Summa Bigpaint 1500 Maintenance Manual

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Service Manual

BigPaint

CalComp Display Products NVRochesterlaan 6

8470 GistelBelgium



Service Manual SummaPaint

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

SECTION 1 KEYBOARDCONTROL

SECTION 2 REPLACEMENT GUIDELINES

SECTION 3 MAINTENANCE

SECTION 4 CALIBRATION

SECTION 5 ERROR CODES - TROUBLESHOOTING

5.1. MOTOR HOT.........................................................................................................5.2

5.2. ERROR IN X-AXIS................................................................................................5.2

5.3. ERROR IN Y-AXIS POSITION..............................................................................5.3

5.4. ERROR IN Y-2 AXIS POSITION...........................................................................5.3

5.5. LOW LINE VOLTAGE...........................................................................................5.4

5.6. HIGH LINE VOLTAGE..........................................................................................5.4

5.7. ILLEGAL PLOT COMMAND.................................................................................5.5

5.8. ILLEGAL CLIP & SCALE SETTINGS..................................................................5.5

5.9. SYNTAX ERROR..................................................................................................5.5

5.10. NVRAM FAILURES AND MESSAGES..............................................................5.6

5.11. RS232 ERROR....................................................................................................5.6

5.12. INTERNAL ERRORS..........................................................................................5.7

Table of Contents TOC-i



SummaPaint Service Manual

5.13. FLASHING ERRORS AND MESSAGES............................................................5.7

5.14. ROM ERROR......................................................................................................5.8

5.15. RAM ERROR.......................................................................................................5.8

5.16. MACHINE UNABLE TO FIND THE KNIFE HOME POSITION...........................5.8

5.17. MARKERS NOT SENSED PROPERLY.............................................................5.8

5.18. TIMEOUT ERROR ON CONTROL PORT B, CHECK CONNECTION...............5.9

5.19. COULD NOT START INTERNAL TEST, PLEASE RETRY...............................5.9

SECTION 6 FIGURES

6.1 SERVICE STATION...............................................................................................6.2

6.2 PRINTER HEAD.....................................................................................................6.5

6.3 KEYBOARD-LCD SCREEN...................................................................................6.8

6.4 IDLER PULLEY....................................................................................................6.10

6.5 Y-MOTORS..........................................................................................................6.13

6.6 CARRIAGE CUTTERHEAD.................................................................................6.14

6.7 PRINTERHEAD + VOVER..................................................................................6.15

6.8 STANDOFFS RIGHT PLATE...............................................................................6.16

6.9 PRINTER CARRIAGE..........................................................................................6.17

6.10 X-MOTORS-TRANSFO......................................................................................6.18

6.11 PRINTER CONTROL BOX................................................................................6.19

TOC-ii Table of Contents




Table of Contents TOC-iii

Blank Page



INTRODUCTION I-1

INTRODUCTION

1. OVERVIEW

This is the CalComp Service Manual for the SummaPaint 1500X Printer Cutter. It

provides information for servicing the PC1500X. All repairs are to be made by, or underthe direction of, authorised CalComp service personnel.

This manual is copyrighted by CalComp 1997. CalComp reserves the right to changeany 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

Figures - part numbers

Appendix A list recommended spare parts

Keyboard control contains the following:

INTRODUCTION I-1




This part contains an overview of the various tests and configurations that can beaccessed 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 formof separate chapters. It is advisable to carefully read the procedure described in eachof the chapters prior to removing or replacing a particular part. In addition tostraightforward step by step procedures you will often find Notes and Cautions. Makesure you read these remarks as they will often facilitate re-installation and avoidmalfunctioning.

Maintenance contains the following:

An overview of the maintenance of various parts of the unit. It is advisable to carefullyread the procedure described in each of the chapters prior to removing or replacing aparticular part. You will often find Notes and Cautions. Make sure you read theseremarks as they will often avoid malfunctioning.

Calibration:

An overview of all the possible calibrations of the unit. Each time the machine isserviced check this section to see if any recalibration needs to be done.

Troubleshooting:

An overview ofall the possible errormessages thatcouldcome onthe LCD screen andthe possible solutions

Figures - part numbers:

Detailed figures of the various parts and assemblies of the machine.

Appendix A:

An overview of all the recommended spare parts, normally only the parts fromthis listwill be provided from CalComp.

3. QUICK TOUR AROUND THE MACHINE

I-2 Introduction




In order to get acquainted with your SummaPaint PC1500X, read the following

description of the machine and components.

FRONT VIEW

1. Control Panel : - The control panel has 12 keys. All machine activity can beinitiated from the control panel. This includes initiating remote mode forcomputer control, local mode for manual operation and menu mode.

2. Display : - The 2x16 character display informs the user about the current statusof the cutting process or about actions that need to be taken.

3. Pinch roller lever arm : - This lever is used to raise and lower the pinch rollers.

4. Pinch rollers : - The pinch rollers (one at each side) hold the media clamped

between the rubber rollers and the media drive sleeves. The PC1500X unitis providedwith anextra low pressure roller in the middle to keep the mediaflat.

