summacut maintenance manual

SERVICE MANUAL FOR THE

S e r i e s

COREL!

Manual number : MI 9977 rev 001 08/96

Service Manual SummaCut Series Cutters

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

I. INTRODUCTION

1. Overview...........................................................................................................I-1

2. Models...............................................................................................................I-1

3. Manual organization........................................................................................I-1

1. MAINTENANCE

1.1. Removing the right hand cover.....................................................................1-1

1.2. Removing the left hand cover........................................................................1-1

1.3. Removing the bottom plate............................................................................1-2

1.4. Replacing the main PCB................................................................................1-2

1.5. Replacing the x-motor with encoder.............................................................1-3

1.6. Replacing the y-motor....................................................................................1-3

1.7. Replacing the x-motor without encoder.......................................................1-4

1.8. Replacing the keyboard.................................................................................1-4

1.9. Replacing the drag head................................................................................1-5

1.10. Configuration of the head or PCB.................................................................1-6

1.10.1 Configuration of the PCB..................................................................................1-61.10.2. Configuration of the drag head.........................................................................1-6

1.11. Replacing the flatcable of the head...............................................................1-7

1.12. Replacing the y-belt........................................................................................1-8

1.13. Replacing the sensors....................................................................................1-9

1.14. Replacing the fan motor...............................................................................1-10

1.15. Replacing the drive drum.............................................................................1-10

1.16. Replacing the cutting strip...........................................................................1-11

1.17. Replacing the camrollers.............................................................................1-11

Table of Contents TOC-i

SummaCut Series Cutters Service Manual

2. TROUBLESHOOTING

LED Codes.......................................................................................................2-1

2.1. Motor hot.........................................................................................................2-2

2.2. Low line voltage..............................................................................................2-2

2.3. High line voltage.............................................................................................2-3

2.4. Error in x-axis position...................................................................................2-3

2.5. Error in y-axis position...................................................................................2-4

2.6. Internal error....................................................................................................2-4

2.7. NVRAM failure.................................................................................................2-4

3. FIGURES

TOC-ii Table of Contents

INTRODUCTION I-1

INTRODUCTION

1. OVERVIEW

This is the Summagraphics Service Manual for the SummaCut Series Cutters. Itprovides information for servicing Summagraphics SummaCut Series Cutters.All repairs are to be made by, or under the direction of, authorizedSummagraphics service personnel.

This manual is copyrighted by Summagraphics Corporation 1996.Summagraphics reserves the right to change any information contained in thismanual without notice. Unauthorized copying, modification, distribution, ordisplay is prohibited. All rights reserved.

2. MODELS

This service manual covers the various SummaCut Series Cutters. The unitshown in the manual is model D520 which is used as a prototype for the entirerange of the SummaCut Series Cutters. Models D520, D620, D760, D1020 andD1220 are effectively identical with regard to operation and parts, the onlydifference being e.g. the number of screws holding the bottom cover in place,the number of sleeves on the drive drum, the length of the strip, etc. Where applicable the difference between lower and higher models is clearlyindicated. The only major difference is that the models D1020 and D1220 aredriven by two X-motors. A separate chapter covers the replacement of X-motorsin the higher models.

3. MANUAL ORGANIZATION

This manual is divided into the following sections:

Table of Contents

Introduction

Maintenance

Troubleshooting

INTRODUCTION I-1


Figures - part numbers

Maintenance contains the following:

An overview of the removal and the replacement of various parts of the unit in the formof separate chapters. It is advisable to carefully read the procedure described in eachof the chapters prior to removing or replacing a particular part. In addition tostraightforward step by step procedures you will often find Notes and Cautions. Makesure you read these remarks as they will often facilitate re-installation and avoidmalfunctioning.

Troubleshooting contains the following:

An overview of all the LED error codes to indicate that a malfunction has occurred. Inaddition to the cause of the problem an elaborate step by step procedure is describedto remedy it.

I-2 Introduction

Maintenance 1-1

SECTION 1

MAINTENANCE

1.1.REMOVING THE RIGHT HAND COVER

To remove the right-hand cover, proceed as follows:

1. Remove the five screws holding the right cover in place. Two are located at the back (the top oneis different in type), one at the top, one at the bottom and in front just under the base plate. Payattention to where each of the screw goes. They should be returned to their original locationwhen re-installed.

