Service Manual

SummaCut D60 and D120

Summa NV
 Rochesterlaan 6
8470 Gistel
Belgium

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

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

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

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

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

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

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:

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.
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

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

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.
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

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)

SECTION 1

Keyboard control

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

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.
 THE MENU KEY

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

 THE X KEY

The x key (cancel key) cancels the current operation

Pressing this key when the cutter is cutting stops the current job.

THE V Key

The V Key (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.

THE TEST Key

If there is a certain test routine in a submenu, then it can be activated to start it.

THE jogging Keys

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.
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 “*”.
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 “*”.
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.
SYSTEM SETUP
This sub menu contains parameters and info, which normally are necessary when the machine is first
installed, or when certain problems occur. Figure below gives the different options in this submenu.

(*) only available when the tool is set to drag knife

SYSTEM SETUP SUMMACUT D60

CONFIDENCE

The CONFIDENCE cut performs an electrical and mechanical test of the cutter to make sure that the cutter
is fully operational. A media sheet of at least A3/A- size should be used for this plot.
Press the key to execute.

DIN CUT

The DIN CUT also performs an electrical and mechanical test of the cutter, in order to check the cut
quality, but also provides the user with feedback on knife setting, knife pressure, knife offset and cutting
depth.

This cut is always run as a DIN A4 portrait/A-size image, regardless of the actual size of the media loaded.
If the media loaded is smaller than DIN A4/A-size, part of the outer box will be clipped (not cut). This cut
is always executed in the sequence prescribed by the ISO DIN standard.
Press the key to execute.

TOOL

The TOOL submenu is used to select the default tool at power up.

After pressing the key then press the or jogging key until the desired tool is displayed on
the LCD and press to confirm.
To configure the cutter for plotting operations, select PEN.
To configure the cutter for cutting operations, select the DRAG KNIFE option.
To configure the cutter for pouncing operations, select the POUNCING TOOL option.
On the LCD, the active tool setting is marked with an “*”.

FLEX-CUT

FLEX-CUT can be set to OFF, to Mode 1 or Mode 2. When the cutter is set to mode 1 or mode 2, it will
alternately cut one length with full pressure, and one length with reduced pressure (length is later referred
to as “HALF”. The feature FLEX-CUT offers the advantage that it cuts completely through the material,
yet allowing the material to stay together by means of the small media bridges.
MODE 1 is the quickest mode, but it is less precise because the pressure changes during the cutting.
MODE 2 is a lot slower, but at the same time it is much more precise, as the cutter stops at every change of
pressure.
After pressing the key then press the or jogging key until the desired mode is displayed
on the LCD and press to confirm.
On the LCD, the active setting is marked with an “*”.
Pressing the key will activate the configuration menu. The different configuration sub menus can

be accessed by pressing the or jogging key. All the values are metric regardless the
“MENU UNITS” setting.
1. CUT

This parameter determines the length that is cut with full pressure. Press the or jogging key to
change the value. By pressing the key, the FLEX-CUT test pattern will be cut.
2. HALF
This parameter determines the length that will be cut with reduced pressure or without pressure. Press the

or jogging key to change the value. By pressing the key, the FLEX-CUT pattern will be
cut.
3. PRES

This parameter determines the pressure of “HALF”. Press the or jogging key to change the
value. By pressing the key, the FLEX-CUT test pattern is cut.

OVERCUT

The OVERCUT submenu enables you to generate an overcut in order to facilitate weeding the cut. Press

the or jogging key to change the value.

The default overcut is set to 1.
The overcut setting can be disabled (=0) or set to any value between 0(=off) and 10. One unit is about 0.1
mm or 0.004 ".
On the LCD, the active value is marked with an “*”.

OPTICUT

The OPTICUT submenu enables you to generate an enhanced overcut in order to facilitate weeding the
cut. This feature however does leave little scratch on your design and may not be appropriate for some
media.

Press the or jogging key to change the value.

The default value is set to OFF.
On the LCD, the active value is marked with an “*”.
EMULATE

The EMULATE submenu is used to select the active cutting/plotting language for the cutter.

After pressing the key then press the or jogging key until the desired language is
displayed on the LCD and press to confirm.
The SummaCut D60 and theD120 supports DM/PL , HP/GL and HP/GL/2.
On the LCD, the active plotting language setting is marked with an “*”.

NOTE

The active cutting/plotting language MUST match the cutting

software.

Always select a language that is supported by the host computer's

cutting software.

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

BAUD RATE

The BAUD RATE submenu is used to set or modify the operating baud rate for RS-232-C serial
communications between your cutter and the host computer.
The default baud rate is 9600 bps.

After pressing the key then press the or jogging key until the desired baud rate is
displayed on the LCD and press to confirm.
The baud rate can be set to any of the following values: 2400 bps, 4800 bps, 9600 bps, 19200 and 38400
bps.
On the LCD, the active baud rate value is marked with an “*”.

NOTE

The baud rate setting of your cutter MUST match the host computer's
baud rate setting.
PARITY

The PARITY submenu is used to set or modify the byte format and parity type for RS-232-C serial
communications between your cutter and the host computer.
The default parity setting is bit 8 = 0 (8 data bits, no parity, the 8th bit being a low bit). The parity can be
set to any of the following values:

LCD information Parity setting Remarks

BIT 8 = 0 8 data bits, no parity bit 8 = low (0)
BIT 8 = 1 8 data bits, no parity bit 8 = high (1)
EVEN 7 data bits, 1 parity bit parity bit = even
ODD 7 data bits, 1 parity bit parity bit = odd

After pressing the key then press the or jogging key until the desired setting is displayed
on the LCD and press to confirm.
RTS/DTR can be set to TOGGLE (hardware handshaking) or HIGH (software handshaking).
On the LCD, the active parity setting is marked with an “*”.

NOTE

The parity setting of your cutter MUST match the host computer’ s parity
setting.

RTS/DTR

The RTS/DTR submenu controls the Request To Send (RTS) and Data Terminal Ready (DTR) signals of
the cutter's RS-232-C serial communications interface for hardware handshaking.
The RTS/DTR default value is TOGGLE.

