Summasign Maintenance Manual

Service Manual SummaSign Series

Summa NV Rochesterlaan 6 8470 Gistel Belgium

Service Manual

SummaSign

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

SECTION 1 KEYBOARD CONTROL 1.1. THE CONTROL PANEL .......................................................................................1.1 1.1.1. THE LIQUID CRYSTAL DISPLAY ....................................................................1.3 1.1.2.

THE RESET/LOAD KEY ..............................................................................1.3

1.1.3. THE ON LINE KEY ..........................................................................................1.4 1.1.4. THE MENU KEY ...............................................................................................1.4 1.1.5. 1.1.6. 2

THE ENTER KEY ..........................................................................................1.6 THE 1 AND 2 KEYS ....................................................................................1.6

1.1.7.THE JOGGING KEYS ........................................................................................1.6 1.1.8.

THE TOOL UP/DOWN KEY ..........................................................................1.6

1.1.9. THE TOOL SELECT KEY ................................................................................1.7 1.2. NORMAL OPERATION ........................................................................................1.8 1.2.1. ON LINE AND OFF LINE ..................................................................................1.8 1.2.2. LOCAL OPERATION ........................................................................................1.9 1.3. THE USER CONFIG MENU ...............................................................................1.10 1.3.1. KNIFE PRESSURE .........................................................................................1.12 1.3.2. PEN PRESSURE .............................................................................................1.12 1.3.3. POUNCING PRESSURE .................................................................................1.12 1.3.4. KNIFE OFFSET ...............................................................................................1.12 1.3.5. POUNCING GAP .............................................................................................1.13

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1.3.6. VELOCITY .......................................................................................................1.13 1.3.7. OVERCUT .......................................................................................................1.13 1.3.8. SYSTEM SETUP .............................................................................................1.13 1.4. SYSTEM SET UP ...............................................................................................1.14 1.4.1. CONCATENATION .........................................................................................1.14 1.4.2. SMOOTHING ...................................................................................................1.14 1.4.3. EMULATE .......................................................................................................1.14 1.4.4. TOOL ...............................................................................................................1.15 1.4.5. MENU UNITS ..................................................................................................1.15 1.4.6. ADDRESSING .................................................................................................1.15 1.4.7. BAUD RATE ....................................................................................................1.15 1.4.8. PARITY ............................................................................................................1.16 1.4.9. RTS/DTR .........................................................................................................1.16 1.4.10. DM/PL ERRORS ...........................................................................................1.17 1.4.11. HP/GL ERRORS ...........................................................................................1.17 1.4.12. HP/GL ORIGIN ..............................................................................................1.17 1.4.13. MEDIA SENSOR ...........................................................................................1.18 1.4.14. AUTOLOAD ..................................................................................................1.18 1.4.15. TOOL COMMAND .........................................................................................1.18 1.4.16. LOAD ON W COMMAND ..............................................................................1.18 1.4.17. FLEX-CUT .....................................................................................................1.19

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1.4.18. RECUT OFFSET ...........................................................................................1.19 1.5. INTERNAL TEST MENU ....................................................................................1.20 1.5.1. TANG. KNIFE CALIBRATION ........................................................................1.21 1.5.2. ADJUST ORIGIN TEST ROUTINE .................................................................1.22 1.5.3. ADJUST LAT. TEST ROUTINE ......................................................................1.23 1.5.4. ADJUST LONG. TEST ROUTINE ...................................................................1.25 1.5.5. CUT BORDER .................................................................................................1.26 1.5.6. MENU PLOT ....................................................................................................1.26 1.5.7. CONFIDENCE CUT .........................................................................................1.27 1.5.8. DIN CUT ..........................................................................................................1.27 1.5.9. SYSTEM TESTS .............................................................................................1.27 1.6. SYSTEM TESTS ................................................................................................1.28 1.6.1. LANGUAGE ....................................................................................................1.28 1.6.2. ROM REVISION ..............................................................................................1.28 1.6.3. SERVICE PLOT ..............................................................................................1.28 1.6.4. SENSOR SETUP .............................................................................................1.29 1.6.5. CALIBRATION ................................................................................................1.29 1.6.6. TRACKING TEST ............................................................................................1.29 1.6.7. FRICTION PLOT .............................................................................................1.29 1.6.8. RS232 TEST ....................................................................................................1.29 1.6.9. RAM TEST ......................................................................................................1.30

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1.6.10. INSTALL MENU ............................................................................................1.30 1.6.11. COIL SETUP .................................................................................................1.30 1.6.12. LCD CONTRAST ..........................................................................................1.30

SECTION 2 REPLACEMENT GUIDELINES 2.1. REMOVING THE LEFT-HAND COVER...................................................................3 2.2. REMOVING THE RIGHT-HAND COVER.................................................................3 2.3. REMOVING THE BOTTOM PLATE.........................................................................5 2.4. REPLACING THE CAMROLLERS..........................................................................5 2.5. REPLACING THE X-MOTOR IN THE 500, 610 AND THE OLD 750.....................7 2.6. REPLACING AN X-MOTOR IN THE MODELS 750/1010 AND 1300.....................9 2.7. REPLACING THE Y-MOTOR................................................................................11 2.8. REPLACING THE LCD OR THE KEYBOARD......................................................13 2.9. REPLACING THE MAIN PCB................................................................................15 2.10. REPLACING THE SMALL PCB ON THE MAIN PCB.........................................19 2.11. REPLACING A DRAG HEAD OR A TANGENTIAL HEAD.................................21 2.12. REPLACING THE FLAT CABLE FOR THE HEAD.............................................25 2.13. REPLACING THE Y-BELT..................................................................................29 2.14. REPLACING THE CUTTING STRIP....................................................................29 2.15. REPLACING THE SENSORS..............................................................................31 2.16. REPLACING THE FAN MOTOR..........................................................................31 2.17. REPLACING THE DRIVE DRUM.........................................................................33

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SECTION 3 MAINTENANCE 3.1. CLEANING THE DRIVE SYSTEM........................................................................3.2 3.2. CLEANING THE SENSORS.................................................................................3.3 3.3. CLEANING THE NOSE PIECE.............................................................................3.4 3.4. OPERATING VOLTAGE CONVERSION..............................................................3.5

SECTION 4 CALIBRATION 4.1. MACHINE TYPE....................................................................................................4.2 4.2. MEDIA CALIBRATION.........................................................................................4.4 4.3. HEAD CALIBRATION...........................................................................................4.5 I. KNIFE CALIBRATION ( TANGENTIAL)...................................................................4.5 II. COIL CALIBRATION...............................................................................................4.5 4.5. OPOS CALIBRATION (OPTIONAL).....................................................................4.8 I. NORMAL CALIBRATION.........................................................................................4.8 II. FINE TUNING...........................................................................................................4.9 4.6. SENSOR TESTS.................................................................................................4.10

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

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5.4. LOW LINE VOLTAGE...........................................................................................5.3 5.5. HIGH LINE VOLTAGE..........................................................................................5.4 5.6. ILLEGAL PLOT COMMAND.................................................................................5.4 5.7. ILLEGAL CLIP & SCALE SETTINGS..................................................................5.4 5.8. SYNTAX ERROR..................................................................................................5.5 5.9. NVRAM FAILURES AND MESSAGES.................................................................5.5 5.10. RS232 ERROR....................................................................................................5.6 5.11. INTERNAL ERRORS..........................................................................................5.6 5.12. FLASHING ERRORS AND MESSAGES (ONLY ON NEW TYPE OF PCB)......5.7 5.13. ROM ERROR......................................................................................................5.7 5.14. RAM ERROR.......................................................................................................5.7 5.15. MACHINE UNABLE TO FIND THE KNIFE HOME POSITION...........................5.8 5.16. MARKERS NOT SENSED PROPERLY.............................................................5.8

SECTION 6 FIGURES

LEFT SIDE...................................................................................................................6-2 RIGHT SIDE (1)............................................................................................................6-3 KEYBOARD ASSY......................................................................................................6-4 RIGHT SIDE (2)............................................................................................................6-5 CUTTER CARRIAGE...................................................................................................6-6

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T-HEAD........................................................................................................................6-7 D-HEAD........................................................................................................................6-8 BOTTOM......................................................................................................................6-9 REAR.........................................................................................................................6-10 MEDIA GUIDING SYSTEM........................................................................................6-11 MOTOR CONNECTIONS...........................................................................................6-12 CAMROLLER ASSY..................................................................................................6-13

SECTION 7 SPARE PARTS LIST

D500 SPARE PARTS..................................................................................................7-1 SUMMASIGN D610 SPARE PARTS...........................................................................7-2 SUMMASIGN D610 PRO SPARE PARTS..................................................................7-3 SUMMASIGN T610 SPARE PARTS...........................................................................7-4 SUMMASIGN T610 PRO SPARE PARTS...................................................................7-5 SUMMASIGN D750 SPARE PARTS...........................................................................7-6 SUMMASIGN D750 PRO SPARE PARTS..................................................................7-7 SUMMASIGN T750 SPARE PARTS...........................................................................7-8 SUMMASIGN T750 PRO SPARE PARTS...................................................................7-9 SUMMASIGN D1010 SPARE PARTS.......................................................................7-10 SUMMASIGN D1010 PRO SPARE PARTS..............................................................7-11 SUMMASIGN T1010 SPARE PARTS.......................................................................7-12

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SUMMASIGN T1010 PLUS SPARE..........................................................................7-13 SUMMASIGN T1010 PRO SPARE............................................................................7-14 SUMMASIGN D1300 SPARE PARTS.......................................................................7-15 SUMMASIGN D1300 PRO SPARE PARTS..............................................................7-16 SUMMASIGN T1300 SPARE PARTS.......................................................................7-17 SUMMASIGN T1300 PRO SPARE PARTS...............................................................7-18

Appendix A removal of the left side Appendix B procedure to flash from internal ROM’s Appendix C procedure to set the pinch roller play Appendix D procedure to change the motor on a T-head

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INTRODUCTION

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

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



Table of Contents



Introduction



Keyboard controls



General replacement guidelines



Maintenance



Calibration



Troubleshooting



Figures - part numbers



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 appear on the LCD screen, and the possible solutions

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

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

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Introduction

Service Manual 3.

SummaSign

QUICK TOUR AROUND THE MACHINE

In order to get acquainted with your SummaSign Pro cutter, read the following description of the rear panel components. Figure 1-1 shows the location of the main components.

1.

RS-232-C Port : - This DB-9P connector provides the communication link between the cutter and a host computer. It allows bidirectional communication between the host computer and the cutter.

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2.

Service Manual

Parallel Port : - This 36-pin Centronics connector provides a unidirectional communication link between the cutter and a host computer. The cutter can receive but not transmit data via this port. Note : only one interface can be active at any one time. The first port that receives data will be the active interface until the cutter is reset.

3.

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

4.

Power Entry Module : - The fuse box, the voltage select board and the AC power cord receptacle are located in the power entry module. The power-up procedure is explained in detail in Section 1.6. For information about the conversion of the cutter's operating voltage, see Section 3.2.

5.

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

6.

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

7.

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

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Introduction

Service Manual

SummaSign

In order to get acquainted with your SummaSign Pro cutter, read the following description of the front panel controls and components. Figure 1-2 shows the location of the main components.

FIGURE 1-2 : SUMMASIGN PRO T-SERIES CUTTERS, FRONT VIEW

1.

Pinch roller lever arm : - This lever is used to raise and lower the pinch rollers (Media loading is discussed in Section 1.8).

2.

Media Drive Sleeves : - The media drive sleeves move the media only when the pinch rollers are in the ‘down’ position. The following table lists the number of media drive sleeves installed on each model of the Pro T-series cutters. Number of media drive sleeves Short sleeve Long sleeve

3. 4.

T610 Pro

T750 Pro

T1010 Pro

T1300 Pro

3 1

4 1

6 1

7 1

Tool Carriage : - The tool carriage is the mount for the tangential cutting head. Control Panel : - The control panel contains 12 keys. All cutter activity can be initiated from the control panel. This includes initiating remote mode for computer

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control, local mode for manual operation and menu mode. Each control panel function is explained in Section 2.1. 5.

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

6.

Sensors : - The sensors detect the presence of media to avoid any 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.

7.

Pinch rollers : - The pinch rollers (one at each side) hold the media clamped between the rubber rollers and the media drive sleeves. The T1010 and T1300 units are provided with an extra low pressure roller in the middle to keep the vinyl media flat.

8.

Cutting strip : - Soft strip to avoid any damage to the knife tip when no media has been loaded. Since cutting is done on the cutting strip it is essential that the cutting strip remains intact.

9.

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.

10.

Stand : - The stand comes standard with the T1010 and T1300 units. For the T610 and T750 units the stand is optional.

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Introduction

Keyboardcontrols

1-1

SECTION 1 KEYBOARD CONTROLS THE CONTROL PANEL The figure below shows the control panel of the SummaSign series cutters. The main functions of the liquid crystal display (LCD) and the control panel keys are explained in the following paragraphs. The explanation has been written for a T-series cutter. The only difference with the Dseries is that some menu and configuration points have been omitted. The D-series cutters work the same as T-series cutters when a drag knife is installed.

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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 1.6.12. 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. Next to the status messages and/or menu options displayed on the LCD, arrow symbols representing the , , , jogging keys and key will tell you what 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 The key (RESET/LOAD) is used to move the origin, to initiate a load sequence, to key reset the cutter, to abort the cut in progress or to recut the last file. When the (RESET/LOAD) is pressed, the cutter goes off line, suspends all operations in key until SET ORIGIN, progress and displays the RESET/LOAD menu. Press the LOAD, RESET, ABORT or RECUT is displayed. To confirm RESET, ABORT or RECUT press the key (ENTER). To execute the SET ORIGIN instruction move the knife origin using 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 RECUT instruction recuts the last file sent to the cutter (provided that it fitted into the buffer). When using the multiple recut function the different copies will be cut in the media in such a way that there is only a minimal loss of media. The distance between the copies can be changed (See Section 1.4.18).

