Summa SummaSign D500 User 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. THE ENTER KEY ..........................................................................................1.6
1.1.6. 2 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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SummaSign Service Manual
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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Service Manual SummaSign
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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SummaSign Service Manual
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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Service Manual SummaSign
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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SummaSign Service Manual
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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Service Manual SummaSign
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 Service Manual
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 I-1

SummaSign Service Manual
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.
I-2 Introduction

Service Manual SummaSign
3. 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.
Introduction I-3

SummaSign Service Manual
2. 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.
I-4 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 T610 Pro T750 Pro T1010 Pro T1300 Pro
Short sleeve 3 4 6 7
Long sleeve 1 1 1 1
3. Tool Carriage : - The tool carriage is the mount for the tangential cutting head.
4. 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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SummaSign Service Manual
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.
I-6 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 D-
series 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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SummaSign series Cutters Service Manual
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
reset the cutter, to abort the cut in progress or to recut the last file. When the key
(RESET/LOAD) is pressed, the cutter goes off line, suspends all operations in
progress and displays the RESET/LOAD menu. Press the key until SET ORIGIN,
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 1or 2key
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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Service Manual SummaSign series Cutters
The key (ON LINE) toggles between on line and off line operation. When the key
is pressed, the selected mode (ON LINE or OFF LINE) is displayed on the LCD.
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 or jogging key to move the tool carriage to the left or right.
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.
The MENU Key
The key (MENU) is used to select one of the menus. Pressing the key will make
the cutter go off line and suspend all operations in progress. Pressing the key
repeatedly will display the different menus one by one. As the menu options are on a
loop, pressing the key when the last option is displayed will automatically return
you to the first option.
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SummaSign series Cutters Service Manual
ONLINE 1
Menu
800mm/s 120g K
USER CONFIG 1
IN TERN A L 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 key
(ON LINE).
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 ,or key will make the cutter go off line, in order to initiate
another operation.
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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 1and 2keys 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 or jogging key is
used to select the new user number and the or jogging key is used to go to the
previous or next menu item.
THE TOOL UP/DOWN KEY
The key (TOOL UP/DOWN) is used while the cutter is off line to raise or lower the
tool. Pressing the key once will lower the tool onto the media. Pressing the key
again will raise the tool.
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 :
Keyboardcontrols 1-5