 CLEANING THE Y-GUIDING

3. Clean the surfaces that are under a 45 degree angle with a soft dampened cloth(both on top and underneath).

4. Move the carriages manually so that you can clean the complete guiding.

3.1.9

CLEANING THE ENCODER STRIP.

After a certain time, the encoder strip may become dirty, which may cause the drawing to shift while printing.

CAUTION The encoder strip is an essential and very fragile part. Handle it with extreme care.

3-6

Maintenance and Cleaning

Service Manual 

SummaPaint

To clean the encoder strip, proceed as follows:

1. Set the machine’s power switch to OFF. 2. Open the safety-cover partly with one hand, and reach with the other hand under the safety cover to open the top cover.

FIGURE 3 CLEANING THE ENCODER STRIP

3. The encoder strip is situated about 2,5 cm (1”) behind the Y-guiding . 4. Clean both sides of the strip extremely carefully with a soft dampened cloth. Move the carriages manually so that you can clean the complete strip.

3.1.10 CLEANING THE OPOS SYSTEM. The optical system will collect dust. It is therefore advised to clean the sensor regularly with a cotton bud. The sensor has a small hole so that it can be cleaned easily.

Maintenance and Cleaning

3-7

SummaPaint

Service Manual

Cutting Head OPOS SYSTEM

Hole FIGURE 3 CLEANING THE OPOS SYSTEM

3-8

Maintenance and Cleaning

Service Manual

SummaPaint

3.1.11 3.1.12

3.1.13

Maintenance and Cleaning

3-9

SummaPaint

Service Manual

3.2. 3.3.

OPERATING VOLTAGE CONVERSION

Before operating the machine for the first time it is advised to check the fuse rating for security reasons. To check the fuse(s), remove the fuse(s) from the fuse box behind the cover plate of the power entry module. Changing to another operation voltage also implies a change of the fuse rate. For 100 or 120 V AC operation, use only T 4 A,250V fuses, 5 x 20 mm (MF9004). For 220 or 240 V AC operation, use only T 2 A,250V fuse, 5 x 20 mm (MF9003).

FIGURE 3 POWER ENTRY MODULE

Fuse change ( see Figure 3 - ) : - Unplug the power supply cable - Remove the fuse block - Replace the fuse with the correct fuse that corresponds with the nominal voltage - Re-install the fuse block

NOTE Always make sure that you are using the correct fuses for your voltage selection.

3-10

Maintenance and Cleaning

Service Manual

SummaPaint

BLANK PAGE

Maintenance and Cleaning

3-11

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

Calibration

4-1

SummaPaint

4.1.

Service Manual

MEDIA CALIBRATION

I. CALIBRATION OF THE X-AXIS 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 thickness 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 thickness 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 SsummaPaint Control program. Select “calibration” in the “configuration” menu. Select “Calibrate x-axis”.

 measure the test pattern and enter it 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).

4-2

Calibration

Service Manual

SummaPaint

II. CALIBRATION OF THE Y-AXIS 1. The unit has to be recalibrated when :  the linear encoder strip has been replaced  the camrollers have been replaced  the PCB has been replaced or defaulted

!NOTE! This calibration is very important when using the cut and print feature of the machine. 2. Calibration:  Load media in the machine (the wider the media, the more accurate the calibration will be).  start the SummaPaint Control program.  Select “calibration” in the “configuration” menu.  Select “Calibrate y-axis”.

 measure the two test patterns and enter the measurements in their respective dialogue box.

Calibration

4-3

SummaPaint

4.2.

Service Manual

CUTTERHEAD CALIBRATION

I. KNIFE CALIBRATION It is recommended to recalibrate the knife, each time it is changed. See section 1.6.1. 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.  Go to to internal system tests - coil set-up. Press the  The following message is displayed on the LCD :

key.