THE ON LINE KEY

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

key

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

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

Press the



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



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

or

jogging key to move the tool carriage to the left or right.

The MENU Key key (MENU) is used to select one of the menus. Pressing the key will make The 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.

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800m m / s 120g ONLINE

K 1

Me nu

 USER CONFIG 1  



INTERNAL TESTS

SUMMASIGN SERIES CONFIGURATION SUBMENUS

To select a menu by scrolling through the different options, press the

jogging key .

To exit from the menus and resume the previous on line operation, press the (ON LINE).

key

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

1-4

or

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

Keyboardcontrols

Service Manual

SummaSign series Cutters

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.

CONTENTS OF THE SUMMASIGN PRO T-SERIES MENUS

THE ENTER KEY The

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 used to select the new user number and the previous or next menu item.

or

or

jogging key is

jogging key is used to go to the

THE TOOL UP/DOWN KEY The

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

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

key

If the tool is not moved for approximately eight seconds, it is raised automatically.

THE TOOL SELECT KEY The

key (TOOL SELECT) is used to select one of the following tools :

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Service Manual

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 1.4.5.

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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 SummaSign cutters. The cutter is on line only when the following message is displayed on the LCD : 800mm/s 120 g .45mm(1) ON LINE

K 1

This display message should be read as follows : 800 mm/s 120 g K = .45 mm(1) ON LINE 1

= velocity = knife pressure or pen pressure knife operation (K) or pen operation (P) or pouncing operation = 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. The host computer will first issue a SELECT sequence to the on line cutter, and the message "*ON LINE" will be displayed on the LCD. The asterisk indicates that the host is in communication with the cutter : i.e. the cutter is now “selected” by the computer. When the cutter is on line and ready to receive instructions from the host computer, it will remain deselected until actual instructions from the computer are received. When the cutter is on line, but has not been selected by the host computer, the message "ON LINE" is displayed on the LCD, without the asterisk. For normal cutting operations, the cutter MUST be on line, so that it can receive instructions from the host computer and the cutting/plotting software.

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When the cutter is on line, but has not been selected by the host computer, the following conditions must be met: 

The cutter must be powered ON.



Media must be loaded. For detailed media loading instructions, see user’s manual .



The proper tool must be installed.



The cutter must be connected to the host computer via a RS-232-C link or a parallel interface.



The cutter must be configured for the scheduled operation.

, or key. Pressing any of these keys will To put the cutter off line, press the suspend the current cutting/plotting operation until the cutter is put on line again. LOCAL OPERATION Local operation is only possible while the cutter is off line. Local operation means that the cutter 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 cutter is still on line, press the move forward over a certain distance.

2.

To move the carriage to the left or right, press the

3.

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

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

1-8

key once to select off line. The media will

or

jogging key.

key. key.

Keyboardcontrols

Service Manual

SummaSign series Cutters

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 jogging key until the desired configuration number is disPress the played next to USER CONFIG.

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

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.



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

1.

Power on the cutter.

2.

Press the

3.

or Press the first line of the LCD.

4.

Press the second line.

5.

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

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

or

Keyboardcontrols

jogging key until the desired submenu is displayed on the

jogging key until the desired value is displayed on the

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* = IN DM/PL ONLY ** = IN HP/GL AND HP/GL/2 ONLY

FLOWCHART SHOWING FACTORY PRESET MENU SETTINGS

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SummaSign series Cutters

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 (400) 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 pen. The default pen pressure value is 80 grams (40grs). The pressure can be set between 0 and 600 (400) grams in 5 gram increments. On the LCD, the active pen pressure value is marked with an *. POUNCING PRESSURE The POUNCING PRESSURE submenu is used to set or modify the pressure of the pouncing tool. The default pouncing pressure value is 120 grams. The pressure can be set between 0 and 600 grams in 5 gram increments. On the LCD, the active pouncing 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.

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POUNCING GAP The pouncing gap submenu is used to set or modify the distance between the pounced wholes. This routine applies to the pouncer only. The default pouncing gap value is 0 mm. The value can be set between o and 50 mm. On the LCD, the active pouncing gap value is marked with an *. VELOCITY The VELOCITY submenu is used to set or modify the velocity of the tool. The default velocity is 800 mm/s (32 ips). The velocity can be set between 50 mm/s (2 ips) and 1000 mm/s (40 ips). 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 1.4.

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Service Manual

SummaSign series Cutters

SYSTEM SET UP 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 SummaSign Pro cutters support DM/PL , HP/GL and HP/GL/2. On the LCD, the active plotting language setting is marked with an *.

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

Whenever possible, select the DM/PL menu option to set the active cutting/plotting language to Houston Instrument Digital Microprocessor/Plotting Language (DM/PL). This selection will allow the cutter to operate with DM/PL-based cutting / plotting software. This language, having special command extensions for cutting, normally gives superior cutting performance. 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).

TOOL The TOOL submenu is used to select the default tool at power up. To configure the cutter for TANGENTIAL KNIFE cutting operations, select the TANG. KNIFE option.

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Service Manual

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 configure the cutter for POUNCING operations, select the POUNCING TOOL option. To select a tool other than the default one temporarily, see section 1.1.9. MENU UNITS The MENU UNITS submenu allows you to select English or metric menu units for DM/PL. In HP/GL & HP/GL/2 the menu units are always in metric. 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 useraddressable resolution. In HP/GL & HP/GL/2 the addressing is fixed at 0.025 mm. 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 RS232-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 submenu is used to set or modify the byte format and parity type for RS232-C serial communications between your cutter and the host computer. The default parity setting is bit 8 = 0 (8 data bits, no parity, the 8th bit being a low bit). The parity can be set to any of the following values:

1-14

Keyboardcontrols

Service Manual LCD information BIT 8 = 0 BIT 8 = 1 EVEN ODD

SummaSign series Cutters 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

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 *.

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SummaSign series Cutters

Service Manual

DM/PL ERRORS The DM/PL ERRORS submenu is used to determine whether or not different DM/PL errors, such as illegal plot commands, invalid parameter ranges or communication errors, will be displayed on the LCD. This menu will only be displayed if PLOT LANGUAGE is set to DM/PL. The DM/PL ERRORS submenu can be set to REPORTED or IGNORED. On the LCD, the active setting is marked with an *. The feature is activated by selecting REPORTED. It is normally used only when attempting to debug a communication link between the cutter and the host computer. After the communication link has been debugged, select IGNORED to disable the feature. HP/GL ERRORS The HP/GL ERRORS submenu is used to determine whether or not different HP/GL errors, such as illegal plot commands, invalid parameter ranges or communication errors, will be displayed on the LCD. This menu will only be displayed if PLOT LANGUAGE is set to HP/GL. The HP/GL ERRORS submenu can be set to REPORTED or IGNORED. On the LCD, the active setting is marked with an *. The feature is activated by selecting REPORTED. It is normally used only when attempting to debug a communication link between the cutter and the host computer. After the communication link has been debugged, select IGNORED to disable the feature. HP/GL ORIGIN The HP/GL ORIGIN submenu will only be displayed if the PLOT LANGUAGE is set to HP/GL. (See Paragraph 1.4.4.) The HP/GL ORIGIN submenu is used to set the origin in the centre (see HP/GL 758x) or the bottom-right corner (see HP/GL 7475) of the loaded media. The HP/GL ORIGIN option can be set to RIGHT_FRONT or CENTRE. On the LCD, the active setting is marked with an *. If the cut is found to be incomplete, and is wholly located in the upper left corner of the media then modify the HP/GL ORIGIN setting to RIGHT FRONT. If the cut is found to be incomplete, and is wholly located in the lower right corner of the media then change the HP/GL ORIGIN setting to CENTRE.

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Service Manual

SummaSign series Cutters

MEDIA SENSOR The MEDIA SENSOR submenu 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. AUTOLOAD The AUTOLOAD option enables the user to the change the vinyl unroll proceedings. When AUTOLOAD is ON , the cutter will automatically unroll the vinyl when needed. When the AUTOLOAD option is OFF, the operator himself should unroll enough media before starting to cut. The default setting is ON. The best results and performance are guaranteed when using this setting. On the LCD display, the active setting is marked with an *. TOOL COMMAND The TOOL COMMAND is used to determine whether the DM/PL and HP/GL pen/knifeselect 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 1.4.4.). 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 W-command, 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.

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SummaSign series Cutters

Service Manual

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 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. RECUT OFFSET The recut offset submenu is used to set or modify the distances between the drawings when making multiple recuts. The default recut offset value is 0 mm. The distance can be set between o and 255 mm. On the LCD, the active recut offset value is marked with an *.

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Service Manual

SummaSign series Cutters

INTERNAL TEST MENU 

To access any internal test, proceed as follows:

1.

Power the cutter on.

2.

Load cutting or plotting media.

3.

Install a knife or a pen.

4.

Press the key.

5.

Press the

6.

To perform the test, press the

key until INTERNAL TEST is displayed and press the

or

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

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

Keyboardcontrols

jogging

key until the desired key.

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Service Manual

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. 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.

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Service Manual



SummaSign series Cutters

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 POSSIBLE KNIFE CALIBRATION GROUNDS

The calibration settings entered during the knife calibration routine are automatically stored in the cutter'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 

INTERNAL TESTS CALIBRATE KNIFE

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1-21

SummaSign series Cutters

Press

Service Manual

to select the ORIGIN test. ADJUST ORIGIN  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 repeat the test, press the Press the

jogging key to correct closing of the circles cut. To key.

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

1-22

jogging key to correct closing of the circles

key.

key to go to the next step of the calibration procedure

Keyboardcontrols

Service Manual

SummaSign series Cutters

ADJUST LAT. test routine ADJUST LAT  0 Press

1

to execute the LAT test.

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 closing of the lines cut. To repeat the test, press the key. Press the

jogging key to correct

key to go to the next step of the procedure.

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SummaSign series Cutters

Service Manual

However, in case your cut resembles the pattern illustrated above, increase the value displayed on the LCD by pressing the cut. To repeat the test, press the key.

jogging key to correct closing of the lines

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.

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 lines cut. To repeat the test, press the key.

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jogging key to correct closing of the

Keyboardcontrols

Service Manual

Press the the routine.

SummaSign series Cutters

key to repeat the calibration procedure or press the

key to interrupt

However, if you obtained a pattern as illustrated above, increase the value displayed on the LCD by pressing the To repeat the test, press the Press the the routine.

jogging key to correct closing of the lines cut. key.

key to repeat the calibration procedure or press the

key to interrupt

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 submenu 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 cutter configuration, i.e. the items selected in the USER CONFIG submenus 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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SummaSign series Cutters

Service Manual

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

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Service Manual

SummaSign series Cutters

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 submenu 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 Field Service Personnel.

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SummaSign series Cutters

Service Manual

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. CALIBRATION Calibration allows the length of the lines cut to be adjusted to within the specifications. For instance, if a cut line should measure 100 mm exactly, the cutter can be adjusted for any discrepancy. TRACKING TEST This test allows the tracking quality of the machine to be verified. FRICTION PLOT This test routine must be performed with a pen and is used to detect problems with the cutter. The FRICTION PLOT is automatically scaled to fit the currently installed paper size. This test should only be performed by qualified service personnel. RS232 TEST The RS232 TEST routine verifies the cutter’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. 

To run the RS-232-C test, proceed as follows :

1. Unplug the RS-232-C data cable from the rear panel of the cutter. 2. Use a loopback test cable to connect pin 2 of the cutter’s data connector to pin 3 and pin 7 to pin 8. 3. With RS232 TEST displayed, press the ENTER key. The cutter will start transmitting and receiving data at all available baud rates and parity settings. The length of the transmissions will vary because of the different baud rates used. The unit then checks the hardware handshake lines. 4. Upon completion of the test, remove the loopback test cable from the cutter rear panel RS-232-C connector. 5. Plug the RS-232-C data cable into the connector. RAM TEST This test completely checks the RAM bit for bit.

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When running this test the cutter will not respond. After this test, power the cutter off, then on . 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). 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 Blank Page increase or reduce the contrast and press to confirm.

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Replacements Guidelines

2-1

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: 1.  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 cords and host cables before transporting the unit to other places.  Reassemble ALL parts (screws, ferrite shield, etc.) to maintain EMI integrity, and guide the loose wires afterwards with tie-wrap in the same manner they were before  Watch for sharp edges on the metal strips etc.  When the covers are off or open:  The printed circuits boards are electrostatically sensitive; use the proper handling techniques.  Keep sensors 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

SummaSign

1 2 3 4 5

2-2

Service Manual

body left end cover right end cover long screws + rozet short screw + rozet

391-367 391-366 MH868 + ND5000-9639 MH595 + ND5000-9639

2x4x 2x1x

Replacements Guidelines

Service Manual

SummaSign

REMOVING THE LEFT-HAND COVER To remove the left-hand cover, proceed as follows: 2. Remove the five screws (four long screws and a short screw) holding the left-hand cover in place. Three are located at the front, one at the rear and one at the bottom (it is not necessary to turn the unit upside down to remove the bottom screw). Pay close attention to where each of the screws goes. They should be returned to their original location when re-installed. 3. Gently tap the top of the cover. 4. Remove the cover. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

REMOVING THE RIGHT-HAND COVER To remove the right-hand cover, proceed as follows: 5. Remove the five screws (four long screws and one short screw) holding the right-hand cover in place. Three are located at the front, one at the rear and one at the bottom (it is not necessary to turn the unit upside down to remove the bottom screw).

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

Pay close attention to where each of the screws goes. They should be returned to their original location when re-installed. 6. Gently tap the top of the cover. 7. 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. 6.