After pressing the key then press the or jogging key until the desired setting is displayed
on the LCD and press to confirm.
RTS/DTR can be set to TOGGLE (hardware handshaking) or HIGH (software handshaking).
On the LCD, the active handshaking setting is marked with an “*”.
RS 232 TEST

The RS232 TEST routine verifies the cutter’s RS-232-C serial communications (transmit data, receive
data, and hardware handshaking) circuits. This test does not require pen, knife or media to be loaded.

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

1. Unplug the RS-232-C data cable from the rear panel of the cutter.

2. Use a loopback test cable to connect pin 2 of the cutter’s data connector to pin 3 and pin 7 to pin 8.

3. With RS232 TEST displayed, press the key. The cutter will start transmitting and receiving
data at all available baud rates and parity settings. The length of the transmissions will vary because
of the different baud rates used. The unit then checks the hardware handshake lines.

If the RS232 port is not working correct, then the cutter returns an error message.

ALIGN MODE

The parameter ALIGN MODE in the menu determines which alignment method is
used. (See section 3 in User’s Manual for complete explanation)

After pressing the key then press the or jogging key until the desired setting is displayed
on the LCD and press to confirm.
On the LCD display, the active setting is marked with an “*”.

AUTOLOAD

The AUTOLOAD option enables the user to the change the vinyl unroll proceedings. When AUTOLOAD
is ON, the cutter will automatically unroll the vinyl when needed. When the AUTOLOAD option is OFF,
the operator himself should unroll enough media before starting to cut.
The default setting is ON. The best results and performance are guaranteed when using this setting.

After pressing the key then press the or jogging key until the desired setting is displayed
on the LCD and press to confirm.
On the LCD display, the active setting is marked with an “*”.
 LANGUAGE

The MENU LANGUAGE submenu is used to set or modify the dialogue language on the LCD. After

pressing the key then press the or jogging key until the desired language is displayed on
the LCD and press to confirm.
The information on the LCD can be displayed in English, French, German, Spanish, Italian or Dutch.
On the LCD, the active plotting language setting is marked with an “*”.

MENU UNIT

The MENU UNITS submenu allows you to select English or metric menu units.

After pressing the key then press the or jogging key until the desired menu unit is
displayed on the LCD and press to confirm.
On the LCD, the active menu units setting is marked with an “*”.

ROM REVISION

Selecting the ROM REVISION option, by pressing the key will furnish the details on the cutter’s
ROM revision. This information is often helpful to technicians when diagnosing problems over the
telephone.

MEDIA SENSOR

The MEDIA SENSOR submenu is used to activate or deactivate the media sensor. The sensor detects the
end of media. In that way the sensor prevents damage to the cutting strip and knife tip.

After pressing the key then press the or jogging key until the desired setting is displayed
on the LCD and press to confirm.
On the LCD, the active setting is marked with an “*”.

SENSOR SETUP

The SENSOR SETUP submenu is used to activate or deactivate the media. After pressing the key
follow the instructions on the LCD. Put a piece of media half on the sensor and then press the key.
The machine will show on the LCD whether the sensor works or not.
 CALIBRATE X/Y

Calibration allows changing the length of the lines that are cut to be adjusted to within the specifications.
For instance, if a cut line should measure 100 mm exactly, the cutter can be adjusted for any discrepancy.
First make sure the media is loaded, and then press the key to perform a test. Measure the lines and

enter the measured x-value by pressing the jogging keys. The or jogging key change the

values in big steps, the or jogging key change the value in small steps. After pressing the
key, the y-value can be changed in the same way.
Do not perform this test when the machine is working properly.

COIL SETUP

This test is used to calibrate knife and pen pressure and to set the knife and pen “landing”.
After adjustment, the value is saved in the system’s non-volatile RAM.
To execute this test a tension gauge of ± 100 gr. and ± 500 gr. is required.
In the upper line of the display the desired pressure appears and in the bottom line of the display the value
that has to be sent to the head to reach this pressure (this value is between 0 and 127). Press the key
to enter the test and follow the guidelines on the LCD screen.

CAUTION

Do not perform the coil test when the machine is working properly.
Changing the parameters to a wrong value may seriously affect
the quality and even damage the cutter.
SECTION 2

Replacements guidelines
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.

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 Y-GUIDING.

• Unplug the line cords and host cables before transporting the unit to other places.

• Reassemble ALL parts (screws, ferrite shield, etc.) to maintain EMI integrity, and guide the loose wires
afterwards with tie-wrap in the same manner they were before

• Watch for sharp edges on the metal strips etc.

• When the covers are off or open:

• The printed circuits boards are electrostatically sensitive; use the proper handling techniques.

• Keep sensors free of scratches and dirt.

• Keep the guiding, at least dirtfree where the wheels of the carriage pass.
1. Body
2. Cover Left/right 399-001
3. Cover Left/right 399-001
4. Screw ND5000-9556 : 4x (2x)
5. Rozetring ND5000-9639 : 4x (2x)
 REMOVING THE LEFT-HAND COVER
To remove the left-hand cover, proceed as follows:

1. Remove the four screws holding the left-hand cover in place. Two are located at the
front and 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.
3. Remove the cover.

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

REMOVING THE RIGHT-HAND COVER

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

1. Remove the four screws holding the right-hand cover in place. Two are located at the
front and 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.
3. Remove the cover.
To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

! CAUTION

Make sure that you do not jam any wires between the cover and the side
plate as this may cause considerable damage.
Give special attention to the flat cables.
1. screw ND5000-9795 : 7x
2. screw ND5000-9556 +rozetring ND5000-9639 : 4x (only 2
lower screws on each side).

1. camroller assy
2. camroller 391-326 : 1x
3. camrollershaft 391-142 : 1x
4. setcrew ND5000-9196 : 2x
REMOVING THE BOTTOM PLATE
To remove the bottom plate, proceed as follows:

1. Turn the unit in a position that front of the unit is facing to the bench.
2. Remove 2 lower screws of each cover.
3. Remove the screws holding the bottom plate in place. Unscrew first the bottom screws
(4 screws) Then remove the 3 top screws.
4. Remove the bottom plate.
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 and no wires are are been
damaged.

