SERVICE MANUAL FOR THE

Series

 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..................................................................................1-6

1.10.2. 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. It
provides information for servicing Summagraphics SummaCut Series Cutters.
All repairs are to be made by, or under the direction of, authorized
Summagraphics service personnel.

This manual is copyrighted by Summagraphics Corporation 1996.

Summagraphics reserves the right to change any information contained in this
manual without notice. Unauthorized copying, modification, distribution, or
display is prohibited. All rights reserved.

2. MODELS

This service manual covers the various SummaCut Series Cutters. The unit
shown in the manual is model D520 which is used as a prototype for the entire
range of the SummaCut Series Cutters. Models D520, D620, D760, D1020 and
D1220 are effectively identical with regard to operation and parts, the only
difference 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 clearly
indicated. The only major difference is that the models D1020 and D1220 are
driven by two X-motors. A separate chapter covers the replacement of X-motors
in the higher models.

3. MANUAL ORGANIZATION
This manual is divided into the following sections:
 Table of Contents
 Introduction
 Maintenance
 Troubleshooting

INTRODUCTION I-1
SummaCut Series Cutters Service Manual

 Figures - part numbers

Maintenance 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.

Troubleshooting contains the following:

An overview of all the LED error codes to indicate that a malfunction has occurred. In
addition to the cause of the problem an elaborate step by step procedure is described
to 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 one
is different in type), one at the top, one at the bottom and in front just under the base plate. Pay
attention to where each of the screw 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.

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 the
screw 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 should
be returned to its original location (top three pins uncovered)
5. 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.

Maintenance 1-1
SummaCut Series Cutters Service Manual

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 on
the cutter type).
3. Lift the bottom plate until the connector of the fan can be reached and disconnected.
4. Remove the bottom plate.

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

! CAUTION

Do not forget to reconnect the fan and make sure the wire cannot touch the
drive 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. They
should 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 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 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 correct
holes. See figure 23 for the exact position of the connectors. Each connector on
the PCB has a reference.
Once the new PCB has been 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 Chapter
1.10. Configuration of the head or the PCB for detailed information on how to do
this.

Maintenance 1-2
Service Manual SummaCut Series Cutters

1.5. REPLACING THE X-MOTOR WITH THE ENCODER

To replace the X-motor, proceed as follows:

1. Remove the left-hand cover (see Chapter 1.2. Removing the left-hand cover).
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 tightened
with metric and the big one with bristol - and take everything off together while gently taking the
load 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 and
setscrews.

 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 the
plus (+) entry. The (+) and (-) signs are located in the corners of the motor’s
label. 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 ).
2. Remove the left-hand cover (see Chapter 1.2. Removing the left-hand cover).
3. While pushing on the y-axis idler assy ( 1 in figure 16 ), to take the tension from the y-belt, remove
the 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.

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

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SummaCut Series Cutters Service Manual

 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 the
plus (+) entry. The (+) and (-) signs are located in the corners of the motor’s
label. 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).
2. Remove the bottom plate (see Chapter 1.3. Removing the bottom plate).
3. Remove the two pulleys and belt (to do this loosen the setscrews - the small pulley is tightened
with metric and the big one with bristol - and take everything off together while gently taking the
load 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.

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

 NOTE

Make sure to weld 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. 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 over the flat part of the axis.

Maintenance 1-4
Service Manual SummaCut Series Cutters

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 the
flatcable comes out of the cover.

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

Maintenace 1-5
SummaCut Series Cutters Service Manual

 NOTE

Note the tape around the connector. The tape has to be there to make sure no
metal parts of the connector touch the inner part of the side cover, which is
metal 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 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.

2. 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.
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 is
described in the SummaSign Upgrade Kit (p/n 391-950). Even though the operating procedure
described in the Upgrade kit applies to a tangential head, it is easy to be followed for a drag
head.
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 flat
cable 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 stored
on the PCB in line with the head and vice versa. See chapter 1.10.1
configuration of the head for detailed information on how to do this.