40 g PRESSURE 19 In the upper line of the LCD the desired pressure is displayed and the bottom line showes the value that has to be sent to the head to reach the pressure displayed. key.  Press the  The following message is displayed on the LCD : 600 g PRESSURE 110  If you have a tension gauge of ± 600g you can check if the pressure is 600 gr. You can adjust the 600gr pressure with the pot-meter located right besides the connector for the LCD en keyboard on the main PCB.  If you don’t have a tension gauge, leave it at 110 .  Press the key.  The following message is displayed on the LCD : 40 g PRESSURE 19  If you have a tension gauge of ± 100g you can check if the pressure is 40 gr. If lavalue lower than 40 gr. is shown on the tension gauge press the

key to adjust. If a value

higher then than 40 gr. is recorded on the tension gauge use the  If you don’t have a tension gauge leave it at 19.

key to adjust.

 Insert the drag knife holder into the tangential head.

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SummaPaint

 Press the key to adjust the ball-point pen landing pressure. The following message will be displayed : DRAG LANDING 14  Press the

key repeatedly until the ball-point pen moves upwards (value around 2).

 Press the 11).

key repeatedly until the ball-point pen holder moves down (value around

 Press the

key another three times.

 Insert the ball-point holder into the tangential head.  Press the key to adjust the ball-point pen landing pressure. The following message will be displayed : PEN LANDING 14  Press the

key repeatedly until the ball-point pen moves upwards (value around 2).

 Press the around 11)

key repeatedly until the ball-point pen holder moves downwards (value

 Press the

key another three times.

 Insert the tangential knife holder into the tangential head (the knife may not stick out).  Press the key to adjust the ball-point pen landing pressure. The following message will be displayed : PEN LANDING 14  Press the around 2).

key repeatedly until the ball-point pen goes in the up position (value

 Press the 11)

key repeatedly until the ball-point pen holder moves down (value around

 Press the

key another three times.

 Press the

(ONLINE) key and power the machine down.

! NOTE! For a good cutting quality, the values of the landings have to be at least 3 less then the 40g pressure

Calibration

4-5

SummaPaint

4.3.

Service Manual

PRINTERHEAD CALIBRATION

I. CARTRIDGE CALIBRATION

!NOTE! Although the cartridge calibration is already described in section 1.8. follows a short explanation on how to calibrate the cartridges with the SummaPaint Control program. It is recommended to do the tests with this program instead of using the internal tests. 1. The cartridge calibration has to be done when:    

Each time the cartridges have been out of their holders. The controlbox has been replaced (the values are stored in the control box) The cutterhead has been replaced (only the print/cut calibration) The cutterhead has been replaced

2. Calibration and selftest  Load media. Put the cartridges in place and insert a tool in the cutterhead.  Start the test “Tune Heads” on the SummaPaint Control program.

 Use the Prime Test to check the print-head and the cartridges.

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 When all nozzles are working fine, the four slanting lines will be continuous. If one colour line is interrupted, one ore more nozzles will be blocked. Repeat this test a second time. If some nozzles are still blocked, the cartridge needs to be cleaned.  Start the Alignment Pattern test

 After printing the colour calibration test you can change the values for the horizontal and vertical offset of the printed colour with reference to the black.  Click on Check Pattern to verify the alignment.

 Start de Offset Test. Type the value, that has the smoothest line with it ,in.

 Make sure the installed tool in the cutterhead is mounted correctly.  Start the Print & Cut.  The printed and cut out pattern depends on the way the tuning of the heads test was started up. If the box was normally clicked then the following pattern is shown.  Check which pattern is correct and fill in the values.  If the box was clicked while holding down the Shift key then the following pattern is shown.

Result :  If the normal test was not sufficient then this test is necessary. Now the offset can be changed drastically. One step is 1/300 of an inch  Start the test again to check the result.

Calibration

4-7

SummaPaint

4.4.

Service Manual

OPOS CALIBRATION

I. NORMAL CALIBRATION Normal calibration of the OPOS system is explained in section 1.6.6. until 1.6.8. However, when this doesn’t work there is an extra calibration method for fine tuning.