REPLACING THE CAM ROLLERS

To replace the cam rollers, proceed as follows:

1. Remove the set screw on either side of the cam rollers .

2. Remove the cam roller shaft (push against the left side of the shaft).
3. Remove the cam roller.

Note:

Cam rollers come in pairs. When one is malfunctioning or broken, both cam rollers
need to be replaced.

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

Note:

It is extremely important that the cam roller be stable and stationary. To achieve
this, press one side of the camshaft while tightening the set screws.
 1. Motor with encoder
2. Screws (3x)
3. Belt 110 teeth : MB9124

1 motor
2 capacitor
3 connector encoder WATCH ORIENTATION !
4 wires motor
REPLACING THE X-MOTOR
To replace the X-motor in these models, proceed as follows:

1. Remove the left hand cover (see Chapter 2.1, Removing the left hand cover).
2. Remove the Bottom plate (see Chapter 2.3, Removing the bottom plate).
3. Push the motor towards the drum and gently remove the belt.
4. Remove the connector from the encoder and solder off the black and the red wire to
expose the X-motor.
5. Remove the three screws holding the X-motor in place.
6. Remove the X-motor.
To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

Note:
When re-installing:
a.Make sure the wire of the connector attached to the encoder runs outward.
b.Make sure to solder the black wire to the minus (-) entry and the red wire to the
plus (+) entry. The (+) and (-) signs are located in the corners of the motor's label.
c.Be extremely careful to plug the connector into the correct holes of the
encoder.

Move the pulley on the motor shaft to prevent the belt from slipping against the big pulley. Make sure to
firmly tighten the set-screw.

The D120 han in the X axis 2 motors, one with an encoder and one without an encoder.
 1. Motor with encoder
2. Screws (3x)

1 motor
2 capacitor
3 connector encoder WATCH ORIENTATION !
4 wires motor
REPLACING THE Y-MOTOR
To replace the Y-motor, proceed as follows:

1. Remove the right-hand cover (see Chapter 2.1, Removing the right-hand cover).
2. Remove the connector from the encoder and solder off the black and the red wire to
expose the Y-motor.
3. Remove the three screws holding the Y-motor in place.
4. Remove the Y-motor.

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

Note:
When re-installing:
a.Make sure the wire of the connector attached to the encoder runs outward.
b.Make sure to solder the black wire to the minus (-) entry and the red wire to the
plus (+) entry. The (+) and (-) signs are located in the corners of the motor's label.
c.Be extremely careful to plug the connector into the correct holes of the
encoder.
d.Move the pulley on the motor shaft to prevent the belt from slipping against the
big pulley. Make sure to firmly tighten the set-screw.
 2

1 4 screws
2 Keyboard and LCD 399-985
REPLACING THE LCD OR THE KEYBOARD

To replace the keyboard, proceed as follows:

1. Remove the right-hand cover and the left hand cover (see Chapter 2.2, Removing the
right-hand cover).
2. Take off the top beam. The keyboard and LCD are mounted on a PCB that is mounted
in the top beam.
3. Pull the flat cable off the PCB.
4. Remove the four screws holding the keyboard in place.
5. Remove the keyboard PCB.
To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.
1 Power entery
2 RS-232 cable
3 Nut
4 Screw
5 Power supply
6 Main board
REPLACING THE MAIN PCB

To replace a PCB, proceed as follows:

1. Remove the bottom cover and the protection sheeld.

2. Disconnect the various connectors. Pay close attention to the positioning of the
connectors. They should be returned to their original location when re-installed.
3. Remove the flat cable for the head by pulling the flat cable connector up. On both
sides of the connector cover there is a small protuberance that you can pry up using a
screwdriver. Gently pull the flat cable out of the connector.
4. Remove the flat cable for the keyboard.
5. Remove the flat cable for the LCD.
At the rear of the PCB

6. Remove the safeguard located a few inches above the grounding wires.
Loosen the two grounding clamps so that the earthing wires can be removed.
At the front of the PCB

8. Remove the left screw holding the power entry module in place and sufficiently loosen
the right screw of the power entry module.

At the side of the PCB

9. Remove the three vertically-aligned screws located on the right-hand cover.

On the bottom of the PCB

10. Remove the fan motor connector.

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

11.Remove the PCB.

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

Note:
a. When re-installing, be extremely careful to plug the connectors into the correct
holes.

Each connector on the PCB has a reference.

b. Once the new PCB has been installed, it is very important that the data stored
on the PCB be brought in line with the head and vice versa. See section 4 on
calibration.
1 cover head
2 Head
3 screws cover head
4 position screws to hold head
5 Flatcable
REPLACING A DRAG HEAD
Below is the description for the replacement of a standard drag head.
To remove the drag head, proceed as follows:

1. Take the knife holder out of the drag head.

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
connector cover there is a small protuberance that you can pry up using a screwdriver.
Gently pull the flat cable out of the connector
4. Remove the drag head. To do this, loosen the three screws with two counterclockwise
rotations using a small diameter screw driver and lift the head upwards to remove it
from the screws.
To re-install the drag head, proceed as follows:

1. Place the head back onto the screws. Tighten the screws with a 1 1/2 clockwise
rotation. Do not tighten them firmly because the height and position of the head still
need to be adjusted.
2. Put the knife holder into the drag head.

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

3. Secure the knife holder.

4. Adjust the height and position of the head.

1 cover head
2 Head
3 screws cover head
4 position screws to hold head
5 Flatcable
 Apart from the standard adjustment tools used in the standard
operating procedure, you can use an ordinary 3½" disk to adjust
the height and position of the head. To do this, proceed as follows:

a. Put the disk against the drag head (the same way as you would
put an adjustment plate against it) to verify that the drag head is
positioned perpendicularly to the cutting surface.

b. Slide the disk under the knife holder. If the disk touches the
knife holder this means that the head is mounted too low. Readjust
the mounting of the head.

5. Firmly tighten the screws once the drag head is properly positioned.
6. Put the flat cable back into the connector and close the connector. To ensure good
contact, the flat cable must be positioned as deeply as possible and in the middle of
the connector.
7. Remount the front cover of the head and firmly tighten the screws.
8. Proceed in the reverse order of removal. Make sure to firmly tighten all screws.

