Summa S2 SERIES User manual

Service manual

Revised January 11, 2021

TOC 1
Table of Contents
Service manual.................................................................................................1-1
1Setup...........................................................................................................1-1
INTRODUCTION........................................................................................1-1
1.1 Overview..........................................................................................1-1
1.2 Manual organization........................................................................1-1
1.3 Quick tour around the machine .....................................................1-3
1.3.1 The Cutter as viewed from the Front................................................... 1-3
1.3.2 The Cutter as viewed from the Back ................................................... 1-4
2Replacements guidelines.........................................................................2-1
2.1 General.............................................................................................2-1
2.2 Precautions......................................................................................2-1
2.3 Removing the left-hand cover........................................................2-3
2.4 Removing the right-hand cover .....................................................2-3
2.5 Removing the bottom plate............................................................2-5
2.6 Replacing the pinch rollers ............................................................2-5
2.7 Replacing the media sensors.........................................................2-7
2.8 Replacing the cutting/pouncing strip............................................2-7
2.9 Replacing an X-motor.....................................................................2-9
2.9.1 Replacing the X-motor with the encoder.............................................. 2-9
2.9.2 Replacing the X-motor without the encoder......................................... 2-9
2.10 Replacing the Y-motor..................................................................2-11
2.11 Replacing the touch screen .........................................................2-13
2.12 Replacing the pinch roller switch................................................2-14
2.13 Replacing the main PCB...............................................................2-15
2.13.1 Required Tools.................................................................................. 2-15
2.13.2 Procedure......................................................................................... 2-15
2.14 Replacing the Power Supply........................................................2-21

TOC 2
2.15 Replacing the toolhead.................................................................2-23
2.16 Replacing the pinch roller sensor................................................2-26
2.17 Replacing the flatcable.................................................................2-28
2.18 Replacing the Pinch Roller Handle..............................................2-29
2.18.1 Required Tools.................................................................................. 2-29
2.18.2 Required Parts.................................................................................. 2-29
2.18.3 Procedure......................................................................................... 2-29
2.19 Replacing the drive drum .............................................................2-33
2.19.1 Required tools................................................................................... 2-33
2.19.2 Required parts .................................................................................. 2-33
2.19.3 Prepare the machine......................................................................... 2-33
2.19.4 Replace the drive drum..................................................................... 2-35
2.19.5 Reassemble the parts....................................................................... 2-37
3Calibration..................................................................................................3-1
General......................................................................................................3-1
3.1 Machine type ...................................................................................3-2
3.1.1 The machine type has to be reset when:............................................. 3-2
3.1.2 Configuration of the PCB:.................................................................... 3-2
3.1.2.1 Via keyboard:............................................................................... 3-2
3.1.2.2 Via computer:............................................................................... 3-3
3.2 Length calibration...........................................................................3-4
3.2.1 The unit has to be recalibrated when:.................................................. 3-4
3.2.2 Calibration via touch panel:................................................................. 3-4
3.2.3 Calibration via Summa Cutter Control:................................................ 3-5
3.3 Head calibration ..............................................................................3-6
3.3.1 Knife calibration .................................................................................. 3-6
3.3.1.1 The knife has to be calibrated when:............................................ 3-6
3.3.1.2 Pressure calibration (drag and tangential):................................... 3-6
3.3.1.3 Knife offset calibration (drag only):............................................... 3-7
3.3.1.4 Knife calibration (tangential only): ................................................ 3-8
3.3.2 Coil calibration .................................................................................. 3-10
3.3.2.1 The coil has to be recalibrated when:......................................... 3-10
3.3.2.2 Calibration:................................................................................. 3-10
3.4 Media sensor calibration..............................................................3-12
3.4.1 The media sensors have to be recalibrated when: ............................ 3-12
3.4.2 Calibration of the media sensors:...................................................... 3-12
3.5 OPOS Calibration..........................................................................3-14
3.5.1 OPOS has to be recalibrated when:.................................................. 3-14
3.5.2 Setting of potentiometers .................................................................. 3-14
3.5.3 OPOS calibration .............................................................................. 3-15
3.5.4 Media calibration for OPOS............................................................... 3-15
3.6 Right margin calibration...............................................................3-17
3.6.1 The margin has to be recalibrated when: .......................................... 3-17
3.6.2 Margin calibration.............................................................................. 3-17

