Summa SummaCut D60 User manual

Service Manual
SummaCut D60 and D120
Summa NV
Rochesterlaan 6
8470 Gistel
Belgium

Service Manual SummaCut D60-D120
TABLE OF CONTENTS......................................................................Page
SECTION 1 KEYBOARD CONTROL
1.1. THE CONTROL PANEL .......................................................................................1.1
1.1.1. THE LIQUID CRYSTAL DISPLAY ....................................................................1.1
1.1.2. THE MENU KEY ...............................................................................................1.2
1.1.3. THE X KEY .......................................................................................................1.3
1.1.4. THE V KEY .......................................................................................................1.3
1.1.5. THE TEST KEY ...............................................................................................1.3
1.1.6. THE JOGGING KEYS .....................................................................................1.3
1.2. COMMON MENU ITEMS ......................................................................................1.4
1.2.1. VELOCITY .........................................................................................................1.4
1.2.2. PEN PRESSURE ...............................................................................................1.4
1.2.3. KNIFE PRESSURE ...........................................................................................1.4
1.2.4. KNIFE OFFSET..................................................................................................1.5
1.2.5. POUNCING PRESSURE ...................................................................................1.5
1.2.6. POUNCING GAP ...............................................................................................1.5
1.2.7. RESET ...............................................................................................................1.6
1.2.8. RECUT ..............................................................................................................1.6
1.2.9. LOAD .................................................................................................................1.6
1.2.10. ALIGN LOAD ..................................................................................................1.6
1.2.11. SYSTEM SETUP .............................................................................................1.6
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SummaCut D60-D120 Service Manual
1.3. SYSTEM SET UP .................................................................................................1.7
1.3.1. CONFIDENCE ...................................................................................................1.8
1.3.2. DIN CUT ............................................................................................................1.8
1.3.3. TOOL .................................................................................................................1.8
1.3.4. FLEX-CUT .........................................................................................................1.8
1.3.5. OVERCUT .........................................................................................................1.9
1.3.6. OPTICUT ...........................................................................................................1.9
1.3.7. EMULATION ...................................................................................................1.10
1.3.8. BAUD RATE ....................................................................................................1.10
1.3.9. PARITY ............................................................................................................1.11
1.3.10. RTS/DTR .......................................................................................................1.11
1.3.11. RS 232 TEST .................................................................................................1.12
1.3.12. ALIGN MODE ................................................................................................1.12
1.3.13. AUTOLOAD ..................................................................................................1.12
1.3.14. LANGUAGE ..................................................................................................1.13
1.3.15. MENU UNIT ...................................................................................................1.13
1.3.16. ROM REVISION ............................................................................................1.13
1.3.17. MEDIA SENSOR ...........................................................................................1.13
1.3.18. SENSOR SETUP ...........................................................................................1.13
1.3.19. CALIBRATE X/Y ...........................................................................................1.14
1.3.20. COIL SETUP .................................................................................................1.14
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Service Manual SummaCut D60-D120
SECTION 2 REPLACEMENT GUIDELINES
2.1. REMOVING THE LEFT-HAND COVER................................................................2.3
2.2. REMOVING THE RIGHT-HAND COVER..............................................................2.3
2.3. REMOVING THE BOTTOM PLATE......................................................................2.5
2.4. REPLACING THE CAMROLLERS.......................................................................2.5
2.5. REPLACING THE X-MOTOR ..............................................................................2.7
2.6. REPLACING THE Y-MOTOR...............................................................................2.9
2.7. REPLACING THE LCD OR THE KEYBOARD...................................................2.11
2.8. REPLACING THE MAIN PCB.............................................................................2.13
2.9. REPLACING A DRAG HEAD ............................................................................2.16
2.10. REPLACING THE FLAT CABLE FOR THE HEAD..........................................2.22
2.11. REPLACING THE Y-BELT...............................................................................2.22
2.12. REPLACING THE CUTTING STRIP.................................................................2.23
2.13. REPLACING THE SENSOR.............................................................................2.23
2.14. REPLACING THE FAN MOTOR.......................................................................2.24
2.15. REPLACING THE DRIVE DRUM......................................................................2.25
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SummaCut D60-D120 Service Manual
SECTION 3 MAINTENANCE
3.1. MAINTENANCE & CLEANING.............................................................................3.2