2. Gently tap the top of the cover.

3. Remove the cover.

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

1.2.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 thescrew 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 shouldbe returned to its original location (top three pins uncovered)



! CAUTION

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

Maintenance 1-1


1.3.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 onthe cutter type).

3. Lift the bottom plate until the connector of the fan can be reached and disconnected.

4. Remove the bottom plate.


! CAUTION

Do not forget to reconnect the fan and make sure the wire cannot touch thedrive drum.

1.4.REPLACING THE MAIN PCB

To replace the pcb, proceed as follows:

1. Remove the left-hand cover (see Chapter 1.2. Removing the left-hand cover).

2. Disconnect the various connectors. Pay close attention to the position of the connectors. Theyshould be returned to their original location when re-installed.

3. Remove the flat cable from the head by pulling the flat cable connector up (on both sides of theconnector cover there is a small protuberance that you can pry up using a screwdriver. Gentlypull the flat cable out of the connector.

4. Remove the flat cable from the keyboard.

5. Remove the four screws in the corner of the pcb (4 on figure 22).

6. Loosen the earthing clamp(s) so that the earthing wires can be removed.

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

NOTE

When re-installing, be extremely careful to plug the connectors into the correctholes. See figure 23 for the exact position of the connectors. Each connector onthe PCB has a reference. Once the new PCB has been has been installed, it is very important that the datastored on the PCB be brought in line with the head and vice versa. See Chapter1.10. Configuration of the head or the PCB for detailed information on how to dothis.

Maintenance 1-2


1.5.REPLACING THE X-MOTOR WITH THE ENCODER

To replace the X-motor, proceed as follows:


2. Remove the bottom plate (see Chapter 1.3. Removing the bottom plate).

3. Remove the pcb (see Chapter 1.4. replacing the main pcb).

4. Remove the two pulleys and belt (to do this loosen the setscrews - the small pulley is tightenedwith metric and the big one with bristol - and take everything off together while gently taking theload off the springs by pushing the motor a little bit upwards). See figure 8.

5. Remove the connector from the encoder and solder off the black and the red wire to expose the X-motor. See figure 6.

6. Remove the three screws holding the X-motor in place. See figure 7.

7. Remove the X-motor.

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

NOTE

Make sure the wire of the connector attached to the encoder runs outward.Make sure to weld the black wire to the minus (-) entry and the red wire to theplus (+) entry. The (+) and (-) signs are located in the corners of the motor’slabel. See fig 6.Do pay close attention to plug the connector into the correct holes. Make sure the setscrew of the small pulley is on the flat part of the axis.

1.6.REPLACING THE Y-MOTOR

To replace the Y-motor proceed as follows:

1. Remove the right-hand cover (see Chapter 1.1. Removing the right-hand cover ).


3. While pushing on the y-axis idler assy ( 1 in figure 16 ), to take the tension from the y-belt, removethe belt from the pulley on the right side ( 3 in figure 15 ).

4. Remove the spring from the y-axis drive assy ( 4 in figure 15 ).

5. Remove the y-axis drive assy from the side plate ( 2 in figure 15 - three screws ).

6. Remove the connector from the encoder and solder off the black and the red wire to expose the Y-motor. See figure 6.

7. Remove the three screws holding the Y-motor in place. See figure 7.

8. Remove the Y-motor .

9. Remove the pulley from the motor axis.


Maintenace 1-3


NOTE

Make sure the wire of the connector attached to the encoder runs outward.Make sure to solder the black wire to the minus (-) entry and the red wire to theplus (+) entry. The (+) and (-) signs are located in the corners of the motor’slabel. See fig 6.Pay close attention to plug the connector into the correct holes of the encoder.Make sure the setscrew of the small pulley is on the flat part of the axis.

1.7.REPLACING THE X-MOTOR WITHOUT THE ENCODER

To replace the X-motor, proceed as follows:

1. Remove the right-hand cover (see Chapter 1.1. Removing the right-hand cover).


3. Remove the two pulleys and belt (to do this loosen the setscrews - the small pulley is tightenedwith metric and the big one with bristol - and take everything off together while gently taking theload off the springs by pushing the motor a little bit upwards.)