Replacement Guidelines

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Service Manual

1 2 3 4

body bottom plate screws # depends on type of machine slot for bottom plate

1 2 3 4

2-4

camroller assy camroller camrollershaft setcrew

Replacements Guidelines

Service Manual

SummaSign

REMOVING THE BOTTOM PLATE To remove the bottom plate, proceed as follows: 8. 9. Turn the unit upside down. 10.Remove the screws holding the bottom plate in place (the number of screws varies depending on the cutter type). 11.Remove the bottom plate. 12.The bottom plate has an additional front and rear plate that can be removed without having to remove any screws. Pay close attention to how the plates are positioned, because they will have to be returned to their original location when re-installed. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 7. Note: 8. Make sure the bottom plate is placed correctly into the slot of the front plate and the rear plate . 9. 10.

REPLACING THE CAM ROLLERS To replace the cam rollers, proceed as follows: 13.Remove the set screw on either side of the cam rollers . 14.Remove the cam roller shaft (push against the left side of the shaft). 15.Remove the cam roller. 16. 11. Note: 12. a. Cam rollers come in pairs. When one is malfunctioning or broken, both cam rollers need to be replaced. 13. b.The models 750, 1010 and 1300 have three cam rollers. The centre cam roller is not matched with the two outer cam rollers and can be installed independently. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

14. Note: 15. It is extremely important that the cam roller be stable and stationary. To achieve this, press one side of the camshaft while tightening the set screws.

Replacement Guidelines

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SummaSign

2-6

Service Manual

1 2 3 4

body motor with encoder screws belt

1 2 3 4

motor capacitor connector encoder wires motor

WATCH ORIENTATION !

Replacements Guidelines

Service Manual

SummaSign

REPLACING THE X-MOTOR IN THE MODELS 500, 610 AND THE OLD MODEL 750 To replace the X-motor in these models, proceed as follows: 17.Remove the left-hand cover (see Chapter 2.1, Removing the left-hand cover). 18.Remove the connector from the encoder and solder off the black and the red wire to expose the Xmotor. 19.Remove the three screws holding the X-motor in place. 20.Remove the X-motor. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

16.

Note:

17.

When re-installing:

18.

a.Make sure the wire of the connector attached to the encoder runs outward.

19. b.Make sure to solder the black wire to the minus (-) entry and the red wire to the plus (+) entry. The (+) and (-) signs are located in the corners of the motor's label. 20. c.Be extremely careful to plug the connector into the correct holes of the encoder. Move the pulley on the motor shaft to prevent the belt from slipping against the big pulley. Make sure to firmly tighten the set-screw.

Replacement Guidelines

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1 2 3 4 5

body motor with encoder motor without encoder screw belt

1 motor with encoder 2 motor without encoder 3 gap between belts

2-8

1 2 3

motor capacitor connector encoder

4

wires motor

WATCH ORIENTATION !

Replacements Guidelines

Service Manual

SummaSign

REPLACING AN X-MOTOR IN THE MODELS 750/1010 AND 1300 The models above are equipped with two X-motors. Although both motors are driven, only the one with the encoder is used for feedback.

REPLACING THE X-MOTOR WITH THE ENCODER To replace the X-motor with the encoder, proceed as follows: 21.Remove the left-hand cover (see Chapter 2.1, Removing the left-hand cover). 22.Disconnect the connector. 23.Remove the three screws holding the motor in place. 24.Remove the motor. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 21.

Note:

22.

When re-installing:

23.

a.Make sure the wire of the connector attached to the encoder runs outward.

24. b.Make sure to solder the black wire to the minus (-) entry and the red wire to the plus (+) entry. The (+) and (-) signs are located in the corners of the motor's label. 25. c.Be extremely careful to plug the connector into the correct holes of the encoder.

REPLACING THE X-MOTOR WITHOUT THE ENCODER To replace the X-motor without the encoder, proceed as follows: 25.Remove the left-hand cover (see Chapter 2.1, Removing the left-hand cover). 26.Remove the brown and the orange wire by soldering them off. 27.Remove the three screws holding the motor in place. 28.Remove the motor. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 26.

Caution:

27. a.Make sure the brown wire is soldered to the minus (-) entry and the orange wire to the plus (+) entry. 28. b.It is extremely important that the two rotating belts do not touch. Make sure to position each belt correctly to avoid malfunctioning.

Replacement Guidelines

2-9

SummaSign

Service Manual

1 2 3

1 2 3 4

2-10

body y-motor screw

(3x)

motor capacitor connector encoder wires motor

WATCH ORIENTATION !

Replacements Guidelines

Service Manual

SummaSign

REPLACING THE Y-MOTOR To replace the Y-motor, proceed as follows: 29.Remove the right-hand cover (see Chapter 2.1, Removing the right-hand cover). 30.Remove the connector from the encoder and solder off the black and the red wire to expose the Ymotor. 31.Remove the three screws holding the Y-motor in place. 32.Remove the Y-motor. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 29.

Note:

30.

When re-installing:

31.

a.Make sure the wire of the connector attached to the encoder runs outward.

32. b.Make sure to solder the black wire to the minus (-) entry and the red wire to the plus (+) entry. The (+) and (-) signs are located in the corners of the motor's label. 33. c.Be extremely careful to plug the connector into the correct holes of the encoder. 34. d.Move the pulley on the motor shaft to prevent the belt from slipping against the big pulley. Make sure to firmly tighten the set-screw. 35.

Replacement Guidelines

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1 2 3 4 5

1 2 3 4 5 6 7

2-12

body keyboard assy nut lockwasher grounding wire

LCD assy keyboard spacer washer nut M2 dust cover LCD cable

Replacements Guidelines

Service Manual

SummaSign

REPLACING THE LCD OR THE KEYBOARD REPLACING THE KEYBOARD To replace the keyboard, proceed as follows: 33.Remove the right-hand cover (see Chapter 2.2, Removing the right-hand cover). 34.Loosen one end of the flat cable for the head by pulling the flat cable connector up. On both sides of the connector cover there is a small protuberance that you can pry up using a screwdriver. Gently pull the flat cable out of the connector and pull the flat cable loose (it sticks to the other flat cables). 35.Pull the flat cable for the keyboard off the PCB. 36.Pull the flat cable for the LCD off the PCB. 37.Remove the four screws holding the keyboard in place. 38.Remove the keyboard. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

REPLACING THE LCD To replace the LCD, proceed as follows: 39.Remove the keyboard (see above). 40.Remove the four screws holding the LCD in place. 41.Remove the LCD. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

Replacement Guidelines

2-13

SummaSign

2a 2b 2c 2d 2e 2f 2g 2h 3

connector paper sensors connector cam switch connector y-encoder connector x-encoder connector main power connector y-motor connector x-motor with encoder connector x-motor without (*) connector flatcable

Service Manual

4 5 6 7 8a 8b 9 10

connector keyboard connector LCD screen place for safeguard grounding clamps completely unscrew this one just loosen this one a bit vertically aligned screws fan motor connector

(*) on the older models on separate pcb

2-14

Replacements Guidelines

Service Manual

SummaSign

REPLACING THE MAIN PCB The SummaSign and SummaCut cutters manufactured since December 1995 have a different main PCB from those manufactured before that date. The boards on the new cutters have the logic for the head control on the same main PCB whereas the parallel input is on an extra board. You can obtain this option by ordering part number 421-174. The new type of boards are fully compatible with the old type of boards, the only difference being the position of particular connectors, and certain parts, previously situated on the small PCB, that can now be found on the main PCB. The old type of boards can be exchanged for the new type of boards. Summarizing, there are two types of main PCBs:

0Type 1: Main PCBs dating from before December 1Type 2: Main PCBs dating from after December 1995 To replace a PCB, proceed as follows: 42.Remove the right-hand cover (see Chapter 2. 2, Removing the right-hand cover). At the top of the PCB 43. 44.Disconnect the various connectors. Pay close attention to the positioning of the connectors. They should be returned to their original location when re-installed. 36. Note: 37. In the Type 1 models the connector for the cam roller switch has to be removed from the small PCB. 45. 46.Remove the flat cable for the head by pulling the flat cable connector up. On both sides of the connector cover there is a small protuberance that you can pry up using a screwdriver. Gently pull the flat cable out of the connector. 38. 39.

Note: In the Type 1 models this connector is located on the top of the small PCB.

47. 48.Remove the flat cable for the keyboard. 49.Remove the flat cable for the LCD. At the rear of the PCB 50.Remove the safeguard located a few inches above the grounding wires. Loosen the two grounding clamps so that the earthing wires can be removed.

Replacement Guidelines

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SummaSign

2a 2b 2c 2d 2e 2f 2g 2h 3

connector paper sensors connector cam switch connector y-encoder connector x-encoder connector main power connector y-motor connector x-motor with encoder connector x-motor without (*) connector flatcable

Service Manual

4 5 6 7 8a 8b 9 10

connector keyboard connector LCD screen place for safeguard grounding clamps completely unscrew this one just loosen this one a bit vertically aligned screws fan motor connector

(*) on the older models on seperate pcb

2-16

Replacements Guidelines

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SummaSign

At the front of the PCB 51.Remove the left screw holding the power entry module in place and sufficiently loosen the right screw of the power entry module. At the side of the PCB 52.Remove the three vertically-aligned screws located on the right-hand cover. On the bottom of the PCB 53.Remove the fan motor connector. 40. 41.

Note: In the Type 1 models the connectors for the sensors also have to be removed.

54. 55.Remove the PCB. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 42.

Note:

43. a. When re-installing, be extremely careful to plug the connectors into the correct holes. 44. See the drawing in section 7 for the exact positioning of the connectors. The drawing shows the PCB of a new model (Type 2). The old model (Type 1) differs on the following points: 45. The connector for the switch is located at the centre on the top of the small board. 46. The connector for the head is located right of centre on the top of the small PCB. 47.

The connectors for the sensors are at the bottom of the main PCB.

48. The connector for the second X-motor is located on the small board at the back of the PCB. 49.

Each connector on the PCB has a reference.

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

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1 2 3 4 5

2-18

main pcb small pcb cover plate screws hex nuts

Replacements Guidelines

Service Manual

SummaSign

REPLACING THE SMALL PCB ON THE MAIN PCB The SummaSign and SummaCut D500 cutters manufactured since December 1995 have a different main PCB from those manufactured before that date. This has also had consequences for the small PCB. There are currently two types of main PCBs: Type 1: Main PCBs dating from before December 1995 Type 2:

Main PCBs dating from after December 1995

The small board on Type 1 main PCBs has head driver and head rotation functions and a parallel port. The small board on Type 2 main PCBs only has a parallel port. To replace the small PCB, proceed as follows : 56.Remove the right-hand cover (see Chapter 2.2, Removing the right-hand cover). 57.Remove the main PCB (see Chapter 2.8, Replacing the main PCB). 58.Remove the screw on either side of the parallel port. 59.Remove the clamp on either side of the serial port. 60.Remove the cover. 61.Remove the two screws holding the small PCB in place. 62.Remove the screw or the two screws on the right-hand side that hold the drivers against the small PCB (this only applies to Type 1 PCBs). 63.Remove the small PCB. 64.To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

2 The old PCB consists of: 

a 3-pin connector for the X-motor. Use the cable coming from the motor with the encoder if you are dealing with a unit with 2 motors. Connect the motor without encoder to the small satellite board.  3-pin connector for the Y-motor;  a 3-pin connector coming from the transformer;  a 4-pin connector coming from the X-motor encoder;  a 4-pin connector coming from the Y-motor encoder;  6 connectors that are not used. On the right-hand side you see the connectors for the LCD and the keyboard. On the bottom you find:  a 2-pin connector coming from the fan motor;  a 5-pin connector coming from the sensor;  2 connectors that are not used.

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SummaSign

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1 2 3 4 5

2-20

cover head head screws cover head position screws to hold head flatcable

Replacements Guidelines

Service Manual

SummaSign

REPLACING A DRAG HEAD OR A TANGENTIAL HEAD Below is the description for the replacement of a standard drag head. The procedure described is also roughly applicable to the replacement of a tangential head. The areas where the replacement procedure for the tangential head differs are indicated between brackets and in italics. The only major difference between replacing a drag knife and a tangential knife is the positioning of the screws on the carriage plate. To remove the drag head, proceed as follows: 65.Take the knife holder out of the drag head. 66.Remove the front cover of the drag head by loosening the two (three) screws . 67.Loosen the flat cable by pulling the flat cable connector cover up. On both sides of the connector cover there is a small protuberance that you can pry up using a screwdriver. Gently pull the flat cable out of the connector 68.Remove the drag head. To do this, loosen the three screws with two counterclockwise rotations using a small diameter screw driver and lift the head upwards to remove it from the screws. To re-install the drag head, proceed as follows: 69.Place the head back onto the screws. Tighten the screws with a 1 1/2 clockwise rotation. Do not tighten them firmly because the height and position of the head still need to be adjusted. 70.Put the knife holder into the drag head. (Put the nose piece into the tangential head). 71. 51. 52.

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

72. 73.Secure the knife holder. 74. 53. 54.

Note: This only applies to the re-installation of a drag head.

75. 76.Adjust the height and position of the head. 77. 78.The standard operating procedure for doing this is described in the SummaSign Upgrade Kit (p/n 391-950). 55. Note: 56. The operating procedure described in the Upgrade Kit applies to a tangential head. However, the procedure to be followed for a drag head is roughly applicable.

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2-22

cover head head screws cover head position screws to hold head flatcable

Replacements Guidelines

Service Manual

SummaSign

Apart from the standard adjustment tools used in the standard operating procedure, you can use an ordinary 3½" disk to adjust the height and position of the head. To do this, proceed as follows: a. Put the disk against the drag head (the same way as you would put an adjustment plate against it) to verify that the drag head is positioned perpendicularly to the cutting surface. b. Slide the disk under the knife holder. If the disk touches the knife holder this means that the head is mounted too low. Readjust the mounting of the head. 79. 80.Firmly tighten the screws once the drag head is properly positioned. 81.Put the flat cable back into the connector and close the connector. To ensure good contact, the flat cable must be positioned as deeply as possible and in the middle of the connector. 82.Remount the front cover of the head and firmly tighten the screws. 83.Proceed in the reverse order of removal. Make sure to firmly tighten all screws. 84. 57. Note: 58. Now that you have replaced the head, it is extremely important that you bring the data stored on the PCB in line with the head and vice versa. See Chapter 11, Configuration of the head or the PCB for detailed information on how to do this. 59. 60.