3.1.1. CLEANING THE DRIVE SYSTEM.....................................................................3.2
3.1.2. CLEANING THE SENSORS..............................................................................3.3
3.2. OPERATING VOLTAGE.......................................................................................3.4
SECTION 4 CALIBRATION
4.1. MEDIA CALIBRATION.........................................................................................4.2
4.2. HEAD CALIBRATION...........................................................................................4.4
I. KNIFE CALIBRATION .............................................................................................4.4
II. COIL CALIBRATION...............................................................................................4.4
4.3.MACHINE TYPE.....................................................................................................4.6
4.4. SENSOR TESTS...................................................................................................4.8
4.5. AUTOMATIC TESTS............................................................................................4.9
SECTION 5 ERROR CODES - TROUBLESHOOTING
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Service Manual SummaCut D60-D120
5.1. ERROR IN X-AXIS................................................................................................5.2
5.2. ERROR IN Y-AXIS POSITION..............................................................................5.3
5.3. SYNTAX ERROR..................................................................................................5.3
5.4. NVRAM FAILURES AND MESSAGES.................................................................5.4
5.5. RS232 ERROR......................................................................................................5.4
5.6. INTERNAL ERRORS............................................................................................5.5
5.7. FLASHING ERRORS AND MESSAGES .............................................................5.6
5.8. RAM ERROR.........................................................................................................5.6
SECTION 6 FIGURES
FRONT SIDE................................................................................................................6-2
REAR SIDE .................................................................................................................6-3
D120 X MOTOR...........................................................................................................6-4
BRAKE.........................................................................................................................6-5
KEYBOARD.................................................................................................................6-6
KEYBOARD.................................................................................................................6-7
BOTTOM PLATE.........................................................................................................6-8
RIGHT SIDE.................................................................................................................6-9
LEFT SIDE.................................................................................................................6-10
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SummaCut D60-D120 Service Manual
MEDIA SENSOR SYSTEM........................................................................................6-11
D60 X-MOTOR ..........................................................................................................6-12
DRUM ASSY..............................................................................................................6-13
MEDIA GUIDE SYSTEM............................................................................................6-14
CARRIAGE.................................................................................................................6-15
FRONT SIDE..............................................................................................................6-16
BOARDS....................................................................................................................6-17
COVERS.....................................................................................................................6-18
CARRIAGE.................................................................................................................6-19
MOTOR CONNECTIONS...........................................................................................6-20
MEDIA SELECT.........................................................................................................6-21
SECTION 7 SPARE PARTS LIST
SUMMACUT D60 SPARE PARTS...............................................................................7-1
SUMMACUT D120 SPARE PARTS.............................................................................7-3
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INTRODUCTION
1. OVERVIEW
This is the Summa Service Manual for the SummaCut D60 and D120 cutters. It
provides information for servicing the cutters. All repairs are to be made by, or under
the direction of, authorised Summa service personnel.
This manual is copyrighted by Summa 1999. Summa reserves the right to change any
information contained in this manual without prior notice. Unauthorised copying,
modification, distribution, or display is prohibited. All rights reserved.
2. MANUAL ORGANIZATION
This manual is divided into the following sections:
Table of Contents
Introduction
Keyboard controls
General replacement guidelines
Maintenance
Calibration
Troubleshooting
List recommended spare parts with pictures
Keyboard control contains the following:
INTRODUCTION I-1

SummaCut D60-D120 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
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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Service Manual SummaCut D60-D120
3. KNOWING YOUR CUTTER
3.1 POSITION OF THE CUTTER ON A TABLE
The cutter is equiped with an extra media guide. In order not to damage this part,
special attention when putting a machine on a surface. The figure below explains the
right position. part 1 should always be over an edge.
POSITION OF THE CUTTER ON A SURFACE
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SummaCut D60-D120 Service Manual
3.2. CUTTER COMPONENTS
In order to get acquainted with your SummaCut D60 and D120, read the following
description of components.
3.2.1. REAR PANEL CONTROLS
The figure below shows the location of the main components.
SUMMACUT D60 REAR VIEW
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Service Manual SummaCut D60-D120
1. USB interface: - This interface is based on the standards specified in Universal
Serial Bus Specifications Revision 1.1. It allows a high-speed serial bi-directional
communication between the host computer and the cutter.