Note:
Now that you have replaced the head, it is extremely important that you bring the
data stored on the PCB in line with the head and vice versa. See Chapter 11,
Configuration of the head or the PCB for detailed information on how to do this.
 Replacing the flat cable for the head

Below is the description for the replacement of the flat cable in small cutters.
To replace the flat cable for the head, proceed as follows:

1. Remove the left-hand cover (see Chapter 1, Removing the left-hand cover).
2. Remove the right-hand cover (see Chapter 2, Removing the right-hand cover).
3. Remove the two screws on either side of the top cover on the D120 on the D60 there
are no screws.
4. Remove the top cover.
5. Remove the bottom cover
6. Loosen one end of the flat cable (the one attached to the PCB) by pulling the flat
cable connector cover up. On both sides of the connector cover there is a small
protuberance that you can pry up using a screwdriver. Gently pull the flat cable out of
the connector.
7. Pull the flat cable for the head off the flat cable for the keyboard.

Note:
Pay close attention to the way the flat cable has been folded. It is advisable to
fold the flat cable in exactly the same way when re-installed.

7. Loosen the flat cable which has been glued to the inner side of the shaft's upright edge.
8. Remove the two screws of the top cover of the head holding the flat cable in place.
9. Remove the cover.

Note:
Pay close attention to the way the flat cable has been folded. The flat cable will
need to be folded in exactly the same way when re-installed.
Loosen the end of the flat cable attached to the head. Follow the same procedure
as before (see point 5).
1 flatcable
2 this edge is ± 110mm
3 screw to hold flatcable holder
4 screws to hold flatcable clamp
5 flatcable holder
6 flatcable clamp
To re-install, proceed as follows:

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

2. Put the flat cable across the top of the head and fold it correctly .

3. Remount the top cover of the head. Press the cover down while firmly tightening the
screws. Check that the up/down part of the head can move freely.
4. Remount the flat cable clamp. Check that the flat cable runs parallel to the inner side
of the shaft's upright edge and that the up/down part of the head can move freely.
5. Slide the flat cable in between the upright edge of the shaft and the top of the head.
6. Bring the head all the way to the left. Make a loop to allow the head to move
unhampered along the length of the unit.

Caution:
Make sure the loop is neither too long nor too short. A very long loop may get
caught behind other parts and break. A very short loop may break as the head
moves along the length of the unit.

7. Glue the flat cable to the inner side of the shaft's upright edge, starting from the middle.
8. Slide the flat cable through the slot on the right-hand side of the shaft.
9. Put the flat cable into the connector and close the connector. The flat cable must be
positioned as deeply as possible in the middle of the connector to have good contact.
10. Fold the cable into the correct position and press it onto the flat cable for the
keyboard.
11. Proceed in the reverse order of removal. Make sure to firmly tighten all screws.
REPLACING THE Y-BELT
To replace the belt, proceed as follows:

1. Remove the left-hand cover (see Chapter 2. 1, Removing the left-hand cover).
2. Remove the right-hand cover (see Chapter 2.2, Removing the right-hand cover).
3. Remove the 2 screws holding the belt against the carriage plate. One is located to the
left of the head and the other to the right.
4. Remove the belt.
To re-install, proceed as follows:

1. Screw one end of the belt firmly against the carriage plate.
2. Put the belt around the left-hand pulley. Pull it along the length of the unit and put it
around 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.

Note:
Because the belt is equipped with a springload system, the belt tension need not
be adjusted.

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 .

2. Gently pull the cutting strip out of the strip slot.
3. Cut the new cutting strip to the correct length and stick it to the unit.
4. Cut the new strip to the correct length and stick it to the unit.
REPLACING THE SENSOR
Cutters are equipped with one sensors. The sensor is lockated at the rear of the machine.

To replace the sensors, proceed as follows:

1. Turn the unit upside down.

2. Remove the bottom plate (see Chapter 2.3, Removing the bottom plate).
3. Remove the screws holding the sensor in place. Pay close attention to the positioning of
the distance sleeves. They should be returned to their original location when re-installed.
4. Disconnect the sensor wire from the sensor PCB.
5. Remove the sensors.
To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

Caution:
Make sure the sensor wire does not touch the drum. The rotating drum may
damage the wire and cause malfunctioning.

REPLACING THE FAN MOTOR

To replace the fan motor, proceed as follows:

1. Turn the unit upside down.

2. Remove the bottom plate (see Chapter 2.3, Removing the bottom plate)
3. Remove the four screws holding the fan motor in place.
4. Disconnect the other end of the fan motor wire from the PCB.
5. Remove the fan motor.
To re-install, proceed in the reverse order of removal. Make sure to firmly tighten all screws.

Caution:
Do not overtighten the 4 screws holding the fan in place as this may damage the
fan's mounting flanges and cause malfunction.
 1 Bearing block
2 gap
3 Drum

det1 push all the bearing blocks in the same direction

det2 equal distances
det3 push the pillow blocks against the sleeves
 2.15. REPLACING THE DRIVE DRUM
To replace the drive drum, proceed as follows:

1. Remove the left-hand cover (see Chapter 2. 1, Removing the left-hand cover).
2. Turn the unit upside down.
3. Remove the bottom plate (see Chapter 2.3, Removing the bottom plate).
4. Remove the various screws holding the drum sleeves in place. The number of sleeves
varies depending on the cutter type.
5. Remove the three screws holding the X-motor(s) in place and put the motor to the side.
It is not necessary to disconnect the wires connected to the motor. On the D120
remove the 2 X motors.
6. Remove the belt.
7. Loosen the two setscrews holding the drive drum pulley in place.
8. Pull the pulley out to its full extent. The pulley need not be removed from the unit.
9. Remove the drive drum.

Note:
Because all the sleeves of the drive drum are accurately matched, it is not
possible to replace just one sleeve.

To re-install, proceed as follows:

1. Put the drum into the shaft in the correct position. The largest sleeve should be to the
side of the keyboard.
2. Put the screws into the blocks but do not tighten them yet.