Maintenance 1-6
Service Manual SummaCut Series Cutters

 NOTE

Apart from the standard adjustment tools used in the standard operating
procedure, you can use an ordinary 3.1/2” disk to adjust the height and the
position 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 positioned
perpendicular to the cutting surface.
2. Slide the disk under the knive holder. If the disk touches the knife holder the
head 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 malfunctioning
and 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. The

calibration procedure is described in the Help file of the Summa Cutter Control
program.

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
SummaCut Series Cutters Service Manual

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 pressure
is 400gr. If not, adjust on the pcb board with a potentio- meter. If you do not have a tension
gauge 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 is
40gr. 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 the
value 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. Then
higher the value one by one, each time checking wether the knife holder touches the vinyl. Then
increase the value with 3.

! CAUTION

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

1.11. REPLACING THE FLAT CABLE FOR THE HEAD

Maintenance 1-8
Service Manual SummaCut Series Cutters

To replace the flat cable, proceed as follows:

1. Remove the left-hand cover (see Chapter 1.2. Removing the left-hand cover).
2. Remove the right-hand cover (see Chapter 1.1. Removing the right-hand cover).
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 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.
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.
9. Remove the cover.
10.Loosen the end of the flat cable attached to the head. Follow the same procedure as before (see
point 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 will
need to be folded in exactly the same way when re-installed.

Maintenace 1-9
SummaCut Series Cutters Service Manual

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 runs
parrallel 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 possible
and in the middle of the connector.
4. Remount the top cover of the head. Press the cover down while firmly tightening the screws. Make
sure 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 along
the 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 be
positioned 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 get
caught behind other parts and break. A very short loop may break as the head
moves along the length of the unit.

1.12. REPLACING THE Y-BELT

To replace the y-belt, proceed as follows:
1. Remove the left-hand cover (see Chapter 1.2. Removing the left-hand cover).
2. 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, remove
the belt from the pulley on the right side ( 3 in figure 15 ).
4. Remove the two screws of the cover of the head.
5. Remove the cover.
6. Remove the screws and clamps holding the belt against the carriage plate. (figure 17).
7. Remove the belt.

Maintenance 1-10
Service Manual SummaCut Series Cutters

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 end pulley (Figure 16). Pull it along the length of the unit and put it
under 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 under
tension.

 NOTE

Because the belt is equipped with a springload system, the belt tension does
not 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 the
machine(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 sensor
tends to start malfunctioning as well. Therefore, to avoid having to perform the
same repair twice within a short span of time, it is advisable to replace both
sensors at the same time.

To replace the sensors, proceed as follows:

1. Remove the left-hand cover (see Chapter 1.2. Removing the left-hand cover).
2. Remove the bottom plate (see Chapter 1.3. Removing the bottom plate).
3. Remove the screws holding the two sensors in place (11 and 12 in figure 24). Pay close attention
to the position of the distance sleeves(4 and 5). They should be returned to their original
location when re-installed.
4. Disconnect the other end of the sensor wire from the PCB.
5. Remove the sensors.

Maintenace 1-11
SummaCut Series Cutters Service Manual

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.

1.14. REPLACING THE FAN MOTOR

To replace the fan motor, proceed as follows:

1. Remove the bottom plate (see Chapter 1.3. Removing the bottom plate).
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 not
tighten the 4 screws holding the fan too much. This can break the mounting flanges of the fan and
can 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 to
disconnect 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 side
to expose the drum.
3. Remove the various screws holding the drum sleeves in place. The number of sleeves varies
depending on the cutter type.
4. 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.

Maintenance 1-12
Service Manual SummaCut Series Cutters

To re-install, proceed as follows:

1. place the drum in the base plate (figure 24).
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:
1) 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 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 sleeve
and tighten the screws of the block.
See fig 25.

1. Now firmly tighten the screws of the other blocks. Make sure they are positioned straight and that
they 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
SummaCut Series Cutters Service Manual

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, both

camrollers need to be replaced.
The models D1020 and D1220 have three camrollers. The centre camroller is not
matched with the two edge camrollers and can be installed independently.

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

Maintenance 1-14
Service Manual SummaCut Series Cutters

 NOTE

It is extremely important that the camroller be stable and stationary. To achieve

this, press one side of the camroll shaft while tightening the setscrews.