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61. 62.

1 2 3

2-24

body flatcable path loop may not touch anything when head is completely on the left

Replacements Guidelines

Service Manual

SummaSign

REPLACING THE FLAT CABLE FOR THE HEAD Below is the description for the replacement of the flat cable in small cutters. Large cutters - the models D/T 1300, D/T 1010 (plus) - have an extra strip that is located along the flat cable. The purpose of this additional strip is to prevent the flat cable from crumpling. For more information, see Additional strip in larger units at the end of this chapter. To replace the flat cable for the head, proceed as follows: 85.Remove the left-hand cover (see Chapter 1, Removing the left-hand cover). 86.Remove the right-hand cover (see Chapter 2, Removing the right-hand cover). 87.Remove the two screws on either side of the top cover. 88.Remove the top cover. 89.Loosen one end of the flat cable (the one attached to the PCB) by pulling the flat cable connector cover up. On both sides of the connector cover there is a small protuberance that you can pry up using a screwdriver. Gently pull the flat cable out of the connector. 90.Pull the flat cable for the head off the flat cable for the keyboard. 91. 63. Note: 64. Pay close attention to the way the flat cable has been folded. It is advisable to fold the flat cable in exactly the same way when re-installed. 92. 93.Loosen the flat cable which has been glued to the inner side of the shaft's upright edge. 94.Remove the two screws (three screws in the case of a T-head) of the top cover of the head holding the flat cable in place. 95.Remove the cover. 96. 65. Note: 66. Pay close attention to the way the flat cable has been folded. The flat cable will need to be folded in exactly the same way when re-installed. 67. Loosen the end of the flat cable attached to the head. Follow the same procedure as before (see point 5).

Replacement Guidelines

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SummaSign

2-26

Service Manual

1 2 3 4 5 6

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

1 2 3

additional strip glued for about 2cm flatcable

Replacements Guidelines

Service Manual

SummaSign

To re-install, proceed as follows: 97.Put the flat cable into the connector of the head and close the connector. To ensure good contact, the flat cable must be positioned as deeply as possible and in the middle of the connector. 98. 68. Note: 69. If the flat cable is connected to a drag head it is advisable to allow for ±7 centimeters of slack. This slack is necessary to be able to upgrade to a tangential head,the connector of whichis located in a lower position. 99. 100.Put the flat cable across the top of the head and fold it correctly . 101. 102.Remount the top cover of the head. Press the cover down while firmly tightening the screws. Check that the up/down part of the head can move freely. 103.Remount the flat cable clamp. Check that the flat cable runs parallel to the inner side of the shaft's upright edge and that the up/down part of the head can move freely. 104.Slide the flat cable in between the upright edge of the shaft and the top of the head. 105.Bring the head all the way to the left. Make a loop to allow the head to move unhampered along the length of the unit. 70. Caution: 71. 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.

106.Glue the flat cable to the inner side of the shaft's upright edge, starting from the middle. 107.Slide the flat cable through the slot on the right-hand side of the shaft. 108.Put the flat cable into the connector and close the connector. The flat cable must be positioned as deeply as possible in the middle of the connector to have good contact. 109.Fold the cable into the correct position and press it onto the flat cable for the keyboard. 110.Proceed in the reverse order of removal. Make sure to firmly tighten all screws. 111. Additional strip in larger units: As mentioned at the beginning of this chapter, larger units have an additional strip that runs alongside the flat cable to prevent the flat cable from creasing. If you need to replace this strip make sure you insert the new strip as follows: 112. 113.Glue ± 2 cm of this end of the strip to the shaft's upright edge. 114.Glue the other end of the strip to the other upright edge of the shaft starting at the protrusion shown in the figure on page 2-26.

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1 2

2-28

Strip Pur unscrew the one closest to the head

Replacements Guidelines

Service Manual

SummaSign

REPLACING THE Y-BELT To replace the belt, proceed as follows: 115.Remove the left-hand cover (see Chapter 2. 1, Removing the left-hand cover). 116.Remove the right-hand cover (see Chapter 2.2, Removing the right-hand cover). 117.Remove the 2 screws holding the belt against the carriage plate. One is located to the left of the head and the other to the right. 118.Remove the belt. To re-install, proceed as follows: 119.Screw one end of the belt firmly against the carriage plate. 120.Put the belt around the left-hand pulley. Pull it along the length of the unit and put it around the right-hand pulley. 121.Screw the other end of the belt firmly to the carriage plate. 122.Proceed in the reverse order of removal. Make sure to firmly tighten all screws. 72. Note: 73. Because the belt is equipped with a springload system, the belt tension need not be adjusted. 123.

REPLACING THE CUTTING STRIP To replace the cutting strip, proceed as follows: 124.Loosen the cutting strip on the left-hand (or right-hand) side . 125.Gently pull the cutting strip out of the strip slot. 126.Cut the new cutting strip to the correct length and stick it to the unit. 127. 74. Note: 75. The newer models all have cutting strips with the tape included. There are two cutting strips. They have the following part numbers: 76. 391-386 for all the models 500/610 and 750; 77. 391-886 for all the models 1010 and 1300. 78. 79. Caution: 80. In older models, the strip is glued to the unit. To replace it with the new type of strip, proceed as follows: 81. 1. Loosen the strip on the left-hand (or right-hand) side. 82. 2. Place a chisel under the strip and move gently along the length of the unit. 83. 3. Remove any debris and thoroughly clean the strip slot. 128. 129. Cut the new strip to the correct length and stick it to the unit.

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130.

1 2 3 4 5 6

2-30

body fan fan guard screws + washers front sensor rear sensor

Replacements Guidelines

Service Manual

SummaSign

REPLACING THE SENSORS Cutters are equipped with two sensors. One is located at the front and the other at the rear of the machine. 84. Note: 85. When one sensor is malfunctioning it is advisable to replace both sensors. Experience has shown that soon after replacing the broken sensor, the other sensor tends to start malfunctioning as well. Therefore, to prevent having to perform the same repair twice within a short span of time, it is advisable to replace both sensors. To replace the sensors, proceed as follows: 131.Remove the right-hand cover (see Chapter 2.2, Removing the right hand cover). 132.Turn the unit upside down. 133.Remove the bottom plate (see Chapter 2.3, Removing the bottom plate). 134.Remove the screws holding the two sensors in place. Pay close attention to the positioning of the distance sleeves. They should be returned to their original location when re-installed. 135.Disconnect the other end of the sensor wire from the PCB. 136.Remove the sensors. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 86. Caution: 87. Make sure the sensor wire does not touch the drum. The rotating drum may damage the wire and cause malfunctioning. 137.

REPLACING THE FAN MOTOR 138. To replace the fan motor, proceed as follows: 139.Remove the right-hand cover (see Chapter 2.2, Removing the right hand cover). 140.Turn the unit upside down. 141.Remove the bottom plate (see Chapter 2.3, Removing the bottom plate) 142.Remove the four screws holding the fan motor in place. 143.Disconnect the other end of the fan motor wire from the PCB. 144.Remove the fan motor. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. 88. Caution: 89. Do not overtighten the 4 screws holding the fan in place as this may bend the fan's mounting flanges and cause malfunction. 90.

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Service Manual

91.

1 2 3 4 5

det1 det2 det3

2-32

body drum screws # depending on the type pulley see remark in text

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

Replacements Guidelines

Service Manual

SummaSign

REPLACING THE DRIVE DRUM To replace the drive drum, proceed as follows: 145.Remove the left-hand cover (see Chapter 2. 1, Removing the left-hand cover). 146.Turn the unit upside down. 147.Remove the bottom plate (see Chapter 2.3, Removing the bottom plate). 148.Remove the four screws holding the fan motor in place. Put the fan motor to the side to expose the drive drum. 149.Remove the screw of the sensor that goes across the drive drum. Put the sensor to the side to expose the drum. 150.Remove the various screws holding the drum sleeves in place. The number of sleeves varies depending on the cutter type. 151.Remove the three screws holding the X-motor(s) in place and put the motor to the side. It is not necessary to disconnect the wires connected to the motor. 152.Remove the belt. 153.Loosen the two setscrews holding the drive drum pulley in place. 154.Pull the pulley out to its full extent. The pulley need not be removed from the unit. 155.Remove the drive drum. 92. Note: 93. Because all the sleeves of the drive drum are accurately matched, it is not possible to replace just one sleeve. To re-install, proceed as follows: 156.Put the drum into the shaft in the correct position. The largest sleeve should be to the side of the keyboard. 157.Put the screws into the blocks but do not tighten them yet. 94. Note: 95. 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: 96. a.Secure the block to the left (or right) of the large sleeve by tightening its screws. Make sure the block is positioned perpendicularly over the holes and that the long sleeve is positioned in the middle of the hole in the base plate. 97. b.Press the block situatedto the right (or left) of the large sleeve firmly against the sleeve and tighten the screws of the block. 158. 159.Now firmly tighten the screws of the other blocks. Make sure they are positioned straight and that they do not have any play. Gently press the blocks against the sleeves when tightening the screws. 160. Thoroughly clean the strip slot. 161.Push the pulley back into its place.

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det1 det2 det3

body drum screws # depending on the type pulley see remark in text

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

162.

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SummaSign

163. 98. Note: 99. Make sure the setscrew is positioned correctly so that it locks itself into the slot. 164. 165.Firmly tighten the screws of the drive drum pulley. 166.Put the belt back into its original position. 167.Re-install the X-motor. Make sure to properly tighten all screws. 168.Re-install the fan motor. 169.Re-install the sensor wire. 170.Proceed in the reverse order of removal. Make sure to firmly tighten all screws. 171. 100. Caution: 101. Make sure the sensor wire does not touch the drive drum. The rotating drum may damage the wire and cause malfunctioning. 172. 102. Note: 103. Not all the different type of machines have this last bearing block. 104. If there is one make sure it is pushed to the side plate (a small ring inside makes sure the drum is grounded) 105. If there is none, check for a small brush which touches the shaft of the drum. If it is worn down, replace it. Here the brush ensures that the drum is grounded.

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106. 107.

Blank page

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Replacements Guidelines

Maintenance and Cleaning

3-1

SECTION 3 MAINTENANCE

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

Maintenance and Cleaning

3-1

SummaSignT-sesiceUser’s Ma

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

To clean the drive sleeves, proceed as follows:

1.

First disable the sensors by covering them, or via the configuration menu (see 1.4.12 Media Sensor).

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.

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 media.

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

7.

Set the cutter's power switch to OFF. VINYL STRIP

PINCH ROLLER

TACKY SIDE ON BOTTOM

SLEEVE

CLEANING OF THE DRIVE SLEEVES

3-2

Maintenance and Cleaning

Service Manual

SummaSignT-se

CLEANING THE SENSORS After a certain time, the sensor may become dirty with accumulated residue from the media. This situation may cause malfunctioning of the cutter. 

To clean the sensor area, proceed as follows:

1.

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

LOCATION OF THE SENSORS

2.

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

Maintenance and Cleaning

3-3

SummaSignT-sesiceUser’s Ma

CLEANING THE NOSE PIECE

CLEANIN The nose piece may become dirty with accumulated residue from the vinyl and 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 as described in section 1.7.

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Maintenance and Cleaning

Service Manual

3.2.

SummaSignT-se

OPERATING VOLTAGE CONVERSION

Maintenance and Cleaning

3-5

SummaSignT-sesiceUser’s Ma

OPERATING VOLTAGE CONVERSION The power entry module cover shows four possible AC voltage settings (100 V, 120 V, 220 V and 240 V). The pin in one of the holes indicates the cutter's active voltage setting. If this setting does not match the voltage supplied to your site, you must change the voltage BEFORE powering on the cutter. When changing the voltage setting, you will also have to change the fuses as appropriate to the voltage. To change the fuse(s), remove the fuse(s) from the fuse box behind the cover plate of the power entry module. For 100 or 120 V AC operation of cutters with 1 x-motor Pro unly 1.0 A Slo-Blo fuses. For 100 or 120 V AC operation of cutters with 2 x-motorsT750T,only 1.25 A Slo-Blo fuses. For 220 or 240 V AC operation of cutters with 1 x-motor , Pr0.5 A Slo-Blo fuses. For 220 or 240 V AC operation of cutters with 2 x-motors /T1010 Pro/TusSlo-Blo fuses.

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

POWER ENTRY MODULE

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blank page

Maintenance and Cleaning

3-7

Calibration

4-1

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

Calibration

4-1

SummaSign

Service Manual

MACHINE TYPE The machine type has to be reset when: The pcb has been changed a “special init” has been done Configuration of the pcb: via keyboard: 1. Initiate a start-up in Factory Set-up Mode (FSM mode or 3-key mode). Do this by switching on the unit while simultaneously pressing the up/down key, the "1" key and the Enter key until the message "Standard init" appears on the LCD.

1.

Caution:

2.

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

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

3.

Caution:

4. WHEN THE MACHINE HAS BEEN STARTED UP IN “SPECIAL INIT” EVERY PARAMETER IN THE MACHINE HAS BEEN DEFAULTED.

THEN

In 3-key mode the following extra items appear under system tests (along with several others, such as "Coil set-up", which are always available).: a. b. c. d. e. f. g. h. i. j.

4-2

Quality plot Set Margin: to set the margins Burn in: only used in factory Autobalance: only used in factory Set-up machine: to set the unit type Set-up tang. : to configure the tangential head Plot time System reg. : only used in factory NEC values: only used in factory ROM to flash: to flash from standard ROMs to flash EPROMs (to be used only when the flash EPROM is broken). (not in the old type boards).