Note:
It is very important that the drive drum be stable and stationary to prevent the
media from shifting about. To achieve this, proceed as follows:
a.Secure the block to the left (or right) of the large sleeve by tightening its screws.
Make sure the block is positioned perpendicularly over the holes and that the
long sleeve is positioned in the middle of the hole in the base plate.
b.Press the block situatedto the right (or left) of the large sleeve firmly against the
sleeve and tighten the screws of the block.

3. Now firmly tighten the screws of the other blocks. Make sure they are positioned straight
and that they do not have any play. Gently press the blocks against the sleeves when
tightening the screws.
4. Thoroughly clean the strip slot.
5. Push the pulley back into its place.
 Note:
Make sure the setscrew is positioned correctly so that it locks itself into the slot.

6. Firmly tighten the screws of the drive drum pulley.

7. Put the belt back into its original position.
8. Re-install the X-motor. Make sure to properly tighten all screws.
9. Proceed in the reverse order of removal. Make sure to firmly tighten all screws.

Caution:
Make sure the sensor wire does not touch the drive drum. The rotating drum may
damage the wire and cause malfunctioning.
SECTION 3

MAINTENANCE

The SummaCut D60 and D120 cutter range has a number of sliding surfaces made of smooth
metals and plastics. They are virtually friction-free and require no lubrication. They will,
however, collect dust and lint which may affect the performance of the cutter. Keep the cutter as
clean as possible by using a dust cover. When necessary, clean the unit with a soft cloth
dampened with isopropyl alcohol or mild detergent. Do not use abrasives.
 MAINTENANCE & CLEANING
The SummaCut D60 and D120 has a number of sliding surfaces made of smooth metals and plastics. They
are virtually friction-free and require no lubrication. They will, however, collect dust and lint, which may
affect the performance of the cutter. Keep the cutter as clean as possible by using a dust cover. When
necessary, clean the unit with a soft cloth dampened with isopropyl alcohol or mild detergent. Do not use
abrasives.

3.1.1. CLEANING THE DRIVE SYSTEM

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

Î To clean the drive sleeves, proceed as follows:

1. First disable the sensors by covering them, or via the configuration menu.

2. Lower the pinch roller arm. Remove the backing from a piece of vinyl.
Place the vinyl with the tacky side down between one of the pinch rollers
and a drive sleeve. Lower the pinch roller arm.

3. Use the or jogging keys to move the piece of vinyl backward or

forward several times, until all residue is removed from the drive sleeves.

4. Raise the pinch roller arm and remove the piece of vinyl media.

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

6. Set the cutter’ s power switch to OFF.

CLEANING THE DRIVE SLEEVES

3.1.2. CLEANING THE SENSORS

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

Î To clean the sensor area, proceed as follows:

1. The sensor is located on the cutter’ s right side just behind the right big sleeve .

2. To keep the sensor clean, it is sufficient to wipe it out now and then with a cotton swab.
3.2. OPERATING VOLTAGE

The power entry module detects the line voltage and switches automatically between 110V and 230V.

The fuse is at the back next to the power inlet.

The fuse rate is 2.0A Slo-Blo for all voltage ratings.

! SAFETY WARNING

Before changing the fuse be sure to disconnect the cutter completely.

POWER ENTRY MODULE

1. Power entry module

2. fuse holder
3. fuse
SECTION 4

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

The unit has to be recalibrated when :

a drum has been replaced

the camrollers have been replaced
the PCB has been replaced or defaulted

!NOTE!

One of the characteristics of a drum driven machine is that different

thicknesses of media give different results while calibrating in the x-direction.
So if a high accuracy is needed, the unit has to be recalibrated when different
thicknesses of material are used.
However, recalibrating is not needed for normal usage.

Calibration:

Load media in the machine (the wider the media, the more accurate the calibration).
Start the SummaCutter Control program.
Select “settings”.

Select “Calibration”.

Measure the test pattern and enter the measurementsit in the dialogue box.
Switch the machine on and off so that the new calibration parameters will come
into effect (the borders will also be corrected).
HEAD CALIBRATION

KNIFE CALIBRATION ( OFFSET)

It is recommended to recalibrate the knife each time it is changed.

See section 1.2.4. for the calibration procedure.
COIL CALIBRATION
The coil has to be recalibrated when:

the head is changed

the PCB is changed
when the cut quality is dubious

Calibration:

Power the machine up when there is no media loaded and while the knife is turned up and
the camrollers are down for smallest media.
Go to internal system tests - coil set-up. Press the key.
The following message is displayed on the LCD :

40 G : 19

On the LCD the desired pressure is displayed and the value

that has to be sent to the head to reach the pressure displayed.

Press the key.

The following message is displayed on the LCD :

400 G : 110

If you have a tension gauge of ± 400g you can check if the pressure is 400 gr. You can
adjust the 400gr pressure with the pot-meter located right besides the connector for the
LCD en keyboard on the main PCB. (the max. pressure with a drag machine is 400grs).
If you don’t have a tension gauge, leave it at 110 .

Press the key.

The following message is displayed on the LCD :

40 G : 19

If you have a tension gauge of ± 100g you can check if the pressure is 40 gr. If a value

lower than 40 gr. is shown on the tension gauge press the key to adjust. If a value

higher then than 40 gr. is recorded on the tension gauge use the key to adjust.
If you don’t have a tension gauge leave it at 19.

Insert the drag knife holder into the head.

Press the key to adjust the drag knife landing pressure. The following message will be
displayed :

DRAGL : 14

Press the key repeatedly until the drag-knife moves upwards (value around 2).

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

Press the key another three times.

Insert the ball-point holder into the head.

Press the key to adjust the ball-point pen landing pressure. The following message will
be displayed :

PENL : 14

Press the key repeatedly until the ball-point pen moves upwards (value around 2).

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

Press the key another three times.

Insert the knife holder into the head (the knife may not stick out).

Press the key to adjust the ball-point pen landing pressure. The following message will
be displayed :

40G : 14

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

1.3. MACHINE TYPE

The machine type has to be reset when:

The pcb has been changed

a “special init” has been done

1.Configuration of the pcb:

via keyboard:

1. Initiate a start-up in Factory Set-up Mode (FSM mode or 3-key mode).

Do this by switching on the unit while simultaneously pressing the

key key and the key until the message "Standard init"
appears on the LCD.