4. Solder off the brown and orange wire to expose the X-motor. See figure 6.

5. Remove the three screws holding the X-motor in place. See figure 31.

6. Remove the X-motor.


NOTE

Make sure to weld the black wire to the minus (-) entry and the red wire to theplus (+) entry. The (+) and (-) signs are located in the corners of the motor’slabel. See fig 6Pay close attention to plug the connector into the correct holes of the encoder.Make sure the setscrew of the small pulley is over the flat part of the axis.

Maintenance 1-4


1.8. REPLACING THE KEYBOARD

To replace the keyboard, proceed as follows:

1. Remove the left-hand cover (see chapter 1.2. Removing the left-hand cover).

2. Remove the keyboard from the side cover, beginning by pressing with a flat screwdriver where theflatcable comes out of the cover.


Maintenace 1-5


NOTE

Note the tape around the connector. The tape has to be there to make sure nometal parts of the connector touch the inner part of the side cover, which ismetal coated and grounded.

1.9.REPLACING THE DRAG HEAD

To replace the drag head, proceed as follows:

1. Take the knife holder out of the drag head. Make sure the knife does not protrude!

2. Remove the front cover of the drag head by loosening the two screws .

3. Loosen the flat cable by pulling the flat cable connector cover up. On both sides of the connectorcover there is a small protuberance that you can pry up using a screwdriver. Gently pull theflat cable out of the connector .

4. Remove the drag head. To do this, loosen the three screws with two counterclockwise rotationsusing 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:

1. Place the head back onto the screws.

2. Tighten the screws with a 1 1/2 clockwise rotation. Do not tighten them firmly because the heightand position of the head still need to be adjusted.

3. Put the knife holder into the drag head

4. Secure the knife holder.

5. Adjust the height and position of the head. The standard operating procedure for doing this isdescribed in the SummaSign Upgrade Kit (p/n 391-950). Even though the operating proceduredescribed in the Upgrade kit applies to a tangential head, it is easy to be followed for a draghead.

6. Firmly tighten the screws once the drag head is properly positioned.

7. Put the flat cable back into the connector and close the connector. To ensure good contact, the flatcable must be positioned as deeply as possible and in the middle of the connector.

8. Remount the front cover of the head and firmly tighten the screws.

! CAUTION

Now that the head is replaced, it is extremely important to bring the data storedon the PCB in line with the head and vice versa. See chapter 1.10.1configuration of the head for detailed information on how to do this.

Maintenance 1-6


NOTE

Apart from the standard adjustment tools used in the standard operatingprocedure, you can use an ordinary 3.1/2” disk to adjust the height and theposition of the head. To do this proceed as follows:1. 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 positionedperpendicular to the cutting surface.

2. Slide the disk under the knive holder. If the disk touches the knife holder thehead is mounted too low.

1.10. CONFIGURATION OF THE HEAD OR THE PCB

When replacing the head or the PCB, it is very important to calibrate them to prevent malfunctioningand ensure optimum performance.

1.10.1 Configuration of the PCB

To configure a new PCB, proceed as follows:

1. Make sure the cutter is connected to a computer.

2. Start up the Summa Cutter Control program.

3. Switch on the cutter.

4. Press Ctrl+Alt+Shift+m (a new PCB is configured at 9600 Baud-No parity-1 stop bit).

5. Choose the correct machine type. Click “OK”.

6. Power down the cutter.

NOTE

After the PCB is reconfigured, it is best to recalibrate the machine. Thecalibration procedure is described in the Help file of the Summa Cutter Controlprogram.

1.10.2 Configuration of the drag head

To configure a drag head, proceed as follows:

1. Make sure the cutter is connected to a computer.

Maintenace 1-7


2. Start up the Summa Cutter Control program.

3. Switch on the cutter.

4. Load media into the cutter.

5. Insert a knife holder in the head. Make sure the knife tip does not protrude.

6. Select “Coil setup” from the configuration menu.

7. Click “400 gram pressure” . If you have a tension gauge of 400gr, you can check if the pressureis 400gr. If not, adjust on the pcb board with a potentio- meter. If you do not have a tensiongauge leave it as it is (default is 110).

8. Click “40 gram pressure” . If you have a tension gauge of 100gr, you can check if the pressure is40gr. If not, adjust the value. If you do not have a tension gauge leave it as it is (default is 19).