Calibration

Service Manual

SummaSign

5. 6.

Caution: DO NOT USE THE SYSTEM TESTS MARKED

“FACTORY

USE ONLY”.

BE

EXTREMELY CAREFUL WHILE IN THAT MODE AND FOLLOW GIVEN GUIDELINES TO THE LETTER.

YOU

CAN INFLICT SERIOUS DAMAGE BEYOND REPAIR TO THE

MACHINE IF THE WRONG PARAMETERS ARE CHANGED.

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

Calibration

4-3

SummaSign

Service Manual

MEDIA CALIBRATION

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

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

Select “Media Calibration”.

Measure the test pattern and enter the measurementsit in the dialogue box.

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

4-4

Calibration

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Calibration

SummaSign

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HEAD CALIBRATION

4-6

Calibration

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SummaSign

KNIFE CALIBRATION ( tangential) It is recommended to recalibrate the knife each time it is changed. See section 1.5.1. for the calibration procedure. COIL CALIBRATION The coil has to be recalibrated when: the head is changed the PCB is changed when the cut quality is dubious Calibration: Power the machine up when there is no media loaded and while the knife is turned up. Go to internal system tests - coil set-up. Press the key. The following message is displayed on the LCD : 40 g PRESSURE 19 In the upper line of the LCD the desired pressure is displayed and the bottom line shows the value that has to be sent to the head to reach the pressure displayed. Press the key. The following message is displayed on the LCD : 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. (the max. pressure with a drag machine is 400grs). 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 a value lower than 40 gr. is shown on the tension gauge press the

Calibration

key to

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Service Manual

adjust. If a value higher then than 40 gr. is recorded on the tension gauge use key to adjust. the If you don’t have a tension gauge leave it at 19. Insert the drag knife holder into the head. Press the key to adjust the drag knife landing pressure. The following message will be displayed : DRAG LANDING 14 Press the 2).

key repeatedly until the drag-knife moves upwards (value around

Press the key repeatedly until the drag knife holder moves down (value around 11). Press the

key another three times.

Insert the ball-point holder into the head. Press the key to adjust the ball-point pen landing pressure. The following message will be displayed : PEN LANDING 14 Press the around 2).

key repeatedly until the ball-point pen moves upwards (value

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

key another three times.

Insert the knife holder into the head (the knife may not stick out). key to adjust the ball-point pen landing pressure. The following Press the message will be displayed : TANG LANDING 14 key repeatedly until the tangential knife goes in the up position Press the (value around 2). Press the 11)

key repeatedly until the tangential knife moves down (value around

Press the

key another three times.

Press the

4-8

(ONLINE) key and power the machine down.

Calibration

Service Manual

SummaSign

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

Calibration

4-9

SummaSign

Service Manual

OPOS CALIBRATION (optional) NORMAL CALIBRATION

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 on the LCD.

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

 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

4-10

Calibration

Service Manual

SummaSign

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.

Calibration

4-11

SummaSign

Service Manual

FINE TUNING 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 in cas of photoquality with thermal wax transfer). Calibration: Load vinyl. Make sure the Opos system is placed perpendicular on the media. Go to the internal test - system test-optical sensor. Remove the black piece of vinyl from the Opos sensor. Turn the left pot meter 15 turns CCW and the 8 turns CW . Place the sensor top above a piece of white matt media. Turn the right pot meter CCW until the LCD display shows a value higher than 300. Then turn CW until the value doesn’t decrease anymore and turn 1/8 of a turn CCW. Place the sensor above a glossy piece of black material. Turn the left pot meter CCW until the display doesn’t increase anymore (more than 8 turns is useless). This value is usually between 1950 and 2000. Continue with the normal calibration.

!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 readout above the media, more than 800. The left pot meter changes the gain and the right pot meter changes the threshold level between black and white.

4-12

Calibration

Service Manual

SummaSign

SENSOR TESTS

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

> 



is shown when the sensor is covered.

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

There is a possibility to change the positions of the bottom arrow with the left and right arrow on the keyboard. 1.

7.

C

Calibration

4-13

Troubleshooting-Error Codes

5-1

SECTION 5 Troubleshooting - Error codes General This section contains information on the error codes which can appear on the LCD screen. A step-by-step procedure is provided in this section to prevent this error.

Troubleshooting-Error Codes

5-1

SummaSign

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.

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: 7. 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. 8. Lower the speed of the media. 9. Check whether the drive drum turns smoothly (first turn the power off and place the cam rollers in the up-position). 10.If the error in the x-axis happens at start-up, check the x-axis motor, the encoder connectors and the cables. 11.Replace the X-motor encoder. 12.Replace the PCB. 13.

5-2

Troubleshooting-Error Codes

Service Manual

SummaSign

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: 14.Remove the crashed media and restart the machine. 15.Lower the speed and/or the knife pressure. 16.Check whether the head moves smoothly (first turn the power off and position the cam rollers on the outer edges of the media). 17.Check the y-axis motor and the encoder cables. 18.Replace the Y-motor. 19.Replace the PCB.

LOW LINE VOLTAGE Cause: The secondary voltage of the transformer 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: 20.Measure the line voltage. Check whether the voltage selector at the back of the machine is set to the correct line voltage. The line voltage should be between the selected voltage +8% or -10%. 21.Check the secondary voltage of the transformer. It should be at least 22VAC. If that is not the case, replace the transformer. 22.Check the DC power on the PCB (on the power cable going to the machine interface board). It should be at least 27VDC. 23.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. 24.When you have done this, plug in the cables one by one until the energy consumer is found. Replace it. 25.Replace the main PCB.

Troubleshooting-Error Codes

5-3

SummaSign

Service Manual

26.

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: 27.Measure the line voltage. Check whether the voltage selector at the back of the machine is set to the correct line voltage. The line voltage should be between the selected voltage +8% or -10%. 28.Check the secondary voltage of the transformer. It should be less than 30VAC. If that is not the case, replace the transformer. 29.Check the DC voltage on the PCB. It should be less than 37VDC. 30.Replace the main PCB. 31.

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: 32.Set DM/PL ERRORS to IGNORED in the MENU to avoid this message. 33.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. 34.Check the cut file for unknown dm/pl commands. 35.

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: 36.Set DM/PL ERRORS to IGNORED in the MENU to avoid this message. 37.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. 38.Check the cut file for unknown dm/pl commands. 39.

SYNTAX ERROR Cause:

5-4

Troubleshooting-Error Codes

Service Manual

SummaSign

Syntax errors occur when an incorrect HPGL command is received by the machine. The next table gives an overview: Error Number 1 2 3 5 7 10-18

Meaning Instruction is not recognised. Wrong number of parameters. Parameter is out of range or illegal character. Unknown character set. Buffer overflow for polygons or downloadable characters. Problems with Device Control Instruction.

Action: 40.Change the data sent to the machine. 41.Refer to the HPGL supported commands. 42. 43.

NVRAM FAILURES AND MESSAGES Non fatal errors: SYSTEM NVRAM HAS BEEN DEFAULTED DUE TO ROM CHANGE, USER NVRAM HAS BEEN DEFAULTED DUE TO ROM CHANGE Action: 44.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. 45.If it does replace PCB. 46. 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: 47.The preceding messages warn for a problem with the (NV)RAM. Important information can be lost, such as calibration, landing pressure. 48.Replace the main PCB. 49. 50.

RS232 ERROR Cause:

Troubleshooting-Error Codes

5-5

SummaSign

Service Manual

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: 51.Make sure that the loopback connections have been made. 52.Check for bad contacts in the RS232 area on the PCB. 53.Replace the main PCB. 54. 55.

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: 56.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. 57.Reflash the ROM’s on the main board. (change the ROM’s on the old type PCB) 58.Replace the main PCB.

5-6

Troubleshooting-Error Codes

Service Manual

SummaSign

59.

FLASHING ERRORS AND MESSAGES (ONLY ON NEW TYPE OF PCB) 60. Non fatal errors: ERASING FLASH, PROGRAMMING,READING IN FLASH FILE Action: 61.Message appears when the internal ROM’s are being reflashed. Just wait untill the operation is done. 62. 63. Fatal errors: ORDER ROM COULD NOT ERASE FLASH CORRUPTED UPGRADE FILE Action: 64.Those are fatal errors. The information in the internal ROM’s is not reliable any more. 65.Order ROM’s and do an internal reflash. 66.Change main PCB. 67. 68.

ROM ERROR Cause: ROM’s are going bad. Action: 69. 70.Reflash the ROM’s. 71.Replace the main PCB. 72.

RAM ERROR Cause: RAM’s are going bad. Action: 73. Replace the main PCB.

MACHINE UNABLE TO FIND THE KNIFE HOME POSITION Cause: The machine doesn’t find the home position for the tangential knife.

Troubleshooting-Error Codes

5-7

SummaSign

Service Manual

Action: 74.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. 75.Check the connection cable, which runs from the head to the PCB. 76.Check the machine with another head. 77.Replace the flat cable which runs from the head to the PCB. 78.Replace the main PCB. 79.

MARKERS NOT SENSED PROPERLY Cause: The machine has trouble during its special load sequence. Action: 80. Check whether there is dust on the sensor tip. 81.Make sure that the markers are black on a white surface. 82.Run the "OPTICAL SENSOR " test and use black and white vinyl to check the different reflection levels. 83.Make sure that the right settings are sent to the machine to sense the markers. 84.Check the flat cable going from the head to the PCB. 85.Should there still be problems, change OPOS. 86.

5-8

Troubleshooting-Error Codes

Figures

6-1

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

1 2 3 4 5 6 7 8 9 10

Figures

391-344 391-809 ND5000-9694 391-198 MB9124 391-152 421-567 421-165 ND5000-9643 ND5000-9683 ND5000-9769

assy motor with encoder assy motor without encoder screw M4x10 pulley+setscrew belt 110T pulley for 2 belts pulley for 1 belt assy idler pulley standoff M4x40 standoff M4x30 spring

6-1

SummaSign

1 391-132 2 391-168 391-150 3 421-229 4 391-344 5 391-346 6 391-342 7 MH0598 8 MH0071 9 ND5000-9175 10 ND5000-9276 11 MH1323 12 MH0899 13 ND5000-0856 14 ND5000-9265 15+16 391-361

6-2

Service Manual

plastic endplate right assy display PRO-version assy display transfo assy motor with encoder assy power entry module assy switc pinch-roller screw 6/32 nut 6/32 screw M2x10 flatwasher M2 screw 10/32 screw 6/32 nut M3 lockwasher M3 assy grounding wire

Figures

Service Manual

1 2 3 4 5 6 7

Figures

384-751 391-168 ND5000-9657 ND5000-9283 ND5000-9269 ND5000-9358 384-682

SummaSign

assy LCD module keyboard PRO series skiffy bus nylon washer 7x3.1x1.4 nut M2 Celrub 9x2mm LCD cable

6-3

SummaSign

1 421-140 2 MB0380 3 391-315 391-555 391-813 4 ND5000-9151 5 391-935 6 421-139 7 MH1317

6-4

Service Manual

shaft belt 150T ass y-belt 610/750 assy y-belt 1010 assy y-belt 1300 PEMstud M3 assy final control board dbl pulley E-ring

Figures

Service Manual

1 391-100 391-191 2 391-365 3 391-313 4 391-314 5 391-182 6 ND5000-9667 ND5000-9668 7 ND5000-9267 8 ND5000-9540 9 ND5000-9231 10 ND5000-9620 11 ND5000-9602 12 see prev. page 13 ND5000-9587 ND5000-9604

391-143 390-643 391-825

Figures

SummaSign

carriage plate 610/1010/1300 carriage plate 750 assy, excentric shaft assy concentric shaft assy flatcable holder flatcable clamp screw M2x4 (model 610/750) screw M2x5 (model 1010/1300 flatwasher M2 hexnut M4 lockwasher M4 washer 8x4.1x.3 screw M2x6 lockwasher M3 screw M3

flatcable 610/750 flatcable 1010/1300 clear shield 915x25 (for 1010/1300)

6-5

SummaSign

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

6-6

391-632 box tang head ND5000-9667 screw M2x4 ND5000-9267 flatwasher M2 391-655 assy motor tang head ND5000-9665 stand off M3 MH0624 washer ND5000-9663 stand off M2 391-662 pcb tang head 391-657 assy main shaft 391-658 assy up/down (coil) 391-627 nose piece (long) 391-613 pulley MB9125 belt ND5000-9666 screw M2x4 391-656 assy wire encoder 391-628 motor bracket 391-661 magnet assy 1 391-201 assy up-down 2 391-206 assy up-down support 3 391-209 magnet assy 4 391-213 bus mount assy 5 391-216 pcb drag head 6 391-215 guiding shaft 7 ND5000-9586 roller cage 4/6.20 8 MR9002 o-ring 4x2 9 ND5000-9596 o-ring 4x1 10 ND5000-9382 truarc 3.2 11 ND5000-9585 roller cage 4/6/2.5 12 ND5000-9584 shaft 4x43.8 13 ND5000-9583 zackenring ZJ10 14 ND5000-0856 nut M3 15 ND5000-9587 external lockwasher M3 16 ND5000-0328 flatwasher M3 17 ND5000-9582 spring .32x4.32x19 18 ND5000-9581 screw M2.5x6 19 ND5000-9558 flatwasher M2.5

Service Manual

Figures

Service Manual

SummaSign

1 391-112 391-405 391-178 2 391-317 391-705 391-735 391-414 391-804 3 ND5000-9695 4 391-113 391-410 391-187 5 391-320 391-803 6 MF0067 7 ND5000-9315 8 ND5000-9606

1 2 3 4 5 6 7 8 9 10

391-153 ND5000-9371 ND5000-9694 ND5000-9332 ND5000-9613 ND5000-9636 391-138 ND5000-9614 ND5000-9613 391-125 391-402 391-174