Maintenace 1-15
TROUBLESHOOTING
2-1

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 a
different state mode. A table of all the different LED codes can be found in the User’s
Manual. A table of the different error codes is given below as a reminder.

POWER OFF- ORIGIN Status

LED LINE LED
LED
[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, bad
command, …).
[*] [ ] [X] NVRAM FAILURE
[X] [X] [X] Other errors (most of the time a hardware error, bad
ROM or bad RAM - faulty PCB).

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

TROUBLESHOOTING
2-1
SummaCut Series Cutters Service Manual

2.1 MOTOR HOT

Cause:
Heavy vinyl can overload the motors, especially the X-motor. The µP on the PCB calculates
the power dissipated in the motors. When this dissipation becomes too high, the message
MOTOR HOT appears. This is not a fatal error. After a while this message will disappear
and 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 if
possible.
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 default
value.
6. Check whether the drive drum is turning smoothly (first switch the machine off and place
the 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 it
measures a value lower than the lower limit setting, the cutter will give this error. This is a
fatal 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 is
set 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 fan
cable, 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 by
one until the energy consumer is found. Replace it.
5. Replace the main PCB.

2-2
TROUBLESHOOTING
Service Manual SummaCut Series Cutters

2.3. HIGH LINE VOLTAGE

Cause:
The secondary voltage of the transformer is measured by the µP on the PCB. When it
measures a value higher than the upper limit setting, the cutter will give this error. This is a
fatal 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 set
to 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.
3. Replace the main PCB.

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 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 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 the
camrollers in the up-position).
3. If the error in the x-axis happens at start-up, check the x-axis motor, the encoder
connectors 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-motor
on the larger SummaSign machines.

Troubleshooting 2-
3
SummaCut Series Cutters Service Manual

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. 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 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 the
camrollers 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 be
an unknown firmware problem in the machine's EPROMs. Do the internal confidence
test. If this test is OK, check the data sent to the cutter. Start with sending data that
gave no problems in the past.
2. Reflash the ROM’s in the PCB.
3. Replace the main 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. As
the 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 and
margins will then also be reset.

2-4
TROUBLESHOOTING
SummaCut Series Cutters Service Manual

Figure 1

1 398-420 side plate right 5 398-410 right holder rollfeed

2 ND5000-9748 screw M2x10 6 ND5000-9759 screw M4x20
3 ND5000-9267 flatwasher M2 7 ND5000-9392 screw M4x6
4 398-517 assy, switch D520 8 391-473 antistatic brush
398-617 assy, switch D620
398-717 assy, switch D760
398-817 assy, switch D1010
398-917 assy, switch D1220

FIGURES 3-1
SummaCut Series Cutters Service Manual

Figure 2

1 MS9008 switch
2 MC1685 connector 2pin
3 MW1224 wire yellow
4 MW1237 wire orange

Figures 3-2
SummaCut Series Cutters Service Manual

Figure 3

1 398-421 side plate left

2 398-235 assy, switch
3 398-411 left holder rollfeed
4 ND5000-9759 screw M4x20
5 ND5000-9711 screw M4x12
6 398-210 assy, power entry
7 ND5000-9766 shrinkable tube

FIGURES 3-3
SummaCut Series Cutters Service Manual

connections on filter

w hite g re y

w hite

b ro w n

b la c k
b la c k b lue

w ire s sw itc h w ire s tra nsfo

Figure 4

Figures 3-4
SummaCut Series Cutters Service Manual

Figure 5
1 398-421 side plate left
2 ND5000-9724 spacer M4
3 398-217 assy transfo D520-D760
421-229 assy transfo D1020- D1220
4 ND5000-9723 screw M4x35
ND5000-9775 screw M4x40 (D1020-D1220)
ND5000-9627 lockwasher M4
5 ND5000-9711 screw M4x12
6 ND5000-9711 screw M4x12
7 ND5000-9683 standoff
8 ND5000-9750 washer M4
9 ND5000-9749 standoff
10 391-362 assy, grounding wire
11 MT9908 ferriet bead