5. Media Drive Sleeves : - The media drive sleeves move the media onlywhenthepinch rollers are in the ‘down’ position.

6. Sensors : - The sensors detect the presence of media to avoid damage to thecutting strip. Upon powering upthe machine, they cause the media to moveall the way to the front edge of the platen.

Introduction I-3




7. Inkjet Carriage : - The inkjet carriage is the mount for the inkjet head.

8. Ink Cartridge : - An ink cartridge is a small reservoir of ink on which a print head

is mounted.

9. Safety Cover : - The safety coverprevents the humanbody frombeing hitby themoving carriage. Therefore it is advised to close the cover while the unit isworking. This cover also prevents dust from falling on the newly printeddrawing.

10. Cutting Carriage : - The cutter carriage is the mount for the tangential cuttinghead.

11. Manual cut-off knife : - Upon completing a sign, move the media forward bypressing the key. Use the manual knife to cut the finished sign off the

media roll. Leave the loaded media in place ready to start your next cut bypressing the key again.

12. Stand : - The stand comes standard with the SummaPaint PC1500X.

13. Cutting strip : - Soft strip to avoid damage to the knife tip when no media hasbeen loaded. Since cutting is done on the cutting strip it is essential that thecutting strip remains intact.

14. Pick-up roll : - The pick-up roll makes it possible to roll up the printed material. This way the PC1500X can print unattendedly without damaging a drawing.

15. Service station : The service station cleans the printing head and prevents thehead from drying out when the unit is not working. The service stationneeds to be cleaned regularly.

16. Pick-up sensor : - This sensor senses the media. When the media reaches tooclose to the ground the pick-up roll will be activated. This way, it preventsthe pictures from touching the ground.

17. Power ON/OFF switch : - This rocker switch sets the machine’s power to ON orOFF. To switch the power ON, press the “I” side of the rocker switch. Toswitch the power OFF, press the “O” side of the rocker switch.

18. Cartridge compartment : - When a cartridge is not being used, it is advised toplace it in a cartridge clamp. These clamps can be placed in the cartridgecompartment.

19. Big ink supply bottles : - The big ink supply bottles can handle 500 ml. ink of each colour. The big ink supply systemenables long unattended printing withoutrefilling the ink.

I-4 Introduction




REAR VIEW

1. Power Entry Module: - The fuse box and the AC power cord receptacle arelocated in the power entry module.

2. Big ink supply sys tem : - The SummaPaint can be upgraded with a second setof ink.

3. Controller : - For details see further.

4. Roll Media Guide Bushes : - The two guide bushes serve to keep the media roll

in place when media is pulled from the roll.

5. Media Flanges : - The media flanges ensure proper routing of the media roll.

6. Media Support Roller : - Rotating support rollers for the media roll.1.

Introduction I-5




1.

2. SUMMAPAINT PC1500X, CONTROLLER

1. RS-232-C Port* : - This DB-9P connector provides the communication linkbetween the cutter and a host computer. It allows bi-directionalcommunication between the host computer and the cutter. This port canonly receive cut data.

2. Parallel Port* : - This printer port provides a unidirectional communication linkbetween the PC1500 and a host computer. The PC1500X can receive printand cut data, but not transmit data via this port.

* Note : only one interface can be active at a time.The first port receiving data will be the active interface until the machine isreset.

I-6 Introduction



Keyboard Controls 1-1`

SECTION 1

Keyboardcontrols

SUMMAPAINT CONTROL.

The SummaPaint Control Program for Windows is a tool to optimize the overall cutting andprinting quality of your PC1500X.

For information on the installation or general set-up of this program, refer to the ‘Readme.txt’file on the installation disk.

The SummaPaintControlprogrambasicallyhas thesame functions as the control panel. It is upto the user to decide how he will work most efficiently. The users who work with theSummaPaint Control program will notice that it is a very powerful and practical tool.

By clicking on the ‘Menu’ button in the main SummaPaint Control window all the machinesettings can be changed.

Four different user configurations can be saved in the cutter’s memory. The selectedconfiguration number is marked at the bottom of the menu window. These four configurationsare maintained independently.

THE CONTROL PANEL

Figure 1-1 shows the control panel of the SummaPaint PC1500X. The main functions of theliquid crystal display (LCD) and the control panel keys are explained in the followingparagraphs.

Keyboard Controls 1-1




FIGURE 1 -SUMMAPAINT PC1500X, CONTROL PANEL

THE LIQUID CRYSTAL DISPLAY

The 32-character liquidcrystaldisplay(LCD) contains two lines of16 characters each. The LCDprovides cutter status information during operations and displays menu options for theconfiguration of the cutter.

The contrast of the LCD can be adjusted from the control panel in order to ensure optimumreadability under varying lighting conditions.Instructions for adjusting the LCD contrast are given in Section 1..

The various menu and submenu items are always presented in a loop, which means that, whenthe lastmenu or submenu itemis displayed, pressing the appropriate key will automaticallytakeyou back to the first item of the same menu or submenu.

In addition to the status messages and/or menu options displayed on the LCD, arrow symbols

representing the , , , jogging keys and the key will tell you which keys topress to go to the next menu item (top line of the display) or to the next value for a givensubmenu item (bottom line of the display).