TOC 3
3.7 Touch screen calibration..............................................................3-18
3.7.1 The touch screen has to be recalibrated when:................................. 3-18
3.7.2 Touch screen calibration................................................................... 3-18
3.7.3 Alternative method............................................................................ 3-18
4Basic Operation......................................................................................... 4-1
4.1 Touch Screen ..................................................................................4-1
4.1.1 Touch screen familiarization................................................................ 4-1
4.2 Configuration Menu ........................................................................4-1
4.2.1 Service................................................................................................ 4-3
4.2.1.1 Calibrate margin........................................................................... 4-3
4.2.1.2 Select machine ............................................................................ 4-3
4.2.1.3 System registers.......................................................................... 4-3
4.2.1.4 Install roll up system?................................................................... 4-3
4.2.1.5 Check media weight..................................................................... 4-3
4.2.1.6 Monitor......................................................................................... 4-3
4.2.1.7 Burn in ......................................................................................... 4-3
4.2.1.8 Hardware test............................................................................... 4-4
4.2.2 Settings............................................................................................... 4-4
4.2.2.1 Tool Selection.............................................................................. 4-4
4.2.2.2 Velocity........................................................................................ 4-4
4.2.2.3 Calibrate Knife ............................................................................. 4-4
4.2.2.4 FlexCut: ....................................................................................... 4-4
4.2.2.5 Advanced Cutting......................................................................... 4-5
4.2.2.5.1 Overcut:..................................................................................... 4-5
4.2.2.5.2 OptiCut:..................................................................................... 4-5
4.2.2.5.3 Paneling.................................................................................... 4-5
4.2.2.5.4 Panel Size................................................................................. 4-5
4.2.2.5.5 Panel Replot.............................................................................. 4-6
4.2.2.5.6 Sorting Vectors.......................................................................... 4-6
4.2.2.5.7 Long Vectors............................................................................. 4-6
4.2.2.5.8 TurboCut:.................................................................................. 4-6
4.2.2.6 General........................................................................................ 4-6
4.2.2.6.1 Media Sensor:........................................................................... 4-6
4.2.2.6.2 Recut Offset: ............................................................................. 4-6
4.2.2.6.3 Cut off margin:........................................................................... 4-7
4.2.2.6.4 Roll up media: ........................................................................... 4-7
4.2.2.6.5 Autoload:................................................................................... 4-7
4.2.2.6.6 Language:................................................................................. 4-7
4.2.2.6.7 Menu Units:............................................................................... 4-7
4.2.2.6.8 LCD contrast ............................................................................. 4-7
4.2.2.7 OPOS .......................................................................................... 4-7
4.2.2.7.1 Calibrate OPOS:........................................................................ 4-7
4.2.2.7.2 Calibrate media (OPOS):........................................................... 4-7
4.2.2.7.3 Alignment mode: ....................................................................... 4-8
4.2.2.7.4 OPOS sheet mode: ................................................................... 4-8
4.2.2.7.5 OPOS paneling: ........................................................................ 4-8
4.2.2.7.6 OPOS monitor:.......................................................................... 4-8
4.2.2.8 Communication............................................................................ 4-9
4.2.2.8.1 Tool Commands........................................................................ 4-9

TOC 4
4.2.2.8.2 USB Class................................................................................. 4-9
4.2.2.8.3 LAN........................................................................................... 4-9
4.2.2.9 Calibrate X(/Y) ............................................................................. 4-9
4.2.2.10 Coil Setup.................................................................................... 4-9
4.2.2.11 Factory defaults ........................................................................... 4-9
4.2.2.12 Copy current user ...................................................................... 4-10
4.2.2.13 Media Sensor Setup................................................................... 4-10
4.2.2.14 Calibrate Touch Screen ............................................................. 4-10
4.2.3 Actions.............................................................................................. 4-10
4.2.3.1 Load........................................................................................... 4-10
4.2.3.2 Reset ......................................................................................... 4-10
4.2.3.3 Replot ........................................................................................ 4-10
4.2.3.4 Cut Sheets................................................................................. 4-10
4.2.3.5 Open file .................................................................................... 4-10
4.2.3.6 Confidence test.......................................................................... 4-11
4.2.3.7 DIN A4 Test ............................................................................... 4-11
4.2.4 ROM REVISION................................................................................ 4-11
4.2.5 Configuration (Quick parameter change)........................................... 4-11
4.2.6 Pause (Online/Offline)....................................................................... 4-11
5Maintenance and Cleaning ......................................................................5-1
5.1 Introduction .....................................................................................5-1
5.2 Cleaning the Drive System.............................................................5-1
5.3 Cleaning the Media Sensors ..........................................................5-2
5.4 Cleaning the Y guiding ...................................................................5-2
5.5 Cleaning the nose piece (tangential machine only).....................5-3
5.6 Cleaning the OPOS system............................................................5-4
5.7 Changing the fuse...........................................................................5-4
6Error codes................................................................................................6-1
6.1 X-axis error! Overflow or Overcurrent!..........................................6-1
6.2 Y-axis error! Overflow or overcurrent!..........................................6-1
6.3 Cutter is unable to find the knife home position..........................6-2
6.4 Up down encoder not working.......................................................6-2
6.5 Unable to lower OPOS....................................................................6-3
6.6 OPOS sensing errors......................................................................6-3
6.7 Illegal plot command.......................................................................6-4
6.8 Syntax error.....................................................................................6-4
6.9 NVRAM failures and messages......................................................6-4
6.10 Internal errors..................................................................................6-5
6.11 Upgrade errors and messages.......................................................6-5
6.12 RAM ERROR....................................................................................6-6