9. Click “drag landing” . Click the “down arrow button” untill the value reaches 1. Then higher thevalue one by one, each time checking whether the knife holder touches the vinyl. When it does,increase the value with 3.

10.Insert a pen. Click “pen landing” . Click the “down arrow button” untill the value reaches 1. Thenhigher the value one by one, each time checking wether the knife holder touches the vinyl. Thenincrease the value with 3.

! CAUTION

If the value of the “drag landing” is more than (“40 grams - 2”) then either thehead is not correctly calibrated or the head or pcb is faulty.

1.11. REPLACING THE FLAT CABLE FOR THE HEAD

Maintenance 1-8


To replace the flat cable, proceed as follows:



3. Remove the two screws on either side of the top cover. (Mind the washers)

4. Remove the top cover.

5. Loosen one end of the flat cable (the one attached to the PCB) by pulling the flat cable connectorcover up. On both sides of the connector cover there is a small protuberance that you can pryup using a screwdriver. Gently pull the flat cable out of the connector.

6. Pull the flat cable free until the side plate.

7. Loosen the flat cable which has been glued along the length of the top beam.

8. Remove the two screws of the cover of the head.


10.Loosen the end of the flat cable attached to the head. Follow the same procedure as before (seepoint 5).

11.Remove two screws from flatcable holder (4 figure 19).

12.Remove the two screws holding the flatcable in place (4 in figure 17).

NOTE

Pay close attention to the way the flat cable has been folded. The flat cable willneed to be folded in exactly the same way when re-installed.

Maintenace 1-9


To re-install, proceed as follows:

1. Put the flatcable in the flatcable holder (see figure 19).

2. Mount the flatcable clamp back on the carriage (figure 17). Make sure that the flatcable runsparrallel to the top beam .

3. 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 possibleand in the middle of the connector.

4. Remount the top cover of the head. Press the cover down while firmly tightening the screws. Makesure that the up/down part of the head moves freely.

5. Slide the flat cable in the slot on the left side plate.

6. Bring the head all the way to the right. Make a loop to allow the head to move unhampered alongthe length of the unit .

7. Glue the flat cable to the top beam, starting from the middle to the left.

8. Put the flat cable into the connector of the PCB and close the connector. The flat cable must bepositioned as deeply as possible and in the middle of the connector to have good contact.

9. Fold the cable into the correct position and glue it down with double backing tape.

Proceed in the reverse order of removal. Make sure to firmly tighten all screws.

! CAUTION

Make sure the loop is neither too long nor too short. A very long loop may getcaught behind other parts and break. A very short loop may break as the headmoves along the length of the unit.

1.12. REPLACING THE Y-BELT

To replace the y-belt, proceed as follows:



3. While pushing on the y-axis idler assy ( 1 in figure 16 ), to take the tension from the y-belt, removethe belt from the pulley on the right side ( 3 in figure 15 ).

4. Remove the two screws of the cover of the head.


6. Remove the screws and clamps holding the belt against the carriage plate. (figure 17).7. Remove the belt.

Maintenance 1-10



1. Screw one end of the belt firmly against the carriage plate.

2. Put the belt around the left end pulley (Figure 16). Pull it along the length of the unit and put itunder the right-hand pulley.

3. Screw the other end of the belt firmly to the carriage plate.

4. Proceed in the reverse order of removal. Make sure to firmly tighten all screws.

! CAUTION

Do not unscrew or fasten the screws of the belt while the y-belt is undertension.

NOTE

Because the belt is equipped with a springload system, the belt tension doesnot need to be adjusted.

1.13. REPLACING THE SENSORS

Cutters are equipped with two sensors. One is located at the front and the other one at the rear of themachine(figure 24).

NOTE

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

To replace the sensors, proceed as follows:



3. Remove the screws holding the two sensors in place (11 and 12 in figure 24). Pay close attentionto the position of the distance sleeves(4 and 5). They should be returned to their originallocation when re-installed.

4. Disconnect the other end of the sensor wire from the PCB.

5. Remove the sensors.

Maintenace 1-11



! CAUTION

Make sure the sensor wire does not touch the drum. The rotating drum maydamage the wire and cause malfunctioning.

1.14. REPLACING THE FAN MOTOR

To replace the fan motor, proceed as follows:


2. Remove the four screws holding the fan motor in place (figure 21).

3. Remove the fan motor.

To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws. Do nottighten the 4 screws holding the fan too much. This can break the mounting flanges of the fan andcan cause malfunctioning of the cutter.