II. FINE TUNING 1. The Opos system has to be fine tuned when:  the normal calibration didn’t do the job.  the Opos system has been removed from the head.  The markers are extremely glossy (sometimes with photoquality with thermal wax transfer). 2. Calibration: Calibration of the Pot meters: There are two pot meters on the Opos assy. Normally they are hidden behind a black piece of vinyl at the front of the assy. The left pot meter adjusts the gain of the sensor. The right one adjusts the “white level”. To accomplice a good calibration you must use shiny white media and mat black (mat: a black square printed with SummaPaint ink on CalComp mat media with a SummaPaint, shiny: a piece of CalComp laminate on CalComp mat media) The procedure is as follows:

a) Start the internal “OPTICAL SENSOR” test. (power on the machine, press key twice to go to “INTERNAL TEST” - press the “SYSTEM TESTS” - press the

key - press the

key twice to go to key three times to got to

“OPTICAL SENSOR” - press the key. b) Turn the left pot meter completely to the right (CW) until you hear or feel a click (maximum 15 turns CW). The gain is now at its minimum c) Place a piece of shiny white media under the Opos sensor (make sure the sensor is perpendicular to the media). Turn the right pot meter CCW until the value on the LCD clearly increases (up until 300 if possible). Now turn the right pot meter CW until the value does not decrease any more. This has to be set very precise. Turn CCW and again CW if you think you have turned too far. Now move the media under the sensor (making sure the sensor stays perpendicular) and watch whether the value does not increase any more. If the value increases, place the sensor above this section of the media and adjust the right pot meter again following the above procedure. d) Place a piece of matte black under the sensor and turn the left pot meter CCW until the value on the LCD screen reaches 1800. e) Check the white value again. f) Go to “CAL. MEDIA” test (one sub menu lower – not in system test). Press choose option “1=SET” and enter value 30. Now the machine can calibrate itself on the media. This means then the unit calculates the best value for one combination of ink-media-laminate. With this test the machine first measures a piece white and then a piece of black (a square of app. 4cm is large enough - then put the sensor in the lower right corner). If the difference between black and white is big enough then a value for this media will appear on the LCD screen. If however this combination is not stable then the machine will give a message.

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Remember this test must only be performed if the default value of 30 does not suffice (which means that you have a stubborn combination of media-ink-laminate) 

!NOTE! When the OPOS system still fails to work properly, do the fine tuning on the media giving trouble. Change the “matt white media” with the troublesome media and change “glossy black media” with the marker on the troublesome media. If everything else fails just try to make the difference, between the readout above the markers and the media, more then 800. The left pot meter changes the gain and the right pot meter changes the threshold level between black and white.

Calibration

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SummaPaint

4.5.

Service Manual

SENSOR TESTS AND CALIBRATION

I. MEDIA SENSORS The front and rear media sensors can be tested with internal test as described in section 1.7.4. . 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.

II. CAM SENSOR If the machine doesn’t sense the position of the camrollers anymore, follow the following procedure: 1. Power the machine up without any media. 2. Go to the test “CAM SENSOR” 3. Lower the camrollers, put the sensor of the cuttinghead above a reflection part of a camroller. 4. Lower or raise the sensor until you get a value higher than 300. 5. Check whether the reflection block doesn’t touch the sensor in the up position.

III. LINEAR ENCODER SENSOR When the machine makes all the movements it is supposed to do but does not print, then the linear encoder sensor may be defective. To check whether it functions properly, do the following: 1. Turn the machine off but leave the controller box on. 2. Gently slide the printercarriage from the left to the right manually while checking the LED marked “y” on the controller box. If it flickers from red to green then everything is OK. 3. If it doesn’t work either replace or reposition it.

!NOTE! If the sensor is repositioned or replaced make sure that the encoder is mounted as shown on the fig below (encoderstrip 1/3 from the back)

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Calibration

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4.6.

SummaPaint

SERVICE STATION CALIBRATION

I. MECHANICAL CALIBRATION 1. The mechanical calibration has to be done when:  The printerhead has been replaced.  the service station has been replaced. 2. Calibration:  Make sure the machine is powered off.  Check whether the capping cushions are mounted correctly (see fig).