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

2.Use the key or key to select "Standard init" or "Special init". If

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

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

In 3-key mode the following extra items appear under system tests
(along with several others, such as "Coil set-up", which are always
available).:

a. Vel Override
b. Burn in: only used in factory
c. select Machine: to set the unit type
d. System reg: only used in factory
e. Rom to flash
f. DMPL Errors
g. Bundling

Caution:
DO NOT USE THE SYSTEM TESTS MARKED “FACTORY USE ONLY”. BE EXTREMELY
CAREFUL WHILE IN THAT MODE AND FOLLOW GIVEN GUIDELINES TO THE LETTER.
YOU CAN INFLICT SERIOUS DAMAGE BEYOND REPAIR TO THE MACHINE IF THE
WRONG PARAMETERS ARE CHANGED.

3.Select "Setup machine" in the list of system tests and choose the
correct model type.
via computer:

1. Start the summa cutter control program

2. press “Alt”, “Ctrl, “Shift” and “m”
3. Choose the right machine type and click “OK”.
SENSOR TEST

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

is shown when the sensor is covered.

-------------------------------->
← ↑ →

is shown when the sensor is uncovered. The bottom arrow

> has to be at least 2 positions further than the top
← ↑ → arrow for the unit to function properly.

There is a possibility to change the positions of the bottom arrow with the
left and right arrow on the keyboard.
With Summa Cutter control the sensor test can also be done. Go to test
then to rear sensor.
 Load the media half way the sensor.

AUTOMATIC TEST

The SummaCut D60 and D120 has an automatic test build in. IT test the complete unit
keyboard, motor, coil, interface etc.

To activate this test press during the power up. Continue pressing till you get the following
message on the display.
 HARDWARE TEST X

1. Since the RS-232-C is tested use a loopback test cable to connect pin 2 of the cutter’s connector to
pin 3 and pin 7to pin 8.

2. On the D60 the parallel input is tested following loopback cable needs to be used. Connect pin 1
to pin 32, connect pin’s 2,4,6,8 and 12 together, connect following pins together 3,5,7,9 and 13,
connect pin 10 with pin 14 and connect pin 11 with pin 13.

3. For the D120 the USB needs to be connected to the USB of a computer.

When the test is running following message will been displayed on the display.

PRESS MENU key

When the key is pressed the following message is displayed on the display.

PRESS TEST key

When the key is pressed the following message is displayed on the display.

PRESS up arrow

When the key is pressed the following message is displayed on the display.

PRESS LEFT

When the key is pressed the following message is displayed on the display.

PRESS RIGHT

When the key is pressed the following message is displayed on the display.

PRESS DOWN

When the key is pressed the following message is displayed on the display.

PRESS X key

When the key is pressed the following message is displayed on the display.

PRESS V key

When the key is pressed the following message is displayed on the display.
 OPEN CAM SWITCH

When the handle is opened the following message is displayed and the cam
switch is tested.

CLOSE CAM SWITCH

When the handle is closed the following message is displayed .

DAC TEST

At this moment the cutter is testing the DAC.

COIL TEST

During this moment the coil is tested.

MOTOR TEST

The X and the Y motor are moving and the motors are tested.

X2 TEST

This test is only possible with the D120 and not with the D60.

When pressing the or the additional motor in the X axis is rotating and tested to continuing
the test press . Then following message will be displayed.

cover back sensor

When the sensor is activated the sensor is tested and following message will be
displayed.

Baud rate 2400

Be sure that the plotter has a loop installed on the RS-232-C connector. If this loop is not connected the
plotter will display an RS-232-C error. When the loop back is installed all the different Baud rates will be
displayed and tested.
When the test was successful following message will be displayed on the D60 with a Parallel port.

RAR. TEST

When the connections are been made on the parallel port this port will be tested.

On the D120 with the USB port following message will be displayed.

USB TEST

When the cutter is connected with a USB port on the computer the USB port will be tested. When the test
was successful the following message will be diplayed.

USB TEST PASSED

SECTION 5

Troubleshooting - Error codes

General
This section contains information on the error codes which can appear on the LCD screen. A
step-by-step procedure is provided in this section to prevent this error.
ERROR IN X-AXIS
Cause:

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

Action:

1. Remove the crashed media and restart the machine. Should this happen
rather frequently, the cause can be :
• knife depth or pressure is not well set.
• bad tracking because an unstabilised media type is used.
• bad tracking because the humidity is too high or too low.
• bad tracking because an unapproved type of media is used.
• the media hit something on the floor while cutting.
• the media shows already different tracks, so that the media does not know which
track to follow.
2. Lower the speed of the media.
3. Check whether the drive drum turns smoothly (first turn the power off and
place the cam rollers in the up-position).
4. If the error in the x-axis happens at start-up, check the x-axis motor, the
encoder connectors and the cables.
5. Replace the X-motor encoder.
6. Replace the PCB.
ERROR IN Y-AXIS POSITION
Cause:

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

Action:

1. Remove the crashed media and restart the machine.

2. Lower the speed and/or the knife pressure.
3. Check whether the head moves smoothly (first turn the power off and position
the cam rollers on the outer edges of the media).
4. Check the y-axis motor and the encoder cables.
5. Replace the Y-motor.
6. Replace the PCB.

SYNTAX ERROR
Cause:

Syntax errors occur when an incorrect HPGL command is received by the

machine.
The next table gives an overview:

Error Number Meaning

1 Instruction is not recognised.
2 Wrong number of parameters.
3 Parameter is out of range or illegal character.
5 Unknown character set.
7 Buffer overflow for polygons or downloadable characters.
10-18 Problems with Device Control Instruction.

Action:

1. Change the data sent to the machine.

2. Refer to the HPGL supported commands.
NVRAM FAILURES AND MESSAGES
Non fatal errors:

WARNING: SOME SYSTEM SETTINGS HAVE BEEN DAFAULTED DUE TO

OPGRADE,
SOME USER SETTINGS HAVE BEEN DEFAULTED DUE TO UPGRADE.