TOC 5
7Identification Plates..................................................................................7-1
8Cutter accessories and consumables....................................................8-1
9First Aid Kit for S Class 2 ........................................................................9-1
9.1 KIT S2 CLASS..................................................................................9-1
9.2 KIT S2 T............................................................................................9-2

TOC 1-1
1Setup
INTRODUCTION
1.1 Overview
This is the Summa Service Manual for the S Class 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.
There will be only one version of this manual. All changes will be send out as appendices or
service aids.
This manual is copyrighted by Summa 2005. 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.
1.2 Manual organization
This manual is divided into the following sections:
•Table of Contents
•Introduction
•Replacement guidelines
•Calibrations
•Error messages
•Menu structure
•Maintenance and cleaning
•Figures - part numbers
•List recommended spare parts
•List of consumables

S Class 2 cutter Service manual
Introduction 1-2
Replacement guidelines contains the following:
An overview of the removal and the replacement of various parts of the unit in the form of
separate sections. It is advisable to carefully read the procedure described in each of the
sections 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.
Calibration contains the following
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.
Error messages contains the following:
This part contains an overview of the error messages that can appear on the touch screen and
how to react.
Menu structure contains the following:
This part contains an overview of the various tests and configurations that can be accessed
via the touch screen.
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 sections 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.
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.
Consumables list:
An overview of all the consumables

S Class 2 cutter Service manual
Introduction 1-3
1.3 Quick tour around the machine
1.3.1 The Cutter as viewed from the Front
FIG 1-1
1-1 S CLASS 2 CUTTER, FRONT VIEW
1. Pinch rollers: The pinch rollers clamp the media to the drive system to ensure accurate
tracking. The S120(T) has one and the S160(T) and S 140(T) have two extra pinch rollers to
ensure that wide media stays flat in the middle. The outer drive pinch rollers have a
selectable pressure; the extra rollers in the middle can be enabled or disabled. Extra pinch
rollers can be added.
2. Touch panel: All cutter activity can be initiated from the 320x240 dot touch panel. The
panel displays information about the cutter’s current status and/or actions that need to
be taken.
3. Pinch roller lever: This lever is used to raise and lower the pinch rollers for media loading.
4. 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 sleeves
installed on each model of the S CLASS 2 cutters.
Number of sleeves
S75 (T)
S120 (T)
S140 (T)
S160 (T)
Short sleeve
4
7
8
9
Long sleeve
1
1
1
1

S Class 2 cutter Service manual
Introduction 1-4
5. Tool carriage: The tool carriage is the mount for the knife holder, pen or pouncing tool. It
has also holds the Optical POSitioning sensor (OPOS) and a cut-off knife to cut a sheet
from the roll when a job is finished.
6. Cutting strip: A self-healing orange strip helps 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
strip remains intact.
7. Pouncing strip: An extra black strip to pounce on.
8. Tool holder: The left end cap has a rim so it can be used for tool storage.
9. Screws to secure the cutter base: Make sure all three screws are secured at each side
before the cutter is used.
10. Media basket: The stand and linen media basket come standard with all S CLASS 2
cutters.
1.3.2 The Cutter as viewed from the Back
FIGURE 1-11:
S CLASS CUTTER, REAR VIEW
1. AC power cord receptacle: It is located at the left-hand side of the power entry module.
The power-up procedure is explained in detail in Section 1.3. Always use a power cord
that was delivered with your cutter.
2. Power On/Off switch: This rocker switch, in the middle of the power entry module, sets
the cutter’s power to ON or OFF. To switch on the power, press the “I” side of the rocker
switch. To switch off the power, press the “O” side of the rocker switch.
3. The fuse box: The fuse is located at the right side of the power entry module. Check the
specification section to see which fuse is used in the S CLASS 2 cutter.