2. RS-232-C Port: - This DB-9P connector provides the communication link
between the cutter and a host computer. It allows bi-directional communication
between the host computer and the cutter.
3. Parallel Port: - This IEEE1284 -B connector provides a bi-directional
communication link between the cutter and a host computer.
Note: only one interface can be active at a time.
The first port that receives data will be the active interface until the cutter is reset.
4. 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.
5. Power Entry Module: - The fuse box and the AC power cord receptacle are
located in the power entry module.
The power-up procedure is explained in detail in Section 1.6.
6. Fuse box: - For information about changing of the fuse, see Section 4.2.
7. Roll Media Guide Bushes: - The two guide bushes serve to keep the media roll in
place when media is pulled from the roll.
8. Media Flanges: - The media flanges ensure proper routing of the media roll.
9. Media Support Roller: - Rotating support rollers for the media roll.
10. Alignment Strip: - Rear alignment strip for easier media loading.
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SummaCut D60-D120 Service Manual
3.2.2.FRONT PANEL CONTROLS
The figure below shows the location of the main components.
SUMMACUT SERIES, FRONT VIEW
1. Pinch roller lever arm: - This lever is used to raise and lower the pinch rollers
during media loading.
2. Media Drive Sleeves: - The media drive sleeves move the media only when the
pinch rollers are in the ‘down’ position.
3. Tool Carriage: - The tool carriage is the mount for the knife holder and the pen.
4. Control Panel: - The control panel contains 8 keys. All cutter activity can be
initiated from the control panel. Each control panel function is explained in
Section 1.
5. Display: - The 16-character display informs the user about the current status of
the cutting process or actions, which need to be taken.
6. Sensor: - The sensor detects the end of media to avoid any damage to the
cutting strip
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Service Manual SummaCut D60-D120
7. Pinch rollers: - The pinch rollers (one at each side) hold the media clamped
between the rubber rollers and the media drive sleeves. (The D120 has an extra
guidin pinch roller in the middle)
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. Alignment strip: - Front alignment strip for easier media loading.
10. Media guide : - Extra guide to prevent badly curled up media from jamming
under the cutter (not in 120 Model)
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SECTION 1
Keyboard control
1.1. THE CONTROL PANEL
The figure below shows the control panel of the SummaCut D60 and the D120. The
main functions of the liquid crystal display (LCD) and the control panel keys are
explained in the following paragraphs.
CONTROL PANEL SUMMACUT D60
1.1.1. THE LIQUID CRYSTAL DISPLAY
The liquid crystal display (LCD) contains one line of 16 characters. The LCD provides
cutter status information during operations and displays menu options for the
configuration of the cutter.
The various menu and submenu items are always presented in a loop, which means
that, when the last menu or submenu item is displayed, pressing the appropriate key
will automatically take you back to the first item of the same menu or submenu.
1.1.2. THE MENU KEY
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SummaCut D60-D120 Service Manual
The Menu key is used to reach the most common menu items of the cutter quickly. A
last menu item in the row gives access to a submenu with which all the other functions
of the cutter can be reached (see section 1.3). The various menu items are illustrated
in the figure below.
Menu differ according to the selected tool
(1) If the PEN is the default tool
(2) If the KNIFE is the default tool
(3) If the POUNCER is the default tool
MAIN MENU SUMMACUT D60 AND THE D120
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Service Manual SummaCut D60-D120
1.1.3. THE XKEY
The xkey (cancel key) cancels the current operation
Pressing this key when the cutter is cutting stops the current job.
1.1.4. THE VKey
The VKey (confirm key) confirms a selected menu or a changed menu item.
As long as this key is not pressed a changed value of a menu item is not saved
internally and can will be lost if the menu is left.
1.1.5. THE TESTKey
If there is a certain test routine in a submenu, then it can be activated to start it.
1.1.6. THE joggingKeys
The use of the jogging keys varies according to the operation in progress.
For example, when working with different submenus, the or jogging key is
used to select the next or previous submenu.
When in a submenu the values can be changed by pressing or .
When the cutter is normal operation, then by pressing either one of the jogging keys,
the origin can be changed.
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SummaCut D60-D120 Service Manual
1.2. COMMON MENU ITEMS
Following paragraphs explain the different submenus.