Action:

1. Message appears when rebooting the machine for the first time after an
upgrade of the ROM’s. The configuration of the machine will be defaulted.
After answering the questions on the display, this message should no longer
appear when the machine is switched on.
2. If it does replace PCB.

Fatal errors:

WARNING: SYSTEM NVRAM CHECKSUM FAILURE - SYSTEM NVRAM HAS BEEN

DEFAULTED TRY TO REBOOT MACHINE,
WARNING: USER NVRAM CHECKSUM FAILURE,
SYSTEM NVRAM WOULD NOT ACCEPT VALUE WRITTEN TO IT,
USER NVRAM WOULD NOT ACCEPT VALUE WRITTEN TO IT.

Action:

1. The preceding messages warn for a problem with the (NV)RAM. Important
information can be lost, such as calibration, landing pressure.
2. Replace the main PCB.

RS232 ERROR
Cause:

These errors can only happen when the RS232 test is being executed. A
special loopback test cable is necessary to do this test. (This cable
connects pin 2 to pin 3 and pin 7 to pin 8). Possible errors:
COULD NOT TRANSMIT DATA
COULD NOT RECEIVE DATA
DATA RECEIVED DID NOT MATCH DATA TRANSMITTED
PARITY/FRAMING/OVERRUN ERROR
COULD NOT TOGGLE RTS HARDWARE HANDSHAKE LINE.
Action:

1. Make sure that the loopback connections have been made.

2. Check for bad contacts in the RS232 area on the PCB.
 3. Replace the main PCB.

INTERNAL ERRORS
Cause:

Happens when there is a Firmware problem or a problem with the main

board (address bus or data bus), the following list gives an overview:

Error Number Meaning

1 bus error
2 address error
3 illegal instruction
4 zero division
5 chk instruction
6 trapv instruction
7 line 1010
8 line 1111

Action:
1. This is an internal error. The cause of this error may be an unknown firmware
problem in the machine's EPROM’s. Do the internal confidence test. If this test
is OK, check the data sent to the machine.
2. Reflash the ROM’s on the main board. (change the ROM’s on the old type
PCB)
3. Replace the main PCB.
FLASHING ERRORS AND MESSAGES

Non errors:

ERASING FLASH, PROGRAMMING,READING DATA

Action:

Message appears when the internal ROM’s are being reflashed. Just wait untill
the operation is done.

Errors:

UPGRADE ERROR: SET JUMPERS TO COPY MODE (ONLY POSSIBLE IN ROM TO

FLASH TEST)

Fatal errors:

ORDER ROM
COULD NOT ERASE FLASH
COULD NOT PROGRAM FLASH
COULD NOT DETECT FLASH

UPGRADE ERROR: CORRUPTED FILE OR COMMUNICATION PROBLEM REBOOT

Action:

1. Those are fatal errors. The information in the internal ROM’s is not reliable any
more.
2. Order ROM’s and do an internal reflash.
3. Change main PCB.

COULD NOTDETECT FLASH: POWER OFF- VERIFY JUMPER SETTINGS-RESTART

REBOOT MACHINE BEFORE FLASHING

UPGRADE ERROR: UPGRADE FILE DOES NOT MATH MACHINE TYPE, REBOOT CUTTER

RAM ERROR
Cause:

RAM’s are going bad.

Action:
 Replace the main PCB.

6. FIGURES
This section contains the detailed drawings of several assys of the SummaSign.
There are no detailed drawings of the base, since the base (containing baseplate assys and the top beam
assys) are considered as a whole and may never be disassembled. If they should ever be taken apart (e.g.
heavy transport damage), then the base has to be reassembled in the factory or by a Summa technician).
1 399-001 Cover left/right
2 399-620 Assy D-head
399-028 Cover head
3 399-019 Molded lever
4 399-618 Assy top cover D120
399-002 Top cover D60
5 399-050 Stand D60
399-085 Stand D120
6 391-386 Cutting strip +tape D60
391-886 Cutter strip + tape D120
7 398-611 Drive drum D60
399-635 Drive drum D120
8 398-515 Assy media select left
9 398-516 Assy media select right
398-530 Assy media select middle(not shown)
1 398-516 Assy media select right
2 398-515 Assy media select left
398-530 Assy media select middle(not shown)
3 399-019 Molded lever
4 399-925 Assy Power entry
5 399-024 Roll D60
399-034 Roll D120
1 398-611 Drive drum assy D60
399-635 Drive drum assy D120
2 391-809 Assy motor without encoder
3 398-224 Assy motor
4 399-013 Roller Guiding
1 399-011 Brake
2 ND5000-9881 Spring brake
3 ND5000-9879 O ring
4 399-013 Roller Guiding
1 399-002 Top Cover D60
399-033 Top cover D120
2 399-985 Assy, PCB keypad and LCD
1 399-016 Keyboard insert D120 only
2 399-025 Keypad
3 399-985 Assy, PCB keypad and LCD
1 398-529 Assy Fan
2 399-921 Power supply
3 399-905 Assy main PCB Parallel
399-975 Assy main PCB USB
4 399-925 Assy power entry
5 399-906 Cable RS232 Internal(not on USB)
1 399-986 Cable keypad and LCD
2 399-639 Assy dbl pulley 120/60T
3 MB9129 Belt
4 398-224 Assy motor
5 399-617 Assy switch pinch roller
6 399-019 Molded lever
7 ND5000-9439 Spring
1 399-631 Assy Y belt D60
399-634 Assy Y belt D120
2 421-165 Assy idler Y-axis
3 421-600 Pulley Idler
4 MB9124 Belt
5 398-224 Assy Motor
6 391-198 Pulley with screw
7 421-567 Pulley
8 399-957 Cable head D120
399-956 Cable head D60
1 398-611 Drive drum assy D60
399-635 Drive drum assy D120
2 399-965 Assy pCB media sensor
3 391-759 Anti-static brush
4 421-198 Bearing block
5 MB0389 Bearing
1 398-611 Drive drum assy D60
399-635 Drive drum assy D120
2 421-198 Bearing block
3 398-224 Assy Motor
1 398-611 Drive drum assy D60
399-635 Drive drum assy D120
2 399-965 Assy, PCB media sensor
3 391-759 Anti static brush
4 399-024 Roll D60
399-034 Roll D120
5 421-198 Bearing block
6 398-224 Assy motor
1 399-011 Brake
2 ND5000-9881 Spring brake
3 ND5000-9879 O ring
4 399-013 Roller Guiding
1 391-365 Assy exc. Shaft
2 391-386 Cutting strip with tape D60
391-886 Cutting strip with tape D120
3 391-326 Assy pinch roller
4 399-029 Belt attachement plate
5 391-313 Assy conc.Shaft
6 399-631 Belt assy D60
399-634 Belt assy D120
7 391-956 Cable head D60
399-957 Cable head D120
 1 399-019 Molded lever
2 398-611 Drive Drum Assy D60
399-635 Drive Drum Assy D120
3 399-620 Assy D-Head
4 399-025 Keypad
5 399-985 Assy PCB Keypad +LCD
6 399-965 Assy PCB Media sensor
7 391-326 Assy Pinch Roller
8 391-386 Cutting strip + tape D60
391-886 Cutting strip + tape D120
9 399-031 Alingment strip
10 399-009 Vinyl Guiding strip only on D60
1 399-925 Assy Power entry
2 399-906 Cable RS-232-C Internal only on D60
3 NUT
4 Screw
5 399-921 Power Supply
6 399-905 Assy Main PCB D60 RS-232
399-975 Assy Main PCB D120 USB
1 399-002 Top Cover D60
399-033 Top Cover D120
2 399-001 Cover left/right
3 399-001 Cover left/right
4 ND5000-9556 Screw
5 ND5000-9639 Ring
 1 399-027 carriage plate
2 391-365 assy, excentric shaft
3 391-313 assy concentric shaft
4 391-314 assy flatcable holder
5 391-182 flatcable clamp
6 ND5000-9667 screw M2x4
7 ND5000-9267 flatwasher M2
8 ND5000-9540 hexnut M4
9 ND5000-9231 lockwasher M4
10 ND5000-9620 washer 8x4.1x.3
11 ND5000-9602 screw M2x6
12 399-631 Assy Belt D60
399-634 Assy Belt D120
13 ND5000-9587 lockwasher M3
ND5000-9604 screw M3
1 motor encoder
2 red on +
3 black on -
4 connector 5pin
5 tie-wrap holder
6 tie-wrap
7 capacitor MC1697
 1 398-451 carriage media select right
2 391-115 pinch roller mount base
3 391-121 eccentric cam
4 398-440 connecting pin
5 ND5000-9621 setscrew M3x12
6 ND5000-9607 truarc dia. 4
7 390-142 shaft camroller
8 ND5000-9196 setscrew M3x5
9 391-326 assy, pinch roller
10 ND5000-9244 spring plunger dia 4
11 391-116 adjustable springholder
12 391-117 Spring