THE RESET/LOAD KEY

1-2 Keyboard Controls




The key (RESET/LOAD) is used to move the origin, to initiate a load sequence, to reset

the machine or to abort the job in progress. When the key (RESET/LOAD) is pressed, theunit goes off line, suspends all operations in progress and displays the RESET/LOAD menu.Press the key until SET ORIGIN, LOAD, RESET, ABORT or SPECIAL LOAD is displayed.

To confirm RESET, ABORT or SPECIAL LOAD press the key (ENTER). To execute the

SET ORIGIN instruction move the knife origin using the , , , jogging keys and

press the key (ENTER) to confirm the new origin position. To initiate the LOAD instructionpress the 1 or 2 key to initiate a load sequence for a ROLL or SHEET respectively. Upontermination of any of these instructions, the cutter goes on line again.

The SET ORIGIN instruction is used to move the knife origin. The LOAD instruction is used to initiate a load sequence. The RESET instruction performs a complete reset of the cutter.

The ABORT instruction simply cancels the cut in progress. Aborting a cut will not reset thecutter parameters: the parameters which had been selected for the cut remain in effect. The SPECIAL LOAD instruction activates the OPOS system .

THE ON LINE KEY

The key (ON LINE) toggles between on line and off line operation. When the key ispressed, the selected mode (ON LINE or OFF LINE) is displayed on the LCD.

Selecting OFF LINE will suspend all operations inprogress. Pressing the key while the cutter

is off line will make the machine go on line again, resuming the suspended operation.





While the machine is off line, the following operations can be performed:

Press the or jogging key to move the tool carriage to the left or right. (disabled inprinting mode)

Press the or jogging key to make the media move forward (towards you) orbackward (away from you). Moving the media forward will prove to be very practicalwhen you require to cut the finished sign off manually.

Press the key (TOOL UP/DOWN) to lower or raise the active tool of the cuttinghead. If the tool is not moved for approximately eight seconds, it is raised automatically(disabled in printing mode).

THE MENU KEY

The key (MENU) is used to select one of the menus. Pressing the key will make the

cutter go off line and suspend all operations in progress. Pressing the key repeatedly will

display the different menus one by one. As the menu options are on a loop, pressing thekey when the last option is displayed will automatically return you to the first option.

The different menus are illustrated in Figure 1-2.





500

FIGURE 1 -SUMMAPAINT PC1500X, CONFIGURATION SUBMENUS

To select a menu by scrolling through the different options, press the jogging key .

To exit the menus and resume the previous on line operation, press the key (ON LINE).

Under normal conditions, the machine is on line; itmay then be selected by the host computer

for a printing or cutting operation or deselected by the host computer. Pressing the , or

key will make the cutter go off line, in order to initiate another operation.

The contents of the different menus are summarised in Table 1-1.





MENU DESCRIPTION

USER CONFIG 1 (->4)Selects a given active cutter configuration fromone of the four

sets of configuration parameters stored in the unit's memory

INTERNAL TESTActivates one of the resident cutting plots provided forinformational purposes.

PRINTER SETTINGSActivates the internal printing tests and printing parameters

TABLE 1-1:CONTENTS OF THE SUMMAPAINT PC1500X MENUS

THE ENTER KEY

The key (ENTER) is used to select the item currently displayed on the LCD.

1 2 THE 1 AND 2 KEYS

The use of the 1 and 2 keys varies according to theoperation in progress; their use is displayedon the LCD as appropriate.

THE JOGGING KEYS

The use of the jogging keys varies according to the operation in progress.

For example, when working in the USER CONFIG menu, the or jogging key is used to

select the new user number and the or jogging key is used to go to the previous or nextmenu item.

THE TOOL UP/DOWN KEY

The key (TOOL UP/DOWN) is used while the cutter is off line to raise or lower the tool.

Pressing the key once will lower the tool onto the media. Pressing the key again willraise the tool.

If the key is pressed while the unit is online, the print carriage will move to the origin, awayfrom the capping station. Pressing any key will move the print carriage back.

THE TOOL SELECT KEY





The key (TOOL SELECT) is used to select one of the following tools :a tangential knifea drag knife

a ballpoint pen

To temporarily change the tool, press the key, then press the or jogging keyuntil

the desired tool appears on the second line o the LCD. Press the key to confirm the tool.An asterisk*appears next to theselectedtool. Whenthecutter is poweredonthenext time, thedefault tool will be selected. For setting up the default tool see Section 1..





NORMAL OPERATION

The term "normal operation" covers on line operation, off line operation and local operation, i.e.the three types of operation for actual cutting or plotting. They are explained in further detail inthe following paragraphs.

ON LINE AND OFF LINE

On line and off line are two important concepts when using the SummaPaint PC1500X. Thecutter is on line only when one of the following messages is displayed on the LCD :

Online in cutting mode:

500mm/s 120 g K .45mm(1) *ON LINE 1

This display message should be read asfollows :

500 mm/s = velocity120 g = knife pressure or

pen pressureK = knife operation (K) or

pen operation (P).45 mm(1) = knife offset - only

displayed when indrag knife mode

ON LINE = cutter is ready toreceive data1 = user number

Online in printing mode:

PRINT MODE K *ON LINE 1

This display message should be read asfollows :

PRINT MODE = indicates that themachine is in print mode.