 Move the printerhead first to the left then to the right until the printerhead touches the right stop of the service station. The inkjethead should now be exactly above the capping cushions. If not, reposition the right stop with the screws on the front. Then set the left stop as high as possible and in such a way that there is a little play for the printer head.

 Check whether all the wipers touch the inkjet heads, when the printer head is moved completely to the right.

Calibration

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Service Manual

3. Fine tuning: There is an internal calibration to change the cleaning and capping position. However this test can only be accessed via FactorySetupMode (FSM or 3-key).

!

1. CAUTION 2. FSM is normally a mode just used in factory. Be extremely careful while in that mode and follow the given guidelines to the letter. You can inflict serious damage beyond repair to the machine if the wrong parameters are changed.

(1) Power on the machine while holding down the (2) Wait until the display shows .

,

1 and

key.

FSM (3) Press the key (4) Load media. (5) Goto internal test - system test. key. (6) Press the (7) Goto internal tests - capping set-up. (8) Press the

key.

(9) Press the or key until the black printhead is in the middle above the right ink dump reservoir

4-12

(10)

Press the

(11)

Press the or key until the printcarriage is in the middle of the two maximum pressure points of the capping cushions against the cartridges.

(12)

Press the

(13) (14)

key. Press the Power the machine down.

key.

key.

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SummaPaint

Blank Page

Calibration

4-13

SECTION 5 Troubleshooting - Error codes General This section contains information on the error codes which can appear on the LCD screen. A step-bystep procedure is provided in this section to ensure this error doesn’t occur any more.

Troubleshooting-Error Codes

5-1

SummaPaint

5.1.

Service Manual

MOTOR HOT

Cause: Heavy media can overload the motors, especially the X-motor. The µP on the PCB calculates the power dissipated in the motors. When this dissipation becomes too high, the message MOTOR HOT appears. This is not a fatal error. After a while this message will disappear and the machine will continue its operation. Action: 1. 2. 3. 4. 5. 6.

5.2.

Wait until the motor has cooled down to an acceptable level. Lower the speed using the menu and use a lower knife pressure if possible. Use lighter or smaller media. Check the cam rollers, replace any damaged cam rollers. Call CalComp for assistance. A system register may have changed the default value. Check whether the drive drum is turning smoothly (first switch the machine off and place the cam rollers in the up-position). Replace motor and/or drum.

ERROR IN X-AXIS

Cause: 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

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5.3.

SummaPaint

ERROR IN Y-AXIS POSITION

Cause: 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. If this error occurs during media loading and the head bashes against the left, then it could be that the media sensor doesn’t work any more. -> Check media sensor with internal test. Replace if necessary. 6. Replace the Y-motor of the machine head. 7. Replace the PCB.

5.4.

ERROR IN Y-2 AXIS POSITION

Cause: The motor driving the printer 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. 2. 3. 4. 5.

Remove the crashed media and restart the machine. Check whether the head moves smoothly (first turn the power off). Check the y-axis motor of the printer head and the encoder cables. Replace the Y-motor of the printer head. Replace the PCB.

Troubleshooting-Error Codes

5-3

SummaPaint

5.5.

Service Manual

LOW LINE VOLTAGE

Cause: The secondary voltage of the power supply is measured by the µP on the PCB. When it measures a value lower than the lower limit setting, the machine will give this error. This is a fatal error. Switching the power off and making a corrective action is the only solution. Action: 1. Measure the line voltage. The line voltage should be between 88V and 132 V or 176V and 264 V. 2. Check the secondary voltage of the power supply. It should be at least 27VAC. If that is not the case, replace the power supply. 3. Check the DC power on the PCB (on the power cable going to the machine interface board). It should be at least 27VDC.. 4. Disconnect the motor cables, the encoder cables, the flat cable going to the head, the fan cable, the sensor cables and the 28V power cable going to the machine interface board, and switch the machine on again. 5. When you have done this, plug in the cables one by one until the energy consumer is found. Replace it. 6. Replace the main PCB.