1.15. REPLACING THE DRIVE DRUM

To replace the drive drum, proceed as follows:

1. Remove the x-motor(s) (see Chapter 1.5. (1.7.) Replacing the x-motor). It is not necessary todisconnect the wires connected to the motor.

2. Remove the screw of the sensor that goes across the drive drum. Put the sensor to the other sideto expose the drum.

3. Remove the various screws holding the drum sleeves in place. The number of sleeves variesdepending on the cutter type.

4. Remove the drive drum.

NOTE

Because all the sleeves of the drive drum are accurately matched, it is notpossible to replace just one sleeve.

Maintenance 1-12



1. place the drum in the base plate (figure 24).

2. Put the screws into the blocks but do not tighten them yet.

1. Now firmly tighten the screws of the other blocks. Make sure they are positioned straight and thatthey do not have any play.

2. Proceed in the reverse order of removal. Make sure to firmly tighten all screws.

1.16. REPLACING THE CUTTING STRIP

To replace the cutting strip, proceed as follows:

1. Loosen the cutting strip on the left-hand (or right-hand) side (figure 26).

2. Gently pull the cutting strip out of the strip slot.

3. Clear all the debris out of the cutting strip slit and degrease it.

4. Cut the new cutting strip to the correct length and stick it to the unit.

Maintenace 1-13

NOTE

It is very important that the drive drum be stable and stationary to prevent themedia from shifting about. To achieve this, proceed as follows:

1) Secure the block to the left (or right) of the large sleeve by tightening itsscrews. Make sure the block is positioned perpendicularly over the holes and thatthe long sleeve is situated in the middle of the hole of the base plate.

2) Press the block to the right (or left) of the large sleeve firmly against the sleeveand tighten the screws of the block.

See fig 25.


1.17. REPLACING THE CAMROLLERS

To replace the camrollers, proceed as follows:

1. Remove the setscrew on either side of the camrollers (figure 20).

2. Remove the pin (push on the left side of the shaft).

3. Remove the camroller.

NOTE

Camrollers come in pairs. When one is malfunctioning or broken, bothcamrollers need to be replaced.The models D1020 and D1220 have three camrollers. The centre camroller is notmatched with the two edge camrollers and can be installed independently.


Maintenance 1-14


NOTE

It is extremely important that the camroller be stable and stationary. To achievethis, press one side of the camroll shaft while tightening the setscrews.

Maintenace 1-15

TROUBLESHOOTING2-1

SECTION 2

TROUBLESHOOTING

The SummaCut has 3 LEDs on its keypad, each of which can be in three different states :ON, OFF or FLASHING. Any combination of LED states represents an error code or adifferent state mode. A table of all the different LED codes can be found in the User’sManual. A table of the different error codes is given below as a reminder.

POWERLED

OFF-LINELED

ORIGINLED

Status

[X] [*] [ ] The motor is hot and waiting to cool down.

[*] [ ] [ ] Low Line Voltage error.

[*] [*] [*] High Line Voltage error.

[*] [ ] [*] X error position.

[*] [*] [ ] Y error position.

[*] [X] [X] Internal error (=division by zero, bus error, badcommand, …).

[*] [ ] [X] NVRAM FAILURE

[X] [X] [X] Other errors (most of the time a hardware error, badROM or bad RAM - faulty PCB).

[ ] LED off ; [X] LED on; [ *] LED flashing.

TROUBLESHOOTING2-1


2.1 MOTOR HOT

Cause:

Heavy vinyl can overload the motors, especially the X-motor. The µP on the PCB calculatesthe power dissipated in the motors. When this dissipation becomes too high, the messageMOTOR HOT appears. This is not a fatal error. After a while this message will disappearand the cutter will continue its operation.

Action:

1. Wait until the motor has cooled down to an acceptable level.

2. Lower the speed using the Summa Cutter Control and use a lower knife pressure ifpossible.

3. Use lighter or narrower vinyl.

4. Check the camrollers and replace any damaged camrollers.

5. Call Summagraphics for assistance. A system register may have changed the defaultvalue.

6. Check whether the drive drum is turning smoothly (first switch the machine off and placethe camrollers in the up-position). Replace motor and/or drum.