K = knife operation (K) orpen operation (P)

*ON LINE = printer is ready toreceive data

1 = user number

In all other cases, the cutter is off line.

When on line, the cutter can be addressed by the host computer, which means that the cutterwill execute cutting or plotting instructions issued by the host computer's application software.

For normal operations, the cutter MUST be on line, so that it can receive instructions fromthehost computer and the printing/cutting software.





When the machine is on line, the following conditions must be met:

The machine must be powered ON.

Media must be loaded.

The proper tool must be installed.

The unit must be connected to the host computer via the parallel interface and / or theRS-232-C link.

The unit must be configured for the scheduled operation.

To put the cutter off line, press the , or key. Pressing any of these keys willsuspend the current printing / cutting operation until the PC1500X is put on line again.

LOCAL OPERATION

Local operation is only possible while the machine is off line. Local operation means that themachine is operated directly by the operator via instructions entered on the control panel.

To work in local operation mode, proceed as follows:

1. If the machine is still on line, press the key once to select off line. The media willmove forward over a certain distance.

2. To move the carriage to the left or right, press the or jogging key. (Disabled inprint mode)

3. To make the media move forwards (towards you) or backwards (away from you), press

the or jogging key.

4. To move the tool head up or down, press the key. (Disabled in print mode)

5. To end local mode and put the cutter on line again, press the key.





THE USER CONFIG MENU

The USER CONFIG(uration) menu gives access to different submenus which allow you toconfigure the cutter's operating parameters. It should be taken into accountthataccess to someof the submenus will be determined by the plotting language you are using.

Four differentuser configurations canbesaved. The selected configurationnumber is displayedon the LCD next to the USER CONFIG message. These four USER CONFIG 1(->4) menus aremaintained independently.

To select anotherconfiguration number , proceed as follows:

1. Power on the cutter.

2. Press the key until USER CONFIG 1(->4) is displayed.

3. Press the or jogging key until the desired configuration number is displayed nextto USER CONFIG.

NOTE

Before altering any of the items in the USER CONFIG menu, make sure that youhave previously selected the right configuration number in the USER CONFIG 1(->4) menu.

Figure 2-3 shows the USER CONFIG submenus.

To select and alter a configuration parameter, proceed as follows:

1. Power on the cutter.

2. Press the key until USER CONFIG 1(->4) is displayed.

3. Press the, or jogging key until the desired submenu is displayed on the first lineof the LCD.

4. Press the or jogging key until the desired value is displayed on the second line.

5. Press the key to confirm the selection, an * will be displayed next to the selectedsetting. (An * is always displayed next to the active value. )





* =in DM/PL ONLY** =IN HP/GL and HP/GL/2 ONLY

FIGURE 1 -

FLOWCHART SHOWING FACTORY PRESET MENU SETTINGS





KNIFE PRESSURE

The KNIFE PRESSURE submenu is used to set or modify the cutting pressure of the knife.

The default knife pressure value is 120 grams. The knife pressure can be set between 0 and 600 grams. The knife pressure value is set in 5 gram increments.On the LCD, the active knife pressure value is marked with an *.

PEN PRESSURE

The PEN PRESSURE submenu is used to set or modify the pressure of the ball point pen.

The default ball point pressure value is 80 grams.

The pressure can be set between 0 and 600 grams in 5 gram increments.On the LCD, the active pen pressure value is marked with an *.

KNIFE OFFSET

The KNIFE OFFSET submenu is used to set or modify the distance between the DRAG knifeblade tip and the centre axis. This routine applies to a drag knife only.

The default drag knife offset value is .45 mm. The value can be set between 0 and 1 mm.Make sure that the selected knife offset value matches thatof the knife. Some fine tuning maybe necessary because of the mechanical tolerances on the knife. To verify the knife offset, atest can be cut by pressing the 1 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.

FIRING RATE

The firing rate submenu is used to set the speed of printing. When using ink types with a highviscosity it is advised to lower the firing rate to obtain a better print quality and a longer life time

of the ink cartridges. Lowering the firing increases the time of printing. The default firing rate is high. The firing rate can be set to LOW, MEDIUM and High.

VELOCITY

The VELOCITY submenu is used to set or modify the velocity of the tool. The default velocity is 500 mm/s (20 ips). The velocity can be set between 50 mm/s (2 ips) and 600 mm/s (24 ips).





OVERCUT

The OVERCUT submenu enables you to generate an overcut in order to facilitate weeding thecut.

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

SYSTEM SETUP

The SYSTEM SETUP submenu covers the menu items you normally only need whenestablishing the initial setup e.g. when you install the cutter in combination with the softwareyou use.

Press the key to access the different submenu items, which are explained in section 1.5.





SYSTEM SET UP

Refer to Figure 1-3.

CONCATENATION

The CONCATENATION feature increases the speed and quality with which cut data having averyhigh resolution is cut. However when changingover to normal characters again, deactivateconcatenation by setting this parameter to 0.On the LCD, the active concatenation value is marked with an *.