remark: for the assy media select left the partnumber for the
molded part (1) is 398-450.
 SUMMACUT D60 SPARE PARTS

Part no Description

391-198 Pulley Motor

391-313 Concentric shaft assy
391-326 Assy, pinch roller
391-365 Assy,exentric shaft
391-386 Strip + tape
391-500 Core holder assy
398-224 Assy motor
398-515 Assy, Media select left
398-516 Assy,Media select right
398-529 Assy, Fan Summacut
398-611 Drive Drum Assy
399-002 Top Cover
399-008 Cam Detection part
399-011 Brake Dia .30
399-019 Molded lever
399-024 Roll D60
399-025 Key pad
399-031 Aligment strip
399-617 Assy,switch pinch rol D60
Blank page
399-620 Assy,D-Head D60
399-621 X-Motor cable D60
399-622 Y-motor cable D60
399-623 X-encoder cable D60
399-624 Y-Encoder cable D60
399-630 Assy Carriage head
399-631 Assy, Y-belt
399-639 Assy DBL Pulley 120/60T
399-905 Assy, Main PCB
399-906 Cable RS-232 internal
399-921 Assy Power supply
399-925 Assy,power entry
399-927 Assy, DC Power cable
399-956 Cable head
399-965 Assy, PCB Media sensor
399-985 Assy,PCB Keypad+LCD
399-986 Cable keypad+LCD
421-198 Bearing Block
421-567 Pulley 72 T
MB0389 Bearing
MB9124 Belt X motor 110T
MB9129 Belt X-motor
ND5000-9879 O ring
ND5000-9881 Spring
 SUMMACUT D120 SPARE PARTS

Part no Description

384-478 Pulley
391-014 Steel strip flatcable
391-198 Pulley Motor
391-312 Roller assy
391-313 Concentric shaft assy
391-326 Assy, pinch roller
391-365 Assy,exentric shaft
391-500 Core holder assy
391-759 Anti-static brush
391-809 Assy Motor without encoder
391-886 CuttingStrip with tape
398-224 Assy motor
398-515 Assy, Media select left
398-516 Assy,Media select right
398-529 Assy, Fan Summacut
398-530 Assy, Media select Middle
399-001 Cover left /right
399-008 Cam Detection part
399-011 Brake Dia .30
399-016 Keyboard insert
399-019 Molded lever
399-025 Key pad
399-026 Spring key pad
399-028 Cover head
399-031 Aligment strip
399-034 Roll D120
399-617 Assy,switch pinch rol D60
399-620 Assy,D-Head D60
399-622 Y-motor cable D120
399-624 Y-encoder cable D120
399-629 X-Motor cable D120
399-630 Assy Carriage head
399-634 Assy, Y-belt
399-639 Assy DBL Pulley 120/60T
399-921 Assy Power supply
399-925 Assy,power entry
399-927 Assy, DC Power cable
399-957 Cable head D120
399-965 Assy, PCB Media sensor
399-975 Assy,main PCB USB
399-985 Assy,PCB Keypad+LCD
421-139 Pulley dbl 120+60T
421-198 Bearing Block
421-567 Pulley 72 T
MB0313 Bumper
MB0389 Bearing
MB9124 Belt X motor 110T
MB9129 Belt X-motor
MF-0067 Guard fan
ND5000-9879 O ring
ND5000-9881 Spring