5.6.

HIGH LINE VOLTAGE

Cause: The secondary voltage of the transformer is measured by the µP on the PCB. When it measures a value higher than the upper limit setting, the machine will give this error. This is a fatal error. Switching the power off and making a corrective action is the only solution. Action: 1. Measure the line voltage. The line voltage should be between 88V and 132 V or 176V and 264 V. 2. Check the secondary voltage of the power supply. It should be less than 37VAC. If that is not the case, replace the power supply. 3. Check the DC voltage on the PCB. It should be less than 37VDC. 4. Replace the main PCB.

5-4

Troubleshooting-Error Codes

Service Manual

5.7.

SummaPaint

ILLEGAL PLOT COMMAND

Cause: For DMPL, when a wrong set of instruction is sent to the machine. This message only appears when the machine is configured to report DMPL ERRORS. Action: 1. Set DM/PL ERRORS to IGNORED in the MENU to avoid this message. 2. If the cut result is not satisfactory, lower the baud rate at the machine side and at the computer side. If the parallel interface is used, make the cable shorter. 3. Check the cut file for unknown dm/pl commands.

5.8.

ILLEGAL CLIP & SCALE SETTINGS

Cause: Appears when wrong parameters are sent after a W command in DMPL. This message only appears when the machine is configured to report DMPL ERRORS. Action: 1. Set DM/PL ERRORS to IGNORED in the MENU to avoid this message. 2. If the cut result is not satisfactory, lower the baud rate at the machine side and at the computer side. If the parallel interface is used, make the cable shorter. 3. Check the cut file for unknown dm/pl commands.

5.9.

SYNTAX ERROR

Cause: 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

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.

Action: 1. Change the data sent to the machine. 2. Refer to the HPGL supported commands.

5.10. NVRAM FAILURES AND MESSAGES Troubleshooting-Error Codes

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Non fatal errors: SYSTEM NVRAM HAS BEEN DEFAULTED DUE TO ROM CHANGE, USER NVRAM HAS BEEN DEFAULTED DUE TO ROM CHANGE Action: 1. Message appears when rebooting the machine for the first time after an upgrade of the ROM’s. 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: SYSTEM NVRAM CHECKSUM FAILURE - SYSTEM NVRAM HAS BEEN DEFAULTED TRY TO REBOOT MACHINE, 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.

5.11. RS232 ERROR Cause: 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. Be 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

Troubleshooting-Error Codes

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SummaPaint

5.12. INTERNAL ERRORS Cause: 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: Error Number 1 2 3 4 5 6 7 8

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

Action: 1. This is an internal error. The cause of this error may be an unknown firmware problem in the machine's EPROM’s. Do the internal confidence test. If this test is OK, check the data sent to the machine. 2. Reflash the ROM’s on the main board. 3. Replace the main PCB.

5.13. FLASHING ERRORS AND MESSAGES Non fatal errors: ERASING FLASH, PROGRAMMING,READING IN FLASH FILE Action: Message appears when the internal ROM’s are being reflashed. Just wait untill the operation is done.

Fatal errors: ORDER ROM COULD NOT ERASE FLASH CORRUPTED UPGRADE FILE Action: 1. Those are fatal errors. The information in the internal ROM’s is not reliable any more. 2. Order ROM’s and do an internal reflash. 3. Change main PCB.

5.14. ROM ERROR Troubleshooting-Error Codes

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Cause: ROM’s are going bad. Action: 1. Reflash the ROM’s. 2. Replace the main PCB.

5.15. RAM ERROR Cause: RAM’s are going bad. Action: Replace the main PCB.

5.16. MACHINE UNABLE TO FIND THE KNIFE HOME POSITION Cause: The machine doesn’t find the home position for the tangential knife. Action: 1. Check whether the knife holder turns smoothly when the power is switched off. If not, something is wrong with the T-head. Replace the head or check the mechanical parts of the head. 2. Check the connection cable, which runs from the head to the PCB. 3. Check the machine with another head. 4. Replace the flat cable which runs from the head to the PCB. 5. Replace the main PCB.