2.2. LOW LINE VOLTAGE

Cause:

The secondary voltage of the transformer is measured by the µP on the PCB. When itmeasures a value lower than the lower limit setting, the cutter will give this error. This is afatal error. Switching the power off and making a corrective action is the only solution.

Action:

1. Measure the line voltage. Check whether the voltage selector at the back of the cutter isset to the correct line voltage. The line voltage should be between the selected voltage+8% or -10%.

2. Check the secondary voltage of the transformer. It should be at least 22VAC. If not,replace the transformer.

3. Check the DC power on the PCB (on the power cable going to the cutter interface board).It should be at least 27VDC.

4. Disconnect the motor cables, the encoder cables, the flat cable going to the head, the fancable, the sensor cables and the 28V power cable going to the cutter interface board,and switch the machine on again. When you have done this, plug in the cables one byone until the energy consumer is found. Replace it.

5. Replace the main PCB.

2-2TROUBLESHOOTING


2.3. HIGH LINE VOLTAGE

Cause:

The secondary voltage of the transformer is measured by the µP on the PCB. When itmeasures a value higher than the upper limit setting, the cutter will give this error. This is afatal error. Switching the power off and making a corrective action is the only solution.

Action:

Measure the line voltage. Check whether the voltage selector at the back of the cutter is setto the correct line voltage. The line voltage should be between the selected voltage +8% or-10%.

1. Check the secondary voltage of the transformer. It should be less than 30VAC. If not,replace the transformer.

2. Check the DC voltage on the PCB. It should be less than 37VDC.


2.4. ERROR IN X-AXIS POSITION

Cause:

The drum motor cannot move to the required position. This is a fatal error. It can only besolved by turning the power off and then on again. This error is usually caused by a mediacrash in the machine.

Action:

1. Remove the crashed vinyl 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 vinyl type is used. bad tracking because the humidity is too high or too low. bad tracking because an unapproved type of vinyl is used. the vinyl hit something on the floor while cutting. the vinyl shows already different tracks, so that the vinyl does not

know which track to follow.

1. Lower the speed of the media.

2. Check whether the drive drum turns smoothly (first turn the power off and place thecamrollers in the up-position).

3. If the error in the x-axis happens at start-up, check the x-axis motor, the encoderconnectors and the cables.

4. Replace the X-motor encoder.

5. Replace the X-driver on the PCB (IC U2), or the small driver PCB for the second X-motoron the larger SummaSign machines.

Troubleshooting 2-3


6. Replace the PCB.

2.5. ERROR IN Y-AXIS POSITION

Cause:

The motor driving the knife head cannot move to the position wanted. This is a fatal error. Itcan only be solved by turning the power off and then on again. This error is usually causedby a media crash.

Action:

1. Remove the crashed vinyl and restart the cutter.

2. Lower the speed and/or the knife pressure.

3. Check whether the head moves smoothly (first turn the power off and position thecamrollers on the outer edges of the vinyl).

4. Check the y-axis motor and the encoder cables.

5. Replace the Y-motor.

6. Replace the Y-driver on the PCB.

7. Replace the PCB.

2.6. INTERNAL ERROR

Action:

1. This is an internal line error of the 68000 microprocessor. The cause of this error may bean unknown firmware problem in the machine's EPROMs. Do the internal confidencetest. If this test is OK, check the data sent to the cutter. Start with sending data thatgave no problems in the past.

2. Reflash the ROM’s in the PCB.


2.7. NVRAM FAILURE

Action:

It is then still possible to work with the cutter, but the cutter has been defaulted to a D610. Asthe nvram has been defaulted to a D610, the margins and the calibration will be incorrect!The correct machine type can be set with SummaCutter Control program. Calibration andmargins will then also be reset.