Figures

base extension plate 610/750 base extension plate 1010 base extension plate 1300 drive drum 610 drive drum 750 old (4 small sleeves) drive drum 750 new (5 small sleeves) drive drum 1010 drive drum 1300 screw M4x20 bottom plate 610/750 bottom plate 1010 bottom plate 1300 fan assy 610/750 fan assy 1010/1300 guard fan flatwasher M4 screw M4x45

cam detection ring spring screw M4x10 screw M4x12 washer 08x8x10 bus 8.2,12,15 lever pinch roller starlock 8 washer 08x8x10 pinch roller bar 610/750 pinch roller bar 1010 pinch roller bar 1300

6-7

SummaSign

1 391-147 391-415 391-751 2 ND5000-9634 3 391-130 4 ND5000-9633 5 ND5000-9632 6 ND5000-9499 7 ND5000-9631 8 391-183 9 391-171

Service Manual

rol 610/750 rol 1010 rol 1300 washer 8.2x25x2.5 distance bus 8x13x3 lockwasher M8 screw M8x16 corex cap screw M8x16 DIN 912 brake roller guiding

1 2 3 4

6-8

391-171 ND5000-9651 ND5000-9698 391-183

roller guiding O-ring dia 48x5 O-ring dia 52x3 brake

Figures

Service Manual

SummaSign

1 2 3 4 5 6 7

Figures

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

6-9

SummaSign

Service Manual

Blank page

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

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

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

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

6-10

Figures

Spare Parts List

7-1

SummaCut D500 SPARE PARTS End of Manufacture: MAY, 1996

Part no

384-751 391-198 391-200 391-312 391-318 391-319 391-320 391-326 391-342 391-344 391-346 391-386 391-463 391-510 391-553 391-555 391-557 391-759 391-935 421-282 421-283 423-155 MB0380 MB9124 MW9987 MW9988

Spare Parts List

Description

Assy LCD module Pulley 24 tooth + setscrew Assy drag head Roller assy Media sensor rear assy Media sensor front Fan assy Assy pinch roller Assy switch pinch roller Assy motor Assy, power entry module Cutting strip with tape Keyboard Set of core holder Drum Belt assy Assy drag board Antistatic brush Assy final control board End cover right End cover left Serial interface cable Belt MXL 150T80 Belt MXL 110T80 ROM lo (rev 010) old board ROM hi (rev 010) old board

7-1

Spare Parts List

7-2

SummaSign D610 SPARE PARTS End of Manufacture: April, 1996 Part no.

Description

384-682 384-751 391-117 391-143 391-144 391-150 391-200 391-222 391-224 391-227 391-311

LCD cable Assy LCD module Spring Flat cable Cutting Strip 84 cm Display keyboard Assy, drag head Cover head Knife, offset 0.45 Lock nut knife holder Centron drag & tang board Roller assy Belt assy Drive drum, Assy Media sensor rear assy Media sensor front assy Fan assy Assy, pinch roller Knife holder assy Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Cutting strip with tape Set of Core holders Assy, final control board Belt 150T80 Belt 110T80 Rom U24 rev 010 Rom U17 rev 010 Knob coreholder O-ring

391-312 391-315 391-317 391-318 391-319 391-320 391-326 391-332 391-342 391-344 391-346 391-366 391-367 391-386 391-510 391-935 MB0380 MB9124 MW9987 MW9988 ND5000-9622 ND5000-9646

391-348 391-358 391-360 391-363 391-400 391-500 391-510 391-595 391-785 423-155 MC1184 MC3545 MI9990

Razor Blade & Holder Sandblast Knife blade Standard Knife Blade Sandblast Knife Holder Cutter Stand (optional) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool Drag OPOS Field upgrade kit Drag Serial Interface Kit Power Supply Cables European type Power Supply Cables American type User’s Manual

ACCESSORIES AND CONSUMABLES 391-146 391-332

Manual Cut-Off Razor Blades (set of 10) Standard Knife Holder

Spare Parts List

7-2

Service Manual

SummaSign

SummaSign D610 PRO SPARE PARTS End of Manufacture: Current Part no.

384-682 384-751 391-117 391-143 391-144 391-168 391-200 391-222 391-224 391-227 391-281 391-312 391-315 391-317 391-318 391-319 391-320 391-326 391-332 391-342 391-344 391-346 391-366 391-367 391-386 391-510 391-935 MB0380 MB9124 ND5000-9622 ND5000-9646 ND5000-9769

Description

LCD cable Assy LCD module Spring Flat cable Cutting Strip 84 cm Display keyboard Assy, drag head Cover head Knife, offset 0.45 Lock nut knife holder Nameplate D610 Pro Roller assy Belt assy Drive drum, Assy Media sensor rear assy Media sensor front assy Fan assy Assy, pinch roller Knife holder assy Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Cutting strip with tape Core holders Assy, final control board Belt 150T80 Belt 110T80 Knob coreholder O-ring Y belt spring

391-348 391-358 391-360 391-363 391-400 391-500 391-510 391-595 391-785 423-155 MC1184 MC3545 MI9020

Razor Blade & Holder Sandblast Knife blade Standard Knife Blade Sandblast Knife Holder Cutter Stand (optional) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool OPOS Field upgrade kit Drag Serial Interface Kit Power Supply Cables European type Power Supply Cables American type User’s Manual + Software on CD

Accessories and consumables 391-146 391-332

Manual Cut-Off Razor Blades (set of 10) Standard Knife Holder

Spare Parts List

7-3

Summasign

Service Manual

SummaSign T610 SPARE PARTS End of Manufacture: APRIL, 1996

Part no.

Description

390-551 391-146

384-682 384-751 391-117 391-143 391-150 391-311

LCD cable Assy LCD module Spring Flat cable Display keyboard Centron drag & tang board Roller assy Belt assy Drive drum, Assy Media sensor rear assy Media sensor front assy Assy, pinch roller Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Cutting strip with tape Set of core holder Assy, tangential head Cover head DC motor tang. head Assy, final control board Bearing block Belt 150T80 Belt 110T80 Belt 63T 2mm Knob core holder Brake O ring

391-348 391-360

391-312 391-315 391-317 391-318 391-319 391-326 391-342 391-344 391-346 391-366 391-367 391-386 391-510 391-600 391-601 391-655 391-935 421-198 MB0380 MB9124 MB9125 ND5000-9622 ND5000-9698

391-400 391-500 391-510 391-596 391-663 391-664 391-666 391-667 391-668 391-669 391-885 423-155 MI9985

Double Tip Knife (single) Manual Cut-Off razor Blades (set of 10) Razor Blade & Holder Drag Knife Blade (set of 5) Cutter Stand (optional) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool Tangential Knife Holder Standard Nose Piece Nose Piece for Masking Stencil (sandblast) Ballpoint Holder Holder for Drag Knife Ballpoint Pen OPOS Field Upgrade Kit T-series Serial Interface Kit User’s Manual

Accessories and Consumables 390-549 390-550

7-4

Standard Tangential Knife Blade (Single) Tangential knife for Masking stencil (sandblast - single)

Spare Parts List

Service Manual

SummaSign

SummaSign T610 PRO SPARE PARTS End of Manufacture: Current

Part no.

384-682 384-751 391-117 391-143 391-168 391-282 391-312 391-315 391-317 391-318 391-319 391-326 391-342 391-344 391-346 391-366 391-367 391-386 391-510 391-600 391-601 391-655 391-935 421-198 MB0380 MB9124 MB9125 ND5000-9622 ND5000-9698 ND5000-9769

Description

LCD cable Assy LCD module Spring Flat cable Display keyboard Nameplate T610 Pro Roller assy Belt assy Drive drum, Assy Media sensor rear assy Media sensor front assy Assy, pinch roller Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Cutting strip with tape Set of core holder Assy, tangential head Cover head DC motor tang. head Assy, final control board Bearing block Belt 150T80 Belt 110T80 Belt 63T 2mm Knob core holder Brake O ring Y belt spring

Spare Parts List

Accessories and Consumables 390-549 390-550 390-551 391-146 391-348 391-360 391-400 391-500 391-510 391-596 391-663 391-664 391-666 391-667 391-668 391-669 391-885 423-155 MD9020

Standard Tangential Knife Blade (Single) Tangential knife for Masking stencil (sandblast) Double Tip Knife (single) Manual Cut-Off razor Blades (set of 10) Razor Blade & Holder Drag Knife Blade (set of 5) Cutter Stand (optional) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool Tangential Knife Holder Standard Nose Piece Nose Piece for Masking Stencil (sandblast) Ballpoint Holder Holder for Drag Knife Ballpoint Pen OPOS Field Upgrade Kit Tseries Serial Interface Kit User’s Manual on CD

7-5

Summasign

Service Manual

SummaSign D750 SPARE PARTS End of Manufacture: April, 1996

Part no.

Description

384-682 384-751 391-117 391-143 391-144 391-150 391-200 391-222 391-224 391-227 391-311

LCD cable Assy LCD module Spring Flat cable Cutting Strip 84 cm Display keyboard Assy, drag head Cover head Knife, offset 0.45 Lock nut knife holder Centron drag & tang board Roller assy Belt assy Media sensor rear assy Media sensor front assy Fan assy Assy, pinch roller Knife holder assy Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Cutting strip with tape Set of Core holders Drive drum, Assy Assy, final control board Belt 150T80 Belt 110T80 Rom U24 rev 010 Rom U17 rev 010 Knob coreholder O-ring

391-312 391-315 391-318 391-319 391-320 391-326 391-332 391-342 391-344 391-346 391-366 391-367 391-386 391-510 391-705 391-935 MB0380 MB9124 MW9987 MW9988 ND5000-9622 ND5000-9646

7-6

Accessories and consumables 391-146 391-332 391-348 391-358 391-360 391-363 391-400 391-500 391-510 391-595 391-785 423-155 MC1184 MC3545 MI9990

Manual Cut-Off Razor Blades (set of 10) Standard Knife Holder Razor Blade & Holder Sandblast Knife blade Standard Knife Blade Sandblast Knife Holder Cutter Stand (optional) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool Drag OPOS Field upgrade kit Drag Serial Interface Kit Power Supply Cables European type Power Supply Cables American type User’s Manual

Spare Parts List

Service Manual

SummaSign

SummaSign D750 PRO SPARE PARTS End of Manufacture: Current

Part no.

Description

384-682 384-751 391-117 391-143 391-144 391-168 391-200 391-222 391-224 391-227 391-283 391-312 391-315 391-318 391-319 391-320 391-326 391-332 391-342 391-344 391-346 391-366 391-367 391-386 391-510 391-705

LCD cable Assy LCD module Spring Flat cable Cutting Strip 84 cm Display keyboard Assy, drag head Cover head Knife, offset 0.45 Lock nut knife holder Nameplate D750 Pro Roller assy Belt assy Media sensor rear assy Media sensor front assy Fan assy Assy, pinch roller Knife holder assy Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Cutting strip with tape Core holders Drive drum, Assy old (4 small sleeves) Drive drum, Assy new (5 small sleeves) Assy, final control board Belt 150T80 Belt 110T80 Knob coreholder O-ring Y belt spring

Accessories and consumables

391-735 391-935 MB0380 MB9124 ND5000-9622 ND5000-9646 ND5000-9769

Spare Parts List

391-146 391-332 391-348 391-358 391-360 391-363 391-400 391-500 391-510 391-595 391-785 423-155 MC1184 MC3545 MI9020

Manual Cut-Off Razor Blades (set of 10) Standard Knife Holder Razor Blade & Holder Sandblast Knife blade Standard Knife Blade Sandblast Knife Holder Cutter Stand (optional) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool Drag OPOS Field upgrade kit Drag Serial Interface Kit Power Supply Cables European type Power Supply Cables American type User’s Manual + Software on CD

7-7

Summasign

Service Manual

SummaSign T750 SPARE PARTS End of Manufacture: APRIL, 1996

Part no.

Description

384-682 384-751 391-117 391-143 391-150 391-311

LCD cable Assy LCD module Spring Flat cable Display keyboard Centron drag & tang board Roller assy Belt assy Media sensor rear assy Media sensor front assy Assy, pinch roller Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Cutting strip with tape Set of core holders Assy, tangential head Cover head DC motor tang. head Drive drum, Assy Assy, final control board Bearing block Belt 150T80 Belt 110T80 Belt 63T 2mm Knob core holder Brake O ring

391-312 391-315 391-318 391-319 391-326 391-342 391-344 391-346 391-366 391-367 391-386 391-510 391-600 391-601 391-655 391-705 391-935 421-198 MB0380 MB9124 MB9125 ND5000-9622 ND5000-9698

391-146 391-348 391-360 391-400 391-500 391-510 391-596 391-663 391-664 391-666 391-667 391-668 391-669 391-885 423-155 MI9985

Manual Cut-Off razor Blades (set of 10) Razor Blade & Holder Drag Knife Blade (set of 5) Cutter Stand (optional) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool Tangential Knife Holder Standard Nose Piece Nose Piece for Masking Stencil (sandblast) Ballpoint Holder Holder for Drag Knife Ballpoint Pen OPOS Field Upgrade Kit T-series Serial Interface Kit User’s Manual

Accessories and Consumables 390-549 390-550

390-551

7-8

Standard Tangential Knife Blade (Single) Tangential knife for Masking stencil (sandblast - single) Double Tip Knife (single)

Spare Parts List

Service Manual

SummaSign

SummaSign T750 PRO SPARE PARTS End of Manufacture: Current

Part no.