5-8

Troubleshooting-Error Codes

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SummaPaint

5.17. MARKERS NOT SENSED PROPERLY Cause: The machine has trouble during its special load sequence. Action: 1. Check whether there is dust on the sensor tip. 2. Make sure that the markers are black on a white surface. 3. Run the "OPTICAL SENSOR " test and use black and white vinyl to check the different reflection levels. 4. Make sure that the right settings are sent to the machine to sense the markers. 5. Check the flat cable going from the head to the PCB. 6. Should there still be problems, change OPOS.

5.18. TIMEOUT ERROR ON CONTROL PORT B, CHECK CONNECTION Cause: The main PCB doesn’t communicate with the printer controller. Action: 1. Turn the machine off. Wait 10s. Power on the machine. Do a print and cut test to check if everything works. 2. Replace the printer controller. 3. Replace the main PCB.

5.19. COULD NOT START INTERNAL TEST, PLEASE RETRY Cause: The internal test, started from the main PCB could not reach the printer controller. Action: 1. Just push 1 and retry (works if there was a timeout error). 2. Turn the machine off. Wait 10s. Power on the machine. Do a print and cut test to check if everything works.

Troubleshooting-Error Codes

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5-10

Troubleshooting-Error Codes

Figures

6-1

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

Figures

6-1

SummaPaint

Service Manual

fig. 6-1a service station

1 2 3 4 5 6 7 8 9

6-2

400-113 400-115 400-114 ND5000-9789 ND5000-9283 ND5000-9785 ND5000-9490 ND5000-9787 ND5000-9693

sliding plate front sliding plate rear end piece capping station spacer M3x35 spcer M3x2 screw M3x10 ISO7380 cable guard spring screw M3x7

Figures

Service Manual

SummaPaint

fig. 6-1b service station

1 2 3 4 5 6

400-112 428-610 428-620 ND5000-9786 ND5000-9788 ND5000-0670

Figures

mounting profile rubber prinhead cap rubber wiper screw M3x40 spacer 3x6x20 nut M3 DIN 985

6-3

SummaPaint

Service Manual

fig. 6-1c service station

1 2 3 4 5 6 7 8 9

6-4

400-112 ND5000-9781 ND5000-9377 ND5000-9231 ND5000-9568 ND5000-9784 ND5000-9676 ND5000-9806 ND5000-9782

mounting profile spacer M4 screw M4x8 lockwasher M4 teflon strip clip M5 o-ring 4.1x1.6 o-ring 5.23x2.62 pen 5x50

Figures

Service Manual

SummaPaint

fig. 6-2a printer head

1 2 3 4 5

Figures

400-170 400-152 400-171 ND5000-9801 ND5000-9668

flexibele platine main plate printhead gummikusen nylon washer M2 screw M2x5

6-5

SummaPaint

Service Manual

fig. 6-2b printer head

1 2 3 4 5 6 7

6-6

ND5000-9244 400-153 ND5000-9802 ND5000-9668 ND5000-9800 ND5000-9327 ND5000-1188 400-154

pressure piece cartridge holder screw M2x10 screw M2x5 kartelknob M5 screw M5x12 DIN912 washer M5 cartridge clamp

Figures

Service Manual

SummaPaint

fig. 6-2c printer head 1 2 3 4 5

Figures

400-151 ND5000-9685 400-935 ND5000-9686 ND5000-9581

base profile printhead Spacer M3x5 print inkjet head screw M3x4 screw M2.5x6

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Service Manual

fig. 6-3 keyboard-LCD display 1 2 3 4 5 6 7 8 9 10 12 13

6-8

391-168 ND5000-9657 384-656 ND5000-9283 ND5000-9269 ND5000-9358 400-143 384-751 MC92122 391-362 ND5000-9265 ND5000-0856

keyboard skiffy bus LCD module nylon washer nut M2 sealing strip 9x2mm keyboard fixing plate assy LCD module connector grouding cable lockwasher M3 nut M3