1.2.1 VELOCITY
The VELOCITY submenu is used to set or modify the velocity of the tool.
The default velocity is 700 mm/s (20 ips).
After pressing the key then press the or jogging key until the desired
speed is displayed on the LCD and press to confirm.
The velocity can be set between 50 mm/s (2 ips) and 800 mm/s (40 ips).
On the LCD, the active plotting speed is marked with an “*”.
1.2.2 PEN PRESSURE
The PEN PRESSURE parameter is used to set or modify the cutting pressure of the
pen.
The default pen pressure value is 80 grams.
After pressing the key then press the or jogging key until the desired
pressure is displayed on the LCD and press to confirm.
The pen pressure can be set between 0 and 400 grams.
The pen pressure value is set in 5 gram increments.
On the LCD, the active pen pressure is marked with an “*”.
1.2.3 KNIFE PRESSURE
The KNIFE PRESSURE parameter is used to set or modify the cutting pressure of the
knife.
The default knife pressure value is 120 grams.
After pressing the key then press the or jogging key until the desired
pressure is displayed on the LCD and press to confirm.
The knife pressure can be set between 0 and 400 grams.
The knife pressure value is set in 5 gram increments.
On the LCD, the active knife pressure is marked with an “*”.
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Service Manual SummaCut D60-D120
1.2.4 KNIFE OFFSET
The KNIFE OFFSET parameter is used to set or modify the distance between the knife
blade tip and the centre axis.
The default knife offset value is .45 mm.
After pressing the key then press the or jogging key until the desired
knife offset is displayed on the LCD and press to confirm.
The value can be set between 0 and 1 mm.
Make sure that the selected knife offset value matches that of the knife. Some
fine-tuning may be necessary because of the mechanical tolerances on the knife. To
verify the knife offset, a test can be cut by pressing on the key.
If the offset value is set too low, the rectangles will not close.
When the offset value is set too high, the rectangles will be distorted.
The offset test is illustrated below.
1.2.5 POUNCING PRESSURE
The POUNCING PRESSURE submenu is used to set or modify the pouncing pressure
of the pouncing tool.
The default pouncing pressure value is 120 grams.
After pressing the key then press the or jogging key until the desired
pressure is displayed on the LCD and press to confirm.
The pouncing pressure can be set between 0 and 400 grams.
The pouncing pressure value is set in 5 gram increments.
On the LCD, the active pouncing pressure value is marked with an “*”.
Pouncing pressure set-up is explained in detail in section 1.8.1.
1.2.6 POUNCING GAP
The pouncing gap submenu is used to set or modify the distance between the pounced
wholes. This routine applies to the pouncer only.
The default pouncing gap value is 1 mm.
After pressing the key then press the or jogging key until the desired
pouncing gap is displayed on the LCD and press to confirm.
The value can be set between 1 mm and 50 mm.
On the LCD, the active pouncing gap value is marked with an “*”.
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SummaCut D60-D120 Service Manual
1.2.7 RESET
The RESET instruction performs a complete reset of the cutter. Press the key to
execute a reset.
1.2.8 RECUT
The RECUT instruction recuts the last file sent to the cutter (provided that it fitted into
the buffer). Press the key to execute the instruction.
1.2.9 LOAD
The LOAD instruction is used to initiate a load sequence. Press the key to
execute. First the origin can be changed if necessary. Press the or jogging key
to change the origin in the Y-direction. Press the or jogging key to change
the origin in the x-direction. Press the key to confirm. Then the media window
can be changed. Press the or jogging key to change the length of the
window or press the key to change the value of the length of the media window.
The or jogging key change the value in steps of 100mm, the or
jogging key change it in steps of 10mm (When the machine is set up in English units,
the step sizes are respectively 0.5” and 2.5”). Then press the key to finish the
load procedure.
1.2.10 ALIGN LOAD
The Align load sub menu is used for contour cutting. Refer to section 3 in the User’s
manual for the complete explanation on contour cutting. Section 1.3.11 explains how to
change the align method. Press the key to execute.
1.2.11 SYSTEM SETUP
The SYSTEM SETUP submenu covers the menu items you normally only need when
establishing the initial set-up e.g. when you install the cutter in combination with the
software you use.
Press the confirmation key to access the different submenu items, which are explained
in section 1.3.
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