2-4TROUBLESHOOTING


Figure 1

FIGURES 3-1

5 398-410 right holder rollfeed6 ND5000-9759 screw M4x207 ND5000-9392 screw M4x68 391-473 antistatic brush

1 398-420 side plate right2 ND5000-9748 screw M2x103 ND5000-9267 flatwasher M24 398-517

398-617 398-717 398-817 398-917

assy, switch D520assy, switch D620assy, switch D760assy, switch D1010assy, switch D1220


Figure 2

Figures 3-2

1 MS9008 switch2 MC1685 connector 2pin3 MW1224 wire yellow4 MW1237 wire orange


FIGURES 3-3

Figure 3

1 398-421 side plate left2 398-235 assy, switch3 398-411 left holder rollfeed4 ND5000-9759 screw M4x205 ND5000-9711 screw M4x126 398-210 assy, power entry7 ND5000-9766 shrinkable tube


Figures 3-4

connections on filter

b lac k

b rown

white

grey

b lue

w ires transfo

b lac k

white

w ires sw itc h

Figure 4


FIGURES 3-5

Figure 5

1 398-421 side plate left2 ND5000-9724 spacer M43 398-217

421-229assy transfo D520-D760assy transfo D1020- D1220

4 ND5000-9723 ND5000-9775

screw M4x35screw M4x40 (D1020-D1220)

ND5000-9627 lockwasher M45 ND5000-9711 screw M4x126 ND5000-9711 screw M4x127 ND5000-9683 standoff8 ND5000-9750 washer M49 ND5000-9749 standoff10 391-362 assy, grounding wire11 MT9908 ferriet bead


Figures 3-6

Figure 5


FIGURES 3-7

1 motor encoder2 red on +3 black on -4 connector 5pin5 ty-wrap holder6 ty-wrap7 capacitor MC1697

1 391-344 motor assy2 398-420 side plate left3 MH0899 screw 6/32x3/8

Figure 7


Figures 3-8

Figure 8

1 398-419 y-belt holder2 ND5000-9693 screw M3x73 MH0426 setscrew4 421-567 pulley 72T 0255 MB0315 belt 80T 0256 391-198 pulley 24T 025

(incl. setsrew)


FIGURES 3-9

Figure 9

1 398-518 assy, y-axis drive2 MH0426 setscrew 6/32x3/163 384-477 pulley xxxxx


Figures 3-10

Figure 10

1 384-477 pulley 24T 0252 ND5000-9380 setscrew M4x43 391-344 assy, motor4 MH0899 screw 6/32x3/165 MC1697 capacitor 10n


FIGURES 3-11

Figure 12

1 398-111 shaft y-axis2 MB0358 bearing3 MH0053 truarc

1 398-434 mount profile y-axis2 MH0053 truarc3 MB0385 bearing4 ND5000-9731 pulley 120T 0255 MB0380 belt 150T 025

Figure 11


Figures 3-12

Figure 14

1 398-518 assy y-axis drive2 ND5000-9693 screw M3x73 belt carriage4 ND5000-9439 spring 5 398-437 cam switch nok6 ND5000-9751 spacer 18/12/17 ND5000-9752 spacer 05/12/18/158 398-407 lever pinch roller

1 398-468 cam switch nok2 ND5000-9298 screw 2.9x133 ND5000-9214 setscrew M4x54 398-407 lever, pinch roller5 ND5000-9214 setscrew M4x5

Figure 15

Figure 13


FIGURES 3-13

1 398-519 assy, y-axis idler2 belt carriage3 ND5000-9727 spring 4 see fig 17 5 figure of older revisions

Figure 16


Figures 3-14

Figure 17

1 391-365 eccentric shaft2 391-314 flatcable holder3 391-313 concentric shaft4 ND5000-9602

ND5000-9267screw M2x6flatwasher M2

5 398-540 398-640 398-740 398-842 398-942

belt D520belt D620belt D760 belt D1020belt D1220

6 ND5000-9620 ND5000-9231 ND5000-9540

washer 4.1x7x.3lockwasher M4hexnut M4

7 ND5000-9168 screw M3x68 ND5000-9778 clamp disk9 ND5000-9777 clamp strap

10 398-444 carriage plate


FIGURES 3-15

Figure 18

dist. +/- 2mm

adjust

1 391-314 flatcable holder2 391-104 flatcable clamp3 ND5000-9667 screw M2x44 ND5000-9267 flatwasher M25 391-143 flatcable

Figure 19


Figures 3-16

Figure 20

1 398-451 carriage media select right2 391-115 pinch roller mount base3 391-121 eccentric cam4 398-440 connecting pin5 ND5000-9621 setscrew M3x126 ND5000-9607 truarc dia. 47 390-142 shaft camroller8 ND5000-9196 setscrew M3x59 391-326 assy, pinch roller