Description

384-682 384-751 391-117 391-143 391-168 391-224 391-284 391-312 391-315 391-318 391-319 391-326 391-342 391-344 391-346 391-366 391-367 391-386 391-510 391-600 391-601 391-655 391-705

LCD cable Assy LCD module Spring Flat cable Display keyboard Knife, offset 0.45 Nameplate T750 Pro Roller assy Belt assy Media sensor rear assy Media sensor front assy Assy, pinch roller Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Cutting strip with tape Core holder Assy, tangential head Cover head DC motor tang. head Drive drum, Assy old (4 small sleeves) Drive drum, Assy new (5 small sleeves) Assy, final control board Bearing block Belt 150T80 Belt 110T80 Belt 63T 2mm Knob core holder Brake O ring

391-735 391-935 421-198 MB0380 MB9124 MB9125 ND5000-9622 ND5000-9698

Spare Parts List

ND5000-9769

Y belt spring

Accessories and Consumables 390-549 390-550

390-551 391-146 391-348 391-360 391-400 391-500 391-510 391-596 391-663 391-664 391-666 391-667 391-668 391-669 391-885 423-155 MD9020

Standard Tangential Knife Blade (Single) Tangential knife for Masking stencil (sandblast) Double Tip Knife (single) Manual Cut-Off razor Blades (set of 10) Razor Blade & Holder Drag Knife Blade (set of 5) Cutter Stand (optional) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool Tangential Knife Holder Standard Nose Piece Nose Piece for Masking Stencil (sandblast) Ballpoint Holder Holder for Drag Knife Ballpoint Pen OPOS Field Upgrade Kit T-series Serial Interface Kit User ’s Manual on CD

7-9

Summasign

Service Manual

SummaSign D1010 SPARE PARTS End of Manufacture: April, 1996

Part no.

Description

384-682 384-751 390-643 391-117 391-150 391-200 391-222 391-224 391-227 391-311

LCD cable Assy LCD module Flat cable Spring Display keyboard Assy, drag head Cover head Knife, offset 0.45 Lock nut knife holder Centron drag & tang board Roller assy Media sensor rear assy Media sensor front assy Assy, pinch roller Knife holder assy Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Drive drum, Assy Belt assy Set of Core holders Fan assy Assy motor without encoder Cutting strip with tape Assy, final control board Pulley 24 tooth + setscrew Belt 150T80

391-312 391-318 391-319 391-326 391-332 391-342 391-344 391-346 391-366 391-367 391-414 391-421 391-510 391-803 391-809 391-886 391-935 398-198 MB0380

MB9124 MW9987 MW9988 ND5000-9622 ND5000-9646

Accessories and consumables 391-146 391-332 391-348 391-358 391-360 391-363 391-500 391-510 391-595 391-785 391-850 423-155 MC1184 MC3545 MI9990

7-10

Belt 110T80 Rom U24 rev 010 Rom U17 rev 010 Knob coreholder O-ring

Manual Cut-Off Razor Blades (set of 10) Standard Knife Holder Razor Blade & Holder Sandblast Knife blade Standard Knife Blade Sandblast Knife Holder Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool OPOS Field upgrade kit Drag Cutter Stand Serial Interface Kit Power Supply Cables European type Power Supply Cables American type User’s Manual

Spare Parts List

Service Manual

SummaSign

SummaSign D1010 PRO SPARE PARTS End of Manufacture: Current

Part no.

Description

384-682 384-751 390-643 391-117 391-168 391-200 391-222 391-224 391-227 391-285 391-312 391-318 391-319 391-326 391-332 391-342 391-344 391-346 391-366 391-367 391-414 391-421 391-510 391-803 391-886 391-935 MB0380 MB9124 ND5000-9622 ND5000-9646 ND5000-9769

LCD cable Assy LCD module Flat cable Spring Display keyboard Assy, drag head Cover head Knife, offset 0.45 Lock nut knife holder Nameplate D1010 Pro Roller assy Media sensor rear assy Media sensor front assy Assy, pinch roller Knife holder assy Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Drive drum, Assy Belt assy Core holders Fan assy Cutting strip with tape Assy, final control board Belt 150T80 Belt 110T80 Knob coreholder O-ring Y belt spring

391-332 391-348 391-358 391-360 391-363 391-500 391-510 391-595 391-785 391-850 423-155 MC1184 MC3545 MI9020

Standard Knife Holder Razor Blade & Holder Sandblast Knife blade Standard Knife Blade Sandblast Knife Holder Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool OPOS Field upgrade kit Drag Cutter Stand (optional) Serial Interface Kit Power Supply Cables European type Power Supply Cables American type User’s Manual + Software on CD

Accessories and consumables 391-146

Manual Cut-Off Razor Blades (set of 10)

Spare Parts List

711

Summasign

Service Manual

SummaSign T1010 SPARE PARTS End of Manufacture: APRIL, 1996

Part no.

Description 390-550

384-682 384-751 390-643 391-117 391-150 391-311 391-312 391-318 391-319 391-326 391-342 391-344 391-346 391-366 391-367 391-414 391-421 391-510 391-600 391-601 391-655 391-886 391-935 421-198 MB0380 MB9124 MB9125 ND5000-9622 ND5000-9698

LCD cable Assy LCD module Flat cable Spring Display keyboard Centron drag & tang board Roller assy Media sensor rear assy Media sensor front assy Assy, pinch roller Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Drive drum, Assy Belt assy Set of core holders Assy, tangential head Cover head DC motor tang. head Cutting strip with tape Assy, final control board Bearing block Belt 150T80 Belt 110T80 Belt 63T 2mm Knob core holder Brake O ring

390-551 391-146 391-348 391-360 391-500 391-510 391-663 391-664 391-666 391-667 391-668 391-669 391-850 391-885 391-596 423-155 MI9985

Blade (Single) Tangential knife for Masking stencil (sandblast - single) Double Tip Knife (single) Manual Cut-Off razor Blades (set of 10) Razor Blade & Holder Drag Knife Blade (set of 5) Flange for Roll Media (single) Flanges for Roll Media (pair) Tangential Knife Holder Standard Nose Piece Nose Piece for Masking Stencil (sandblast) Ballpoint Holder Holder for Drag Knife Ballpoint Pen Cutter Stand (optional) OPOS Field Upgrade Kit Tseries Pouncing Tool Serial Interface Kit User’s Manual

Accessories and Consumables 390-549

7-12

Standard Tangential Knife

Spare Parts List

Service Manual

Spare Parts List

SummaSign

713

Summasign

Service Manual

SummaSign T1010 PLUS SPARE End of Manufacture: Current

Part no

Description

384-751 390-643 391-254 391-261 391-263 391-311

Assy LCD module Flat cable head Assy belt Y 1010 Plus Drum Assy sensor Centron drag & tang. board Roller assy Media sensor rear assy Media sensor front assy Assy pinch roller Assy switch roller Assy motor Power entry module Endcover left black plastic Set of core holders Assy tangential head Assy DC motor head Assy nose piece long Nose piece, sandblast Fan assy Motor without encoder Cutting strip with tape Final controller board Pulley 24 tooth + setscrew Serial interface cable Belt 150T80 Bearing Belt 140T80 Belt 370T EPROM lo EPROM hi

391-312 391-318 391-319 391-326 391-342 391-344 391-346 391-367 391-510 391-600 391-655 391-664 391-666 391-803 391-809 391-886 391-935 398-198 423-155 MB0380 MB9121 MB9129 MB9130 MW9987 MW9988

7-14

ND5000-9702

Spring sprocket assy

Accessories and Consumables 390-549 390-550

390-551 391-146 391-348 391-360 391-500 391-510 391-596 391-663 391-664 391-666 391-667 391-668 391-669 391-850 391-885 423-155 MI9985

Standard Tangential Knife Blade (Single) Tangential knife for Masking stencil (sandblast) Double Tip Knife (single) Manual Cut-Off razor Blades (set of 10) Razor Blade & Holder Drag Knife Blade (set of 5) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool Tangential Knife Holder Standard Nose Piece Nose Piece for Masking Stencil (sandblast) Ballpoint Holder Holder for Drag Knife Ballpoint Pen Cutter Stand (standard) OPOS Field Upgrade Kit Serial Interface Kit User’s Manual

Spare Parts List

Service Manual

SummaSign

SummaSign T1010 PRO SPARE End of Manufacture: Current

Part no

Description

390-643 391-168 391-286 391-312 391-318 391-319 391-326 391-342 391-344 391-346 391-366

Flat cable Keyboard Nameplate T1010 Pro Roller assy Media sensor rear Media sensor front Assy pinch roller Switch pinch roller Assy motor Power entry module Endcover right blk plastic Endcover left blk plastic Drum Assy belt Core holder Assy tangential head Assy DC motor T head Assy nose piece long Fan assy Motor without encoder Cutting strip with tape Assy final control board Pulley 24 tooth + setscrew Bearing block Transformer Serial interface cable Y belt spring

391-367 391-414 391-421 391-510 391-600 391-655 391-664 391-803 391-809 391-886 391-935 398-198 421-198 421-229 423-155 ND5000-9769

Accessories and Consumables 390-549 390-550 390-551 391-146

Standard Tangential Knife Blade (Single) Tangential knife for Masking stencil (sandblast) Double Tip Knife (single) Manual Cut-Off razor

Spare Parts List

715

Summasign

7-16

Service Manual

Spare Parts List

Service Manual

SummaSign

391-348 391-360 391-500 391-510 391-596 391-663 391-664 391-666 391-667 391-668 391-669 391-850 391-885 423-155 MD9020

Spare Parts List

Blades (set of 10) Razor Blade & Holder Drag Knife Blade (set of 5) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool Tangential Knife Holder Standard Nose Piece Nose Piece for Masking Stencil (sandblast) Ballpoint Holder Holder for Drag Knife Ballpoint Pen Cutter Stand (standard) OPOS Field Upgrade Kit Serial Interface Kit User’s Manual

717

Summasign

Service Manual

SummaSign D1300 SPARE PARTS End of Manufacture: APRIL, 1996 Accessories and consumables Part no.

Description 391-146

384-682 384-751 390-643 391-117 391-150 391-200 391-222 391-224 391-311 391-312 391-318 391-319 391-320 391-326 391-332 391-342 391-344 391-346 391-366 391-367 391-510 391-803 391-804 391-809 391-813 391-860 391-886 391-935 421-198 MB0380 MB9124 MW9955 MW9965

7-18

LCD cable Assy LCD module Flat cable Spring Display keyboard Assy, drag head Cover head Knife, offset 0.45 Centron drag & tang. board Roller assy Media sensor rear assy Media sensor front assy Fan assy Assy, pinch roller Knife holder assy Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Set of core holders Fan assy Drive drum, Assy Assy motor without encoder Belt assy Assy driver PCB 1300 Cutting strip with tape Assy, final control board Bearing block Belt timing Belt 110 Rom U24 Rom U17

391-332 391-348 391-358 391-360 391-363 391-500 391-510 391-595 391-785 391-850 423-155 MC1184 MI9990

Manual Cut-Off Razor Blades (set of 10) Standard Knife Holder Razor Blade & Holder Sandblast Knife blade Standard Knife Blade Sandblast Knife Holder Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool OPOS Field Upgrade Kit Cutter Stand Serial Interface Kit Power Supply Cables User’s Manual

Spare Parts List

Service Manual

SummaSign

SummaSign D1300 PRO SPARE PARTS End of Manufacture: Current

Part no.

384-682 384-751 390-643 391-117 391-168 391-200 391-222 391-224 391-287 391-311 391-312 391-318 391-319 391-320 391-326 391-332 391-342 391-344 391-346 391-366 391-367 391-510 391-803 391-804 391-809 391-813 391-860 391-886 391-935 421-198 MB0380 MB9124 ND5000-9769

Description

LCD cable Assy LCD module Flat cable Spring Display keyboard Assy, drag head Cover head Knife, offset 0.45 Nameplate D1300 Pro Assy, Centron drag & tang. board Roller assy Media sensor rear assy Media sensor front assy Fan assy Assy, pinch roller Knife holder assy Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Core holder Fan assy Drive drum, Assy Assy motor without encoder Belt assy Assy driver PCB 1300 Cutting strip with tape Assy, final control board Bearing block Belt 150T80 Belt 110T80 Y belt spring

Spare Parts List

Accessories and consumables 391-146 391-332 391-348 391-358 391-360 391-363 391-500 391-510 391-785 391-850 391-595 423-155 MC1184 MI9990

Manual Cut-Off Razor Blades (set of 10) Standard Knife Holder Razor Blade & Holder Sandblast Knife blade Standard Knife Blade Sandblast Knife Holder Flange for Roll Media (single) Flanges for Roll Media (pair) OPOS Field Upgrade Kit Cutter Stand Pouncing Tool Serial Interface Kit Power Supply Cables User’s Manual

719

Summasign

Service Manual

SummaSign T1300 SPARE PARTS End of Manufacture: APRIL, 1996

Part no.

384-571 384-682 390-643 391-150 391-311 391-312 391-318 391-319 391-326 391-342 391-344 391-346 391-366 391-367 391-510 391-600 391-601 391-655 391-803 391-804 391-809 391-813 391-860 391-886 391-935 MB0380 MB9124 MB9125 MW9987 MW9988

Description

Assy LCD module LCD cable Flat cable Display keyboard Centron drag & tang. board Roller assy Media sensor rear assy Media sensor front assy Assy, pinch roller Assy, swit ch pinch roller Assy, motor Power entry module Endcover right Endcover left Set of core holders Assy, tangential head Cover head DC motor tang. head Fan assy Drive drum, Assy Motor without encoder Belt assy D1300 Assy driver PCB 1300 Cutting strip with tape Final control board T1300 Belt 150T80 Belt 110T80 Belt 63T 2mm Rom U24 Rom U17

391-360 391-500 391-510 391-596 391-663 391-664 391-666 391-667 391-668 391-669 391-850 391-885 423-155 MI9985

Drag Knife Blade (set of 5) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool Tangential Knife Holder Standard Nose Piece Nose Piece for Masking Stencil (sandblast) Ballpoint Holder Holder for Drag Knife Ballpoint Pen Cutter Stand (standard) OPOS Field Upgrade Kit Serial Interface Kit User’s Manual

Accessories and Consumables 390-549 390-550 390-551 391-146 391-348

7-20

Standard Tangential Knife Blade (Single) Tangential knife for Masking stencil (sandblast) Double Tip Knife (single) Manual Cut-Off razor Blades (set of 10) Razor Blade & Holder

Spare Parts List

Service Manual

SummaSign

SummaSign T1300 PRO SPARE PARTS End of Manufacture: Current

Part no.