Figures

Service Manual

SummaPaint

fig. 6-4a idler pulley

1 2 3 4 5

1 MB02752 400-1243 400-1224 400-1235

400-518 assy, idler wheel 400-121 holder idler assys bearing 400-123 shaft idler pulley ND5000-9382 truarc 3.2mm mount idler pulley ND5000-9714 nylon washer shaft idler pulley ND5000-9382 truarc 3.2mm

Figures

6-9 fig. 6-4b idler pulley

SummaPaint

Service Manual

fig. 6-4c idler pulley

1 2 3 4 5 6

6-10

400-119 400-120 ND5000-9694 391-503 MH0291 MH0289

extra plate spacer 103 srew M4x10 spacer 67 lockwasher n°6 screw 6/32

Figures

Service Manual

SummaPaint

fig. 6-4d idler pulley

1 2

Figures

400-120 ND5000-9694

spacer screw M4x10

6-11

SummaPaint

Service Manual

fig. 6-5 y-motors 1 2 3 4

400-526 384-478 ND5000-9380 fxture

5 6 7 8 9

400-126 391-502 391-503 MH0071 MH0291

6-12

motor assy pulley setscrew M4x4 3.2mm from top shaft to pulley for printer carriage motor 3.2mm between pulley and plate for cutter carriage holder dbl pulley spacer 14 spacer 67 nut 6/32 lockwasher n° 6

Figures

Service Manual

SummaPaint

fig. 6-6 Carriage cutterhead

1 2 3 4 5 6 7 8 9 10 11 12 13

Figures

400-128 400-522 ND5000-9952 391-365 398-497 ND5000-9540 ND5000-9231 ND5000-9269 421-350 400-525 391-313 ND5000-9791 ND5000-9401

plate cutterhead vinyl width sensor screw M3x10 excentric shaft assy excentric nut to calibrate-every wheel should touch special1 spacer hexnut2M4 approx 1.5mm lockwasher M4 hexnut M2 clamp belt belt cutterhead concentric shaft assy screw M2x10 nylon washer

6-13

SummaPaint

Service Manual

fig6-10 x-motors-transfo

1 2 3 4 5 6

fig6-7 printerhead cover 1 400-132 carrige+plate printhead 2 400-532 up wheel system 400-155 cover printhead right 3 400-527 assy tubes + flatcable holder ND5000-9785 screws M3x10 1 1 ND5000-9683 standoff M4x30 (4x) 400-526 assy motor+encoder 4 ND5000-9693 screw M3x7 +washer ND5000-9686 screws M3x4 2 2 ND5000-9643 standoff M4x40 (3x) encoder 391-809 assy motor without 5 400-140 sensor plate lin. encoder 3 3 ND5000-9683 standoff M4x30 400-550 printhead 400-905 transformer 16”(3x) leads 6 4 400-537 assy sensor linear encoder ND5000-9711 schroef M4x12 DIN965 400-540 carriage printhead (without 4 391-362 assy grounding cable tube holder) 7 5 ND5000-9602 screw M2x6 schroef M4x10 6.7mm distance between printhead and baseplate 5 ND5000-9694 ND5000-9775 screw M4x40 8 400-539 up wheel system left 6 MH0899 screw 6/32 9 ND5000-9827 screw M2x12 RVS 7 400-521 assy y axis dbl drive 10 ND5000-9401 nylon washer 8 side primair leads 11 421-350 clamp belt 12 ND5000-9269 nut M2 13 400-533 lower wheel system 14 400-142 headfix right 15 390-198 special screw 16 ND5000-9272 screw M3x16 17 ND5000-9587 lockwasher M3 18 400-141 headfix left

6-14

Figures fig6-8 standoffs fig6-9 right plate printer carriage

Service Manual

SummaPaint

fig6-11 printercontrolbox

1 2 3 4 5 6

Figures

400-952 400-956 400-953 400-954 400-955 400-951

parallel board serial board processor board encoder board print head controller board power supply box