FIGURES 3-5
SummaCut Series Cutters Service Manual

Figure 5

Figures 3-6
SummaCut Series Cutters Service Manual

1 motor encoder
2 red on +
3 black on -
4 connector 5pin
5 ty-wrap holder
6 ty-wrap
7 capacitor MC1697

Figure 7

1 391-344 motor assy

2 398-420 side plate left
3 MH0899 screw 6/32x3/8

FIGURES 3-7
SummaCut Series Cutters Service Manual

Figure 8

1 398-419 y-belt holder

2 ND5000-9693 screw M3x7
3 MH0426 setscrew
4 421-567 pulley 72T 025
5 MB0315 belt 80T 025
6 391-198 pulley 24T 025
(incl. setsrew)

Figures 3-8
SummaCut Series Cutters Service Manual

Figure 9

1 398-518 assy, y-axis drive

2 MH0426 setscrew 6/32x3/16
3 384-477 pulley xxxxx

FIGURES 3-9
SummaCut Series Cutters Service Manual

Figure 10

1 384-477 pulley 24T 025

2 ND5000-9380 setscrew M4x4
3 391-344 assy, motor
4 MH0899 screw 6/32x3/16
5 MC1697 capacitor 10n

Figures 3-
10
SummaCut Series Cutters Service Manual

Figure 11

1 398-434 mount profile y-axis

2 MH0053 truarc
3 MB0385 bearing
4 ND5000-9731 pulley 120T 025
5 MB0380 belt 150T 025

1 398-111 shaft y-axis

2 MB0358 bearing
3 MH0053 truarc

Figure 12

FIGURES 3-
11
SummaCut Series Cutters Service Manual

Figure 14
Figure 13

1 398-468 cam switch nok

2 ND5000-9298 screw 2.9x13
3 ND5000-9214 setscrew M4x5
4 398-407 lever, pinch roller
5 ND5000-9214 setscrew M4x5

Figure 15

1 398-518 assy y-axis drive

2 ND5000-9693 screw M3x7
3 belt carriage
4 ND5000-9439 spring
5 398-437 cam switch nok
6 ND5000-9751 spacer 18/12/1
7 ND5000-9752 spacer 05/12/18/15
8 398-407 lever pinch roller

Figures 3-
12
SummaCut Series Cutters Service Manual

Figure 16

1 398-519 assy, y-axis idler

2 belt carriage
3 ND5000-9727 spring
4 see fig 17
5 figure of older revisions

FIGURES 3-
13
SummaCut Series Cutters Service Manual

Figure 17

1 391-365 eccentric shaft

2 391-314 flatcable holder
3 391-313 concentric shaft
4 ND5000-9602 screw M2x6
ND5000-9267 flatwasher M2
5 398-540 belt D520
398-640 belt D620
398-740 belt D760
398-842 belt D1020
398-942 belt D1220
6 ND5000-9620 washer 4.1x7x.3
ND5000-9231 lockwasher M4
ND5000-9540 hexnut M4
7 ND5000-9168 screw M3x6
8 ND5000-9778 clamp disk
9 ND5000-9777 clamp strap
10 398-444 carriage plate

Figures 3-
14
SummaCut Series Cutters Service Manual

dist. +/- 2mm

adjust

Figure 18

Figure 19

1 391-314 flatcable holder

2 391-104 flatcable clamp
3 ND5000-9667 screw M2x4
4 ND5000-9267 flatwasher M2
5 391-143 flatcable

FIGURES 3-
15
SummaCut Series Cutters Service Manual

Figure 20
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.