10 ND5000-9244 spring plunger dia 411 391-116 adjustable springholder12 391-117 spring

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


FIGURES 3-17

Figure 21

1 398-435 398-462 398-433 398-432 398-595

bottom plate D520bottom plate D620bottom plate D760bottomplate D1020bottomplate D1220

2 398-529 assy fan SummaCut3 ND5000-9760 screw st4.8x134 ND5000-1128


Figures 3-18

Figure 22

1 391-945 391-975

Final pcb SummaCutpcb D1020-D1220

2 ND5000-9745 spacer M3x453 ND5000-9761 spacer M3x404 ND5000-9272 screw M3x16

ND5000-9587 lockwasher M3


FIGURES 3-19

1. x-motor (3 pins)2. y-motor (3 pins)3. transfo (3 pins)4. x encoder (4 pins)5. y encoder (4 pins)6. switch (2 pins)7. sensor (5 pins)8. fan (2 pins)

help: red opposite to red for motors

Figure 23


Figures 3-20

Figure 24

5 ND5000-9612 (4x) washer diam4.2x26 391-318

398-718398-818398-918

assy media sensor rearid D760id D1020id D1220

7 391-319 assy media sensor front8 ND5000-9695 (8x) screw M4x20 with washers9 391-759 anti-static brush

10 ND5000-9392 screw M4x611 ND5000-9332 screw M4x1212 ND5000-9712 screw M4x16

1 398-401398-412398-423398-424398-596

base plate D520base plate D620base plate 760base plate 1020base plate 1220

2 ND5000-1128 ty-wrap holder3 398-511

398-611398-711398-811398-911

drive drum D520drive drum 620drive drum 760drive drum 1020drive drum 1220

4 ND5000-9612 (2x) washer diam4.2x2


FIGURES 3-21

1. all bearing blocks pushed to 1 side2. +/- equal distance

Figure 25


Figures 3-22

Figure 26

8 398-416 top beam finished9 398-100 right end cover

10 398-454 gloss sticker SummaCut11 398-525

398-625398-725398-825398-925

rollfeed D520rollfeed D620rollfeed D760rollfeed D1020rollfeed D1220

12 398-540 belt 13 391-386

391-886cutting strip D520 - D620cutting strip D760 - D1020 -D1220

1 398-490 left end cover2 398-449 keyboard SummaCut3 398-417

398-418398-442398-443398-599

top cover D520 top cover D620top cover D760 top cover D1020 top cover D1220

4 398-515 assy media select left5 391-200 assy, drag head6 391-222 cover head7 398-516 assy media select right

398-530 assy media select mid(mid wheel for 1020 and1220)


FIGURES 3-23

1 398-409 left plug, shaft rollfeed2 398-532 assy, left plug3 398-406

398-429 398-430 398-431 398-597

shaft rollfeed D520 shaft rollfeed D620shaft rollfeed D760shaft rollfeed D1020 shaft rollfeed D1220

4 ND5000-9754 retainer ring dia.195 398-533 assy, right plug6 ND5000-9754 retainer ring dia.197 398-408 right plug, shaft rollfeed8 ND5000-9763 O-ring dia 16.82

Figure 27


Figures 3-24

1 398-469 ring rollfeed2 ND5000-9762 insert M33 ND5000-9757 O-ring dia 184 398-470 plug machined5 416-1046 clutch6 MH0091 flatwasher 4/407 ND5000-9756 screw M3x30

Figure 28


FIGURES 3-25

Figure 29

7 ND5000-9632 screw M8x168 ND5000-9499 cap M89 ND5000-9411 (2x) washer M8

10 ND5000-9952 screw M3x1211 391-171 roller guiding12 391-183 brake

1 398-422 roll2 398-438 rollfeed plate , right3 398-439 rollfeed plate , left4 ND5000-9634 washer 8.2x25x2.55 391-130 spacer 8x136 ND5000-9633 lockwasher M8

Figure 30

1 391-171 roller guiding2 ND5000-9651 O-ring dia 48x53 ND5000-9698 O-ring dia 52x34 391-183 brake


Figures 3-26

1 391-809 motor without encoder2 MH0899 screw 6/323 398-445 side plate right (1020-1220)

Figure 31

summacut maintenance manual

Documents

drag head

fan motor

motor hot

manual number

manual organization

main pcb

low line voltage

high line voltage