SMOOTHING

The SMOOTHING feature helps to cut smoother curves when curve data with many short

vectors is received from the computer. The default setting is OFF.On the LCD, the active setting is marked with an *.

EMULATE

The EMULATE submenu is used to select the active cutting/plotting language for the cutter. The SummaPaint PC1500X supports HP/GL, HP/GL/2 and DM/PL.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 which is supported by the host computer's cuttingsoftware.

Select the HP/GL menu option to set the active cutting/plotting language to HP/GL. The cutterwill emulate an HP model 758xB plotter (with selectable origin, see 1.4.12).

Selectthe DM/PL menu option to set the active cutting/plotting language to Houston InstrumentDigital Microprocessor/Plotting Language (DM/PL). This selectionwill allowthe cutter to operatewith DM/PL-based cutting / plotting software. This language, having special command

extensions for cutting, normally gives superior cutting performance.

TOOL

The TOOL sub-menu is used to select the default tool at power up. To configure the cutter for TANGENTIAL KNIFE cutting operations, select the TANG. KNIFEoption. To configure the cutter for PLOTTING operations, select the BALL POINT option. To configure the cutter for DRAG KNIFE cutting operations, select the DRAG KNIFE option. To select a tool other than the default one temporarily, see section 1..

HPGL RESOLUTION





The HPGL RESOLUTION sub-menu is used to select the cutter's default HPGL user-addressable cutting resolution. The default addressing resolution is HIGH (0.01 mm) .

The user-addressable resolution can be set to NORMAL (0.025 mm) or HIGH (0.01 mm).On the LCD, the active resolution value is marked with an *

MENU UNITS

The MENU UNITS submenu allows you to select English or metric menu units for DM/PL.

For models sold in the US, English units are the default setting.For models sold in Europe, metric units are the default setting.On the LCD, the active menu units setting is marked with an *.

ADDRESSING

The ADDRESSING submenu is used to select the cutter's default DM/PL user-addressablecutting resolution. The default addressing resolution is 0.025 mm (Europe) or 0.001" (US). The user-addressable resolution can be set to 0.025 mm or 0.001" or 0.1 mm or 0.005".On the LCD, the active resolution value is marked with an *

BAUD RATE

The BAUD RATE submenu is usedto set ormodify the operating baud rate forRS-232-C serialcommunications between your cutter and the host computer.

The default baud rate is 9600 bps. The baud rate can be set to any of the following values: 2400 bps, 4800 bps, 9600 bps, 19200and 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 ratesetting.

PARITY

The PARITY sub-menu is used to set or modify the byte format and parity type for RS-232-Cserial communications between your cutter and the host computer.

The defaultparity setting is bit8 =0 (8data bits, no parity, the 8th bitbeinga low bit). The paritycan 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 =evenODD 7 data bits, 1 parity bit parity bit =odd





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.RTS/DTR can be set to TOGGLE (hardware handshaking) or HIGH (software handshaking).On the LCD, the active handshaking setting is marked with an *.

SPECIAL LOAD

The special load submenu is used to determine which alignment procedure is used whenactivating the special load procedure (see section 1). By using the the special load procedure,a contour cut can be done on a preprintedsign. On the LCD the active value is marked with an*. The default setting is OPOS. The SPECIAL LOAD can be set to X-AXIS ALIGN, XY-AXIS ALIGN, XY-ADJ USTMENT andOPOS.

MEDIA SENSOR

The MEDIA SENSOR sub-menu is used to activate or deactivate the media sensors. On theLCD, the active setting is marked with an *. The sensors detect whether media is loaded or detect the end of media. The sensors preventdamage to the cutting strip and knife tip.

FRONT SENSOR

The FRONT SENSOR sub-menu is used to activate or deactivate the front media sensors. Onthe LCD, the active setting is marked with an *. The front sensors detects the front edge of the media. Disabling the front sensors prevent thatthe media is pulled back in the loading sequence. This is necessary when the pick-up roll isused.

PICK-UP ROLL

The PICK-UP ROLL sub-menu is used to activate or deactivate the pick-up roll. When usingsheets or when you simplydo not want to use the pick-up roll you can switch itoff. The defaultsetting is ON.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. WhenAUTOLOAD is ON , the PC1500X will automatically unroll the media when needed. When theAUTOLOAD option is OFF, the operator himself should unroll enough media before starting tocut.

The default setting is ON. Best results and performance are usually guaranteed when usingthis setting. On the LCD display, the active setting is marked withan *. When using weak or soft materials, e.g. canvas, better results are achieved when

autoload is off.

CLEANING

The CLEANING sub-menu is used to set the cleaning frequency of the cleaning procedure.While printing the print-carriage moves periodically to the service station to clean the printheads and to spit some ink out of all its nozzles to prevent blocking of the nozzles. It is advisedto set the cleaning as low as possible to work faster and save some ink. In this way thereservoirs of the service station can be used longer before they need to be cleaned (see section

3).However if the cleaning frequency is to low, nozzles will block. The default setting is MEDIUM.Cleaning can be set to OFF, LOW, MEDIUM and HIGH.