384-682 384-751 390-643 391-117 391-168 391-224 391-288 391-312 391-318 391-319 391-326 391-342 391-344 391-346 391-366 391-367 391-510 391-600 391-601 391-655 391-803 391-804 391-809 391-813 391-860 391-886 391-935 MB0380 MB9124

Description

LCD cable Assy LCD module Flat cable Spring Display keyboard Knife, offset 0.45 Nameplate T1300 Pro Roller assy Media sensor rear assy Media sensor front assy Assy, pinch roller Assy, switch pinch roller Assy, motor Power entry module Endcover right Endcover left Core holder Assy, tangential head Cover head DC motor tang. head Fan assy Drive drum, Assy Motor without encoder Belt assy D1300 Assy driver PCB 1300 Cutting strip with tape Final control board T1300 Belt 150T80 Belt 110T80

Spare Parts List

MB9125 ND5000-9769

Belt 63T 2mm Y belt spring

Accessories and Consumables 390-549 390-550 390-551 391-146 391-348 391-360 391-500 391-510 391-596 391-663 391-664 391-666 391-667 391-668 391-669 391-850 391-885 423-155 MD9020

Standard Tangential Knife Blade (Single) Tangential knife for Masking stencil (sandblast) Double Tip Knife (single) Manual Cut-Off razor Blades (set of 10) Razor Blade & Holder Drag Knife Blade (set of 5) Flange for Roll Media (single) Flanges for Roll Media (pair) Pouncing Tool Tangential Knife Holder Standard Nose Piece Nose Piece for Masking Stencil (sandblast) Ballpoint Holder Holder for Drag Knife Ballpoint Pen Cutter Stand (standard) OPOS Field Upgrade Kit Serial Interface Kit User’s Manual

721

CHANGING BRAKE

THE

O-RING

ON

THE

To remove the left-hand cover, proceed as follows: 1. Remove the five screws (four long screws and a short screw) holding the left-hand cover in place. Three are located at the front, one at the rear and one at the bottom (it is not necessary to turn the unit upside down to remove the bottom screw). 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. (fig1)

fig1 4. Unscrew the black bolt situated on place 1 in fig 2. 5. Gently lift the lift and slide the two bushing which normaly hold the flanges. 6. Take the o-ring(s) of the brake (black part on the end of the roll). 7. Put new o-rings on it.

fig2 To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

REMOVING THE LEFT HAND COVER To remove the left-hand cover, proceed as follows: 1. Remove the five screws holding the left cover in place. Two are located at the back, one at the top, one at the bottom and in front just under the baseplate Pay attention to where each of the screw goes. They should be returned to their original location when re-installed. 2. Gently tap the top of the cover. 3. Be careful not to tear the flatcable off the keyboard 4. Remove the connector. Play close attention to where the connector of the flatcable goes. It should be returned to its original location (top three pins uncovered) 5. Remove the cover. To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

!

CAUTION

Make sure that you do not jam any wires between the cover and the side plate as this may cause considerable damage.

Procedure to flash from internal ROM’s General: There exist a critical point of time on which you may not switch of the machine while you reflash it. Normally if you wait long enough there will not occur any problems. In case something rare happens during reflashing and you are unable to boot the pcb then there exist a method to falsh the flash Rom’s from internal Rom’s. Procedure: 1. Do all the necessary stuff to expose the main PCB, make sure the unit is not powered on. 2. Put in MW9955 and MW9965 in (LO and HI are marked on the PCB) 3. Put jumpers next to the ROM’s on 12 and 34 (this usually means that they all have to be put one pin lower). 4.Power the unit on, wait for at least 5 minutes (the cutter beeps if it is ready). 5.Power the unit down. 6. Remove the ROM’s, put the jumpers back on position 23 and 45. 7. Power the unit back on and check whether the flashed PCB works. 8. Put everything back you’ve disassembled.

Internal Reflash

B-1

APPENDIX A Removal of the left side General Under normal conditions, it is not advisable to remove the left side because the base is assembled with different fixtures and molds to ensure straightness of the base. However in some unexceptional conditions, it might be necessary to do so. The following procedure is a guideline to do so, but does not guarentee succes. Some unforseen things can happen which will make the unit unstable. Therefore the suggested test at the end of the explanation should be performmed meticolous to either ensure good performance of the machine or either suggest a special handling, done by a certified calcomp thechnitian, or a second “operation” guided over the phone with a calcomp technician. Also make sure that you a spare stralock for 8 as a spare since the one that will be removed will be damaged during removal.

Procedure To remove the left side proceed as follows:

1. Take the machine of its stand. Put it on a steady and flat table. 1. !!Open the camrollers and leave the lever in that position until the top cover is back on the machine!!

2. Remove the left and right cover. (2 times 5 screws) 3. Remove the top cover. (4 screws - mind the washers, if any, between the cover and the side.) 4. Remove the headcover. (2 screws for the d and 3 for the t) Slide the head to the right. 2. !!Mind the two washers of the t-head, so they do not end up inside the head through magnetism !!

5. Measure the distance between the nose piece or knife holder and the cutting strip on the left and right. Write down and remember the values, you wil have to reassemble the unit in exact the same way. 6. Push the idler y-pulley to the side to take the tension of the y-belt. 7. Unscrew the y-belt (only the right screw situated on the left side of the headcarriage) 8. Release the idler pulley gently (so the spring does not jumps away). 9. Remove the idler pulley and the spring (in the mean time the y-belt will have to come out of the side plate.) 10.Remove the belt(s) from the x-motor(s). Do this by pushing the motor(s) towards the x- pulley and turning movement.

Left Plate Removal

A-1

11.Unscrew the motor(s). 3 screws a piece. There is no need to disconnect them, just lay them apart. 12. Remove the x-pulley. (1 or 2 setscrews) 13. Remove the plastic endplate. This plate is held with only1 screw situated near the drum left).

(up-

14.Unscrew the guiding rol near the machine. On the other side the rol is fixed with (removable) loctite so the screw on the left side should come loose the first. 15. Remove the two caps from the screws holding the rear guiding rol. Remove the rol. 16. Remove the star lock from the pinch roller bar. Remove the nylon bush. 17. Measure the distance between the base plate and the top beam. Also check the perpendiculrity between the top beam and the base plate. Write down and remember the values, you will have to reassemble the unit in exact the same way. 18. Put something soft between the base and the table and between the base and the top

beam.

19. Unscrew the left steel plate. (6 screws) if it does not have to be replaced, then just put a little bit aside just enough to reach the faulty components. 20. Now the camroller assys or the headcarriage can be removed. The headcarriage sits between the outer camrollercarriages and has to be removed if there is a defect with the right camroller. 21. Remove and replace the faulty components.

3. !! If a Ccamroller assy is replaced, make sure the plastic cam inside the assy is 4. positioned the same way as the one the are removed!!

To reassemble: 22.Reseat hte left steel plate. 23.First secure the base plate with three screws, beginning with the one closest to the drive drum. Screw the first one almost completely in, the check whether the sideplate is perpendicular to the table then secure it. The hight of the base will be almost correct since the diameter of the hole in the siede plate for this screw is the smallest. Then secure the side plate to the base with the other two screws. 24.Secure the top-beam with three screw, beginning with the lowest one. check the hight and perpendicularity between the base and the top beam before thightining the screw. Adjust if necessary. Secure the top beam with the other two screws. 25.Proceed in the reverse order of removal starting from 16. 26. 5. CAUTION 6. While reinstalling the belt, make sure the right double pulley seats in its place 7. Also make sure the long y-belt follows the right path

Check the hight between the nose piece or knife holder and the cutting strip left and right, if they differ more then .3mm then the base has to be adjusted a little bit.

Left Plate Removal

A-2

8. !! IMPORTANT !! 9. 10. If the unit is assembled, then do following test : 11. cutting dept test : 12. Load the widest vinyl available. 13. Set the knife depth critical on the right side 14. Check the knife over the full width of the machine, check for irregularity in 15. cutting dept - be critical. 16. If not in order reset the top beam and base plate or call for help 17. tracking test : 18. Do a couple of tracking test (preferably over 6m or more) to ensure the tracking 19. quality 20. If it fails the test then following action might be taken : 21. Check the sleeves for dirt 22. Check the brake on the roller guiding 23. Try switching the camrollers 24. Try and set the rear backscrews in the camrollerassy the same as the one you might 25. have removed. 26. Measure the pressure each camroller has and change if necesarry

Left Plate Removal

A-3

APPENDIX B Procedure to flash from internal ROM’s General: There exist a critical point of time on which you may not switch of the machine while you reflash it. Normally if you wait long enough there will not occur any problems. In case something rare happens during reflashing and you are unable to boot the pcb then there exist a method to falsh the flash Rom’s from internal Rom’s. Procedure: 1. Do all the necessary stuff to expose the main PCB, make sure the unit is not powered on. 2. Put in MW9955 and MW9965 in (LO and HI are marked on the PCB) 3. Put jumpers next to the ROM’s on 12 and 34 (this usually means that they all have to be put one pin lower). 4. Power on the unit whilst pressing on PEN_UPDOWN, ONE and ENTER (FSM mode). This brings the unit in a special mode, from now on anything can go wrong. If the display shows

FSM MODE STANDARD INIT

Then

=> press ENTER

Note: If the displays shows a message concerning the NVRAM or new ROM revision remark, then go through the usual procedure until you get at the above mentioned message and follow the procedure further (just follow the guidelines on the display) Flashing : go to INTERNAL TESTS search SYSTEM TEST search ROM TO FLASH display shows

=> press MENU MENU => press several times UP and then ENTER => press several times UP and then ENTER ERASING FLASH PLEASE WAIT PROGRAMMING FLASH PLEASE WAIT

Wait until display shows “ROM COPIED SUCCESSFULLY TO FLASH “ Then the PCB is flashed successful 5.Power the unit down. 6. Remove the ROM’s, put the jumpers back on position 23 and 45.

Internal Reflash

B-1

7. Power the unit back on and check whether the flashed PCB works. 8. Put everything back you’ve disassembled.

Internal Reflash

B-2

APPENDIX C Procedure to set the pinch roll lever play General: The amount of play the lever has is not critical, but there should be at least some. Otherwise you have troubles with tracking. The following procedure describes how to check it and how to recalibrate is the setting is off.

Procedure: 1. Remove the right hand cover. 2. Put the camrollers in the up position. Loosen the setscrew in the lever (item 7). 3. Put the camrollers down on the sleeves without media under them. 4. In order to avoid damage to the cam detection switch (blue switch, not visible on figure), loosen careful the cam detection ring (item 1 - 1 setscrew). 5. Stand in front of the machine. 6. Whilst holding the pinch roller bar (it 10) and the lever with one hand loosen the other setscrew in the lever. 7. Turn the pinchroller bar away from you whilst pushing it to the right, then turn it 3 degrees back. 8. Tighten the setscrew in the lever. 9. Check the play of the lever by measuring the distance between the bumper and the lever , this distance should be between 2 a 7mm. By play I mean that you can move the lever before the cams on the pinch roller bar begin to push the camroller upwards. 10.Put the camroller up and tighten the second setscrew on the lever. 11.Push the lever of the blue switch against the switch so you can reposition the cam detection ring again. 12.Turn the cam detection ring clockwise so that the long screw (it 4) is just under the end of the lever on the blue switch. Before tightening the setscrew be sure that there is no lateral play on the pinch roller bar

Lever play

C-1

1 2 3 4 5

cam detection ring spring screw M4x10 screw M4x12 washer 08x8x10

Lever play

6 7 8 9 10

bus 8.2,12,15 lever pinch roller starlock 8 washer 08x8x10 pinch roller bar

C-2

APPENDIX D Procedure to set change the motor on a T-head General: Although a head is considered as a spare part on its whole (because fixtures are used in PR while assembling it) there exist a method to change the motor on its own.

Procedure: 1. For removal of the head and putting it back on the machine, refer to the service manual 2. Once the head is off and before taking off the motor check the tension of the belt and remember it. When you will replace the motor then the tension of the belt should be exactly the same (more or less). The tension this belt needs is not as much as one should think. 3. disconnect the motor from the head. 4. loosen the setscrew in the pulley on the motor in order to access more easily the hex screws 5. remove the motor from the head (two hex screw 4mm) 6. put the new motor on with the two hex screws you can set the belt tension, but do not secure the pulley on the motor yet. 7. connect the motor to the head and connect the head to the flatcable of the machine 8. start the machine in FSM mode (standard) 9. press the "menu" key until you come to "internal test" 10 press the "up arrow " until you get to knife calibration 11 press "enter" 10.press "2" this will set the motor on the head in its origin position. 11.turn the nose piece holder so that the two holes in it (there to hold the nose piece) face the back of the head. Be sure it is aligned with the head because you are now busy setting the mechanical zero point of the knife. If you are to far off then you will never be able to set the origin correct if you do knife calibration. It is here that in production a fixture is used to put the head in so that the mechanical origin is set almost perfect. 12.when you are sure that the nose piece holder is aligned and that you haven't turned the motor shaft , then you may secure the pulley on the motor shaft. to be sure press the "2" key again to check whether the origin point of the knife is correct (after pressing "2" the nosepieceholder should be aligned with the head and the two holes should be facing the back of the head.) 13.Power the machine down, the head is now ready to be remounted.

Changing the motor on a T-head

D-1

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motor assy motor pulley setscrew on motor pulley check belt tension disconnect encoder here disconnect motor here hex screws holes facing rear of head

Changing the motor on a T-head

D-2