6-15

Appendix A List of recommended spare parts Product number

Description

384-682 390-549 391-152 391-168 391-198 391-224 391-326 391-342 391-500 391-601 391-663 391-664 391-667 391-668 391-669 391-809 391-885 398-210 398-235 400-131 400-145 400-598 400-147 400-149 400-150 400-155 400-162 400-170 400-174 400-204 400-281 400-282 400-283 400-284 400-511 400-513 400-515 400-516 400-517 400-521 400-522 400-525 400-526 400-535

LCD cable standaard T knife 36° pulley 72t -x drive shaft keyboard pulley 24t- motor knife offset 0.45 pinch roller switch assy - pinch roller core holder 75mm cover tangential head tang knife holder nose piece long ball point holder drag knife holder-tang.head ball point pen assy, X-motor without encoder OPOS tang head Assy, power entry Assy, On / off switch steel guiding strip -flat cable end connection tube chain 8 inks-tube top cover rolller lenght 1867mm roler brake cover ink jet head flatcable - 15 lines flexible platine diven roller lenght 1867mm safety cover silkscreened Assy cap blue Assy cap yellow Assy cap red Assy cap black drive drum assy media sensor rear, assy media sensor front, assy assy Y-guiding+ lin.enc.strip assy capping station assy Yaxis double pulley drive assy, vinyl width sensor assy belt cutterhead assy motor + encoder assy belt print head

Appendix A

Qty/unit 1 1 1 1 4 1 3 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 3 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1

A-1

SummaPaint

400-537 400-541 400-544 400-547 400-548 400-549 400-550 400-551 400-552 400-555 400-556 400-559 400-560 400-565 400-581 400-582 400-583 400-584 400-590 400-592 400-593 400-600 400-601 400-602 400-603 400-604 400-611 400-612 400-613 400-614 400-662 400-905 400-910 400-914 400-915 400-925 400-926 400-935 400-951 400-952 400-953 400-954 400-955 400-956 400-970 400-985 404-102 421-198 423-155 428-610 428-620 MB0380

A-2

Service Manual

sensor lin.encoder assy keyboard-display fan with cable assy left cover assy right cover assy carriage cutterhead assy ink jet head fixingknob inkjet cartridge priming bulb cable ultrasonic print tube chain assy assy carriage printhead assy core holder 2inch cutting strip PUR with tape Assy bottle cyan Assy bottle yellow Assy bottle magenta Assy bottle black Assy, 4 bottle ink system ink connection kit carriage ink connection kit bottle tray tangential head + OPOS ink cartridge yellow ( empty) ink cartridge magenta (empty) ink cartridge cyan (empty) ink cartrigde lack (empty) SummaInk kit - yellw UV-dur SummaInk kit - magen UV-dur SummaInk kit - cyan UV-dur SummaInk kit - black UV-dur print T-head transformer linear encoder strip cable serial, 9p - 9p, 400mm enc.cable, 15p - 15p, 550mm cable serial, 9p - 25p, 400mm print head cable, 26p - 26p, 570mm print ink jet head power supply box parallel board processor board encoder board print head controller board serial board print ultrasonic sensor controller PCB -motor-Thead parallel print cable bearing block drive drum serial interface cable kit rubber printhead capping rubber wiper belt 150t - Y motor

1 1 2 1 1 1 1 4 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 11 1 4 4 2

Appendix A

Service Manual

MB0389 MB9124 MF0017 MF1000 MF9000 MF9001 MI9935 MI9936 ND5000-9371 ND5000-9826

Appendix A

SummaPaint

bearing drive drum belt 110t - X motor Fuse 0.6A slow 5 x 20 Fuse 1.25A slow 5 x 20 Fuse 0.6A slow 6.3 x 32 Fuse 1.25A slow 6.3 x 32 User manual PC1500 Quick start manual PC1500 spring guide roller Cardboard roll L=1m45, dia=76mm

11 2 1 1 1 1 1 1 1 1

A-3