TOOL COMMAND

The TOOL COMMAND is used to determine whether the DM/PL and HP/GL pen/knife-selectcommands (the P and SP commands respectively) are ignored or accepted.When the TOOL COMMAND option is set to “ACCEPT”, the P orSP commands will change theselected tool in the cutter according to the suffix that follows the pen/knife command. Thecutter’s LCD will, e.g. prompt the user with the following message: “INSERT PEN”when a P2

command is sent. When the TOOL COMMAND option is set to “IGNORE”, the pen/knifecommands are ignored.On the LCD, the active setting is marked with an *. The default setting is “ACCEPT”.

LOAD ON W COMMAND

The LOAD ON W CMD submenu will only be displayed if the PLOT LANGUAGE is set toDM/PL (See Paragraph 1..). The LOAD ON W CMD determines, when receiving the DM/PLWindow-command (W-command), whether aside from the scaling function, media is loaded or

not. Besides scaling, the W-command is also very useful when cutting long signs. With the W-command, media loading will go smoother. Sufficient media will be pulled off the roll at once.Even when AUTOLOAD is off, there is no need anymore to unroll the media manually.

FLEX-CUT

FLEX-CUT can be set to OFF, to Mode 1 or Mode 2. When the cutter is set to mode 1 or mode2, itwill alternately cut one length with full pressure, and one length with reduced pressure. Thefeature FLEX-CUT offers the advantage that it cuts completely through the material, yetallowing 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. Pressing the 1 key will activate the configuration menu,which allows you to set the cutting pressure and the cut length.

1. CUT LENGTH

This parameter determines the length that is cut with full pressure. By pressing the 1 key, theFLEX-CUT test pattern will be cut.

2. FLEX-CUT LENGTH This parameterdetermines the length thatwill be cutwith reducedpressure orwithoutpressure.

By pressing the 1 key, the FLEX-CUT pattern will be cut.

3. FLEX PRESSURE

This parameterdetermines the pressure of theFLEX-CUT LENGTH. By pressing the1 key, theFLEX-CUT test pattern is cut.





INTERNAL TEST MENU

To access any internal test, proceed as follows:

1. Power the machine on.

2. Load cutting or printing media. 3. Install a knife or a pen.

4. Press the key until INTERNAL TEST is displayed and press the jogging key.

5. Press the or jogging key until the desired internal test is displayed.

6. To perform the test, press the key.

To exit from this menu and go to another menu, press the key until the desired menu isdisplayed.

To exit from the menus and put the cutter on line again, press the key.

Figure 1 - shows the different INTERNAL TEST submenus.





FIGURE 1 -INTERNAL TESTS SUBMENUS

TANG. KNIFE CALIBRATION

The purpose of the knife calibration routine is to detect and, if need be, to correct problemsrelated with the concentricity of the TANGENTIAL knife blade. This routine should only be runwhen required. When noticing cut quality problems with a new knife, perform a knife calibrationtest as described in the following paragraphs.





During the knife calibration routine, the cutter will cut a series of test patterns which will allowyou to identify errors in knife rotationand concentricity. Corrective measures canbe takenusingthe control panel keys.

Knife calibration errors may be due to any of the following causes (see Fig. 1-5):

Concentricity misalignment. The knife tip is slightly rotated in relation to its theoretical0 angle. This error can be corrected by means of the ADJ UST ORIGIN test routine.

Horizontal misalignment. The knife tip deviates from its theoretical longitudinal centre. This error can be corrected by means of the ADJ UST LONG. test routine.

Vertical misalignment. The knife tip deviates from its theoretical lateral centre. Thiserror can be corrected by means of the ADJ UST LAT. test routine.

LONGITUDINAL deviation

LATERAL deviation

Theoretical centre

of the knife

Theoretical 0º

angle of the knife

ORIGIN deviation

FIGURE 1 -POSSIBLE KNIFE CALIBRATION GROUNDS

The calibration settings entered during the knife calibration routine are automatically stored inthe machine’s memory and will be maintained after power down.

NOTE

Prior to knife calibration, load vinyl and install a knife to avoid damage to thecutting strip.

ADJUST ORIGIN TEST ROUTINE

INTERNAL TESTSCALIBRATE KNIFE

Press to select the ORIGIN test.

ADJ UST ORIGIN





0

Press to execute the ORIGIN test.

This is the correctly cut test pattern.

Weed out the ring and compare the circle pattern cut in the vinyl with the circle patternillustrated above. If you obtained this kind of pattern, increase the value displayed on the LCD

by pressing the jogging key to correct closing of the circles cut. To repeat the test, press

the key.

Press the key to go to the next step of the calibration procedure

However if you obtained the kind of pattern illustrated above, then, decrease the value

displayed on the LCD by pressing the jogging key to correct closing of the circles cut.

To repeat the test, press the key.

Press the key to go to the next step of the calibration procedure

ADJUST LAT. test routine

ADJ UST LAT 0 1

Press to execute the LAT test.





1 runs from the horizontal line at the bottom to the centre.2 runs from the horizontal line at the top to the centre.3 runs from the centre to the horizontal line at the top.4 runs from the centre to the horizontal line at the bottom.