Figures 3-
16
SummaCut Series Cutters Service Manual

Figure 21

1 398-435 bottom plate D520

398-462 bottom plate D620
398-433 bottom plate D760
398-432 bottomplate D1020
398-595 bottomplate D1220
2 398-529 assy fan SummaCut
3 ND5000-9760 screw st4.8x13
4 ND5000-1128

FIGURES 3-
17
SummaCut Series Cutters Service Manual

Figure 22

1 391-945 Final pcb SummaCut

391-975 pcb D1020-D1220
2 ND5000-9745 spacer M3x45
3 ND5000-9761 spacer M3x40
4 ND5000-9272 screw M3x16
ND5000-9587 lockwasher M3

Figures 3-
18
SummaCut Series Cutters Service Manual

Figure 23

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

FIGURES 3-
19
 SummaCut Series Cutters Service Manual

Figure 24

1 398-401 base plate D520 5 ND5000-9612 (4x) washer diam4.2x2

398-412 base plate D620 6 391-318 assy media sensor rear
398-423 base plate 760 398-718 id D760
398-424 base plate 1020 398-818 id D1020
398-596 base plate 1220 398-918 id D1220
2 ND5000-1128 ty-wrap holder 7 391-319 assy media sensor front
3 398-511 drive drum D520 8 ND5000-9695 (8x) screw M4x20 with washers
398-611 drive drum 620 9 391-759 anti-static brush
398-711 drive drum 760 10 ND5000-9392 screw M4x6
398-811 drive drum 1020 11 ND5000-9332 screw M4x12
398-911 drive drum 1220 12 ND5000-9712 screw M4x16
4 ND5000-9612 (2x) washer diam4.2x2

Figures 3-
20
SummaCut Series Cutters Service Manual

Figure 25

1. all bearing blocks pushed to 1 side

2. +/- equal distance

FIGURES 3-
21
SummaCut Series Cutters Service Manual

Figure 26

1 398-490 left end cover 8 398-416 top beam finished

2 398-449 keyboard SummaCut 9 398-100 right end cover
3 398-417 top cover D520 10 398-454 gloss sticker SummaCut
398-418 top cover D620 11 398-525 rollfeed D520
398-442 top cover D760 398-625 rollfeed D620
398-443 top cover D1020 398-725 rollfeed D760
398-599 top cover D1220 398-825 rollfeed D1020
4 398-515 assy media select left 398-925 rollfeed D1220
5 391-200 assy, drag head 12 398-540 belt
6 391-222 cover head 13 391-386 cutting strip D520 - D620
7 398-516 assy media select right 391-886 cutting strip D760 - D1020 -
398-530 assy media select mid D1220
(mid wheel for 1020 and
1220)

Figures 3-
22
SummaCut Series Cutters Service Manual

Figure 27

1 398-409 left plug, shaft rollfeed

2 398-532 assy, left plug
3 398-406 shaft rollfeed D520
398-429 shaft rollfeed D620
398-430 shaft rollfeed D760
398-431 shaft rollfeed D1020
398-597 shaft rollfeed D1220
4 ND5000-9754 retainer ring dia.19
5 398-533 assy, right plug
6 ND5000-9754 retainer ring dia.19
7 398-408 right plug, shaft rollfeed
8 ND5000-9763 O-ring dia 16.82

FIGURES 3-
23
SummaCut Series Cutters Service Manual

Figure 28

1 398-469 ring rollfeed

2 ND5000-9762 insert M3
3 ND5000-9757 O-ring dia 18
4 398-470 plug machined
5 416-1046 clutch
6 MH0091 flatwasher 4/40
7 ND5000-9756 screw M3x30

Figures 3-
24
SummaCut Series Cutters Service Manual

Figure 29

1 391-171 roller guiding

2 ND5000-9651 O-ring dia 48x5
3 ND5000-9698 O-ring dia 52x3
4 391-183 brake

Figure 30

1 398-422 roll 7 ND5000-9632 screw M8x16

2 398-438 rollfeed plate , right 8 ND5000-9499 cap M8
3 398-439 rollfeed plate , left 9 ND5000-9411 (2x) washer M8
4 ND5000-9634 washer 8.2x25x2.5 10 ND5000-9952 screw M3x12
5 391-130 spacer 8x13 11 391-171 roller guiding
6 ND5000-9633 lockwasher M8 12 391-183 brake

FIGURES 3-
25
SummaCut Series Cutters Service Manual

Figure 31

1 391-809 motor without encoder

2 MH0899 screw 6/32
3 398-445 side plate right (1020-1220)

Figures 3-
26