S Class 2 cutter Service manual
Introduction 1-5
WARNING: For continued protection against risk of fire, replace only with the
same type and rating of fuse.
4. USB port type A female: For plugging in a USB stick.
5. Ethernet port RJ45: For connecting the cutter to the LAN.
6. USB port Type B female: This interface is based on the standards specified in Universal
Serial Bus Specifications Revision 1.1. It allows a high-speed bi-directional communication
between the host computer and the cutter.
7. Pinch roller lever: This lever is used to raise and lower the pinch rollers for media loading.
8. Roll media guide bushes: The two flange guides serve to keep the media roll in place
when media is pulled from the roll.
9. Pinch rollers: The pinch rollers clamp the media to the drive system to ensure accurate
tracking. The S120(T) has one and the SS160(T) and S 140(T) have two extra pinch rollers
to ensure that wide media stays flat in the middle. The outer drive pinch rollers have a
selectable pressure; the extra rollers in the middle can be enabled or disabled. Do not
move the pinch roller assemblies while holding them from this side only.
10. Screws to secure the cutter base: Screws (3 left and 3 right) hold the cutter base to its
stand. All the screws must be properly tightened before using the cutter.
11. Tubes for media basket: Tubes in the back and front hold the media basket. They can
easily pulled outwards to put the basket in its place.
12. Casters: The casters on the stand are equipped with locking brakes. Once the cutter has
been moved to its new location, press the brakes with your foot to lock the casters.
13. Media support rollers: Rotating support rollers for the media roll.
14. Media basket: The stand and linen media basket come as standard equipment with all S
CLASS 2 cutters.

Replacements guidelines 2-1
2Replacements guidelines
2.1 General
This section contains information on replacing defective parts and adjustment procedures. A
step-by-step 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.
2.2 Precautions
Observe simple, common sense rules and procedures whilst servicing the unit. They include,
but are not limited to the following:
•The base of the unit has been assembled on a fixture to assure straightness all along the y-
axis. To keep this: DO NOT REMOVE THE 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 testing the cutter, make sure that the base plate is horizontal (otherwise flat cable
tool carriage will get caught).
•When the covers are off or open:
•The printed circuits boards are electrostatically sensitive; use the proper handling
techniques. Make sure no screws or washer are left behind on the printing plate, they can
cause short circuits which can damage the circuits boards.
•Keep sensors free of scratches and dirt.
•Keep the guiding, at least dirt free where the wheels of the carriage pass.

S Class 2 cutter Service manual
Replacements guidelines 2-2
Left end cover
395-211
(without label)
Right end cover S2
395-212
(without touch screen)
Long screws
ND5000-9556
5L + 5R
Rozet
ND5000-9639
5L + 5R

S Class 2 cutter Service manual
Replacements guidelines 2-3
2.3 Removing the left-hand cover
To remove the left-hand cover, proceed as follows:
1. Remove the five screws holding the left-hand cover in place. Three are located at the
front, two at the rear. Pay close attention to where each of the screws goes. They should
be returned to their original location when re-installed.
2. Gently tap the top of the cover, lift it and slide outwards.
3. Remove the cover.
To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.
2.4 Removing the right-hand cover
To remove the right-hand cover, proceed as follows:
1. Remove the power cord and the communication cable.
2. Remove the 5 screws holding the left-hand cover in place. Three are located at the front,
one at the rear and one just above the USB connection. 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, lift it and slide outwards.
Note:
The touch screen is built in in the cover. It is connected with a flat cable to the
main board. Before removing the cover locate the flat cable and disconnect.
Do this by opening the cover first for app 2cm (3/4 inch) and look inside. The
cover can be completely removed while the flat cable is attached, be careful
though. It is easiest to re-install when the flat cable is loosened at the side of the
cover. 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(s) out of the
connector.
4. Remove the cover.
To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.
Note:
Make sure that you do not jam any wires between the cover and the side plate
as this may cause considerable damage.
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.

S Class 2 cutter Service manual
Replacements guidelines 2-4
Bottom plate 75
395-363
120
395-373
140
395-383
160
395-353
screw
ND5000-9125 (# depends on type of machine)
Pinch wheel
391-326
Retaining ring 3.2mm
ND5000-9382
Pinchwhee(2)+circlips
392-401

S Class 2 cutter Service manual
Replacements guidelines 2-5
2.5 Removing the bottom plate
To remove the bottom plate, proceed as follows:
1. Turn the unit upside down.
2. Remove the screws holding the bottom plate in place (the number of screws varies
depending on the cutter type).
3. Carefully remove the bottom plate, mind the fan cable.
To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.
Note:
Make sure the bottom plate is placed correctly into the slots of the bottom
plate.
2.6 Replacing the pinch rollers
To replace the pinch rollers, proceed as follows:
1. Remove the retaining ring at one side.
2. Remove the pinch roller shaft (push against the other side of the shaft).
3. Remove the pinch roller.
Note:
a. Pinch rollers come in pairs. When one is malfunctioning or broken, both need
to be replaced.
b. The models 120 have three, the 140 and the 160 four pinch rollers. The centre
pinch rollers are not matched with the two pinch cam rollers and can be
installed independently.
To re-install, proceed in the reverse order of removal.

S Class 2 cutter Service manual
Replacements guidelines 2-6
Sensor board
399-965
screw
ND5000-9392
1
cutting strip 75 & 120
391-886
160
400-565
2
pouncing strip 5m
391-598