Carefully check the alignment of the different cuts: the two vertical lines should meet seamlesslyprecisely in the middle, without any gaps.

Weed out the rectangle and if you obtained the kind of pattern illustrated above, decrease the

value displayed on the LCD by pressing the jogging key to correct closing of the lines cut.

To repeat the test, press the key.Press the key to go to the next step of the procedure.

However, in caseyour cut resembles the pattern illustrated above, increase the value displayed

on the LCD by pressing the jogging key to correct closing of the lines cut.


A complementary test has been added to fine tune the LAT. adjustment.Press the 2 key to perform the vertical test shown above. All the squares should be identical.

Press the key to go to the next step of the procedure.





ADJUST LONG. TEST ROUTINE

ADJ UST LONG 0 1

Press to execute the LONG test.

The test pattern is similar to the LAT-test.Check the quality of the cuts: the end of the vertical cuts should coincide precisely with thehorizontal cuts, without any gaps.

Weed out the rectangle and if you obtained a pattern as illustrated above, decrease the value

displayed on the LCD by pressing the jogging key to correct closing of the lines cut.


Press the key to repeat the calibration procedure or press the key to interrupt theroutine.

However, if you obtained a pattern as illustrated above, increase the value displayed on the

LCD by pressing the jogging key to correct closing of the lines cut.


Press the key to repeat the calibration procedure or press the key to interrupt theroutine.





A complementary test has been added to fine tune the LONG. adjustment.Press the 1 key to perform the horizontal test; all the squares should be identical.

CUT BORDER

The CUT BORDER sub-menu is used to cut the border of the media area which was definedduring the load sequence. This function is particularly useful if you want to verify the exactcutting area.

MENU PLOT

The MENU PLOT is a hard copy of the present machines configuration, i.e. the items selectedin the USER CONFIG sub-menus described in Section 1.3. The plot is organised by menucategories to show the current values for the various USER CONFIG 1(->4) configurations. To

run this plot, load a sheet of plotting paper and install a pen.





NOTE

It is strongly recommended to produce a MENU PLOT hard copy each time youalter the cutter configuration. The resulting plot should be kept with the machine’sdocumentation in order to provide other users with details of the actualconfigurations of the unit.

CONFIDENCE CUT

The CONFIDENCE cut performs an electrical and mechanical test of the cutter to make surethat the cutter is fully operational. A media sheet ofatleast A3/A- size should be used for thisplot.

DIN CUT

The DIN CUT also performs anelectrical and mechanical testof thecutter, inorder to check thecut quality but also provides the user with feedback on knife setting, knife pressure, knife offsetand cutting depth.

This cut is always run as a DIN A4 portrait/A-size image, regardless of the actual size of themedia loaded. If the media loaded is smaller than DIN A4/A-size, part of the outer box will beclipped (not cut). This cut is always executed in the sequence prescribed by the ISO DINstandard.

CALIBRATION OPOS.

The CALIBRATION OPOS sub-menu is used to calibrate the OPOS (Optical positioningsystem). This calibration is normallydone in the factory. Whenthe systemis no longer working preciselya calibration test must be performed. Calibration allows to fix the exact distance between theknife tip and the sensor.

To calibrate the optical system, proceed as follows:

1. Power up the unitand load a piece of black vinyl with a white backing. The load procedureis described in section 1.

2. Set the origin on a clean, blank part of the vinyl.

3. Press the key (MENU) key until the message ‘INTERNAL TEST’ is displayed on theLCD.





INTERNAL TESTS

4. Press the jogging key until the message ‘ CAL OPOS’ is displayed.

INTERNAL TESTS CAL. OPOS

Press the key to confirm the selection.

The cutter will now cut out a rectangle.

5. The message ‘WEED RECTANGLE’ will appear on the display:

WEED RECTANGLEPRESS MENU

Weed carefully with tweezers the rectangle cut and press the key.

The cutter will now measure the rectangle and set its calibration parameters.

OPTICAL SENSOR

The OPTICAL SENSOR option is a useful routine to check whether or not the OPOS sensor isfunctioning properly. If the sensor is placed above black the sensor output should be High(above 1500). If the sensor is placed above white the sensor output should be low (below 700).

MEDIA CALIBRATION.

The OPOS is calibrated to work on a wide range of materials. However certain material will notwork with the default setup (high glossy materials). The media calibration test will change thesensor value in such way that it is most reliable to sense the markers.

To calibrate the media, proceed as follows:

Print on the media and with the ink that will be used with OPOS a black square of at least4x4cm.

Power up the cutter and load that piece of media. The load procedure is described in theSummaSign User’s Manual.

Press the key (MENU) key until the message ‘INTERNAL TESTS’ is displayed on theLCD.

INTERNAL TESTS





Press the jogging key until the message ‘ CAL MEDIA’ is displayed.

INTERNAL TESTS

CAL. MEDIA

Press the key to confirm the selection. The following message is displayed.

1 = SET

2 = MEASURE

The 1 Option is to set the value manually. This is handy when you have already calibratedthis kind of media and you know the value. Or to set the default value back again. Otherwisechoose 2 to proceed.

PUT ON WHITE

AREA

Click the sensor down and use the arrows to place the sensor on top of a white area. Press

on the key. The cutter will now sense the white area and display following message:

PUT ON BLACK

PRINTED AREA

use the arrows to place the sensor in the lower right part of the black printed square. Press

on the key. The cutter will now sense the black area. Normally a value will be displayed on the LCD:

VALUE : 38

This value is a specific value for this kind of media. It is advisable to memorise this value. Lateryou can calibrate the media quickly by setting this value manually in stead of measuring it.

It may happen that an error message appears. In this case the sensor is not able todifferentiate black and white. Make sure that the test has been performed correctly. If OPOS

in not able to sense the markers the manual alignment methods can be used.

SYSTEM TESTS

The SYSTEM TESTS sub-menu covers the menu items you only occasionally need to adjust.

Press the ENTER key to access the different sub-menu items which are explained in section1.6 below.





SYSTEM TESTS

The SYSTEM TESTS menu is a special set of procedures which are not required for normalcutter operation. Field service personnel, however, will use the SYSTEM TESTS menuoccasionally. When in SYSTEM TESTS, the cutter is fully operational and performs asdescribed in this manual.

LANGUAGE

The MENU LANGUAGE sub-menu is used to set or modify the dialogue language on the LCD.

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, Dutch, Spanish orItalian.

ROM REVISION

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

SERVICE PLOT

The SERVICE PLOT provides information about the cutter, which is helpful when requestingservice for your cutter. The SERVICE PLOT is always plotted at the same size and should be

performed with a pen on paper.

The plotshows the cuttermodel number, the revision numbers of the installed ROM (ReadOnlyMemory) circuits, the selected baud rate, the resolution and buffer (memory) size.

CAUTION

The following test routines are normally restricted to CalComp’s Field ServicePersonnel.

SENSOR SETUP

The SENSOR SETUP option is a useful routine to check whether or not the front and rearmedia sensor are functioning properly and whether the switching levels of these sensors arecorrectly set.





CAM SENSOR

The OPTICAL SENSOR option is a useful routine to check whether or not the cam sensor isfunctioning properly. The cam sensor is the sensor mounted to the cut carriage. This sensorsenses the location of the pinch rollers.

CALIBRATION

CALIBRATION allows to adjust the length of the lines cut, within the specifications.For instance, if a cut line should measure 100 mm exactly, the cutter can be adjusted for anydiscrepancy.

ROLL TEST

The ROLL TEST option is a useful routine to check whetherornot thepick-up roll and the pick-up sensor are functioning properly. The pick-up roll can be activated by means of the arrowkeys.

RS232 TEST

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

RAM TEST

This test completely checks the RAM bit by bit.When running this test the unit will not respond. After this test, power the unit off, then on again.

INSTALL MENU

The INSTALL MENU routine restores the factory-defined menu settings in all four USERCONFIG menus. This test routine can be performed without a tool and without media.

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 thedisplaythe value thathas to be sentto the head to reach this pressure (this value is between 0and 127).





LCD CONTRAST

The LCD CONTRAST submenu is used to adjust the contrast (or intensity) of the liquid crystaldisplay on the control panel.

Press the or jogging key to increase or reduce the contrast and press to confirm.





PRINTER SETTINGS

To access any printer setting, proceed as follows:

1. Power the machine on.

2. Load printing media. 3. Install the ink cartridges and a knife or a pen .

4. Press the key until PRINTER SETTINGS is displayed and press the jogging key.

5. Press the or jogging key until the desired printer setting is displayed.

6. To perform the test (if available) press the 1 key.

7. To change parameters (if available), press the key.

To exit fromthis menu and go to another menu, press the key until the desired menu isdisplayed.

To exit from the menus and put the machine on line again, press the key.

Figure 1-6 shows the different PRINTER SETTINGS sub-menus.

NOTE

The printer settings are not stored in the user configurations.

NOTE

Al l the tests described further in this section can also be activated through the

SummaPaint Control program. To install this program read the readme.txt file on theinstallation disk.





FIGURE 1 -

PRINTER SETTINGS

NOZZLE TEST

To make sure that all nozzles of the 4 cartridges are working properly, do the NOZZLE TEST.

Press the 1 key to perform a nozzle test as illustrated in the figure below.





NOZZLE TEST PATTERN

When all nozzles are working fine, the four slanting lines will be continuous. If one color line isinterrupted, one ore more nozzles will be blocked. Repeat this test a second time. If somenozzles are still blocked, the cartridge needs to be cleaned (see section 2).

CARTRIDGE CAL.

The CARTRIDES CAL(ibration) aligns the cartridges.

Press the 1 Key to perform a color calibration test as illustrated below:

After printing the color calibration testyou can change the values for the horizontal and verticaloffset of the printed color with reference to the black.

Select again ‘COLOR CAL.’

Press the key to change the color calibration parameters.

CYAN HORZ. *0

Examine the horizontal and vertical tests carefully. Verify per row in which square the coloredlines are in a direct line with the black lines. The value figuring on top of the corresponding

column is the value thathas to be entered. Press the and jogging keys to change the

value. Press the key to confirm the selection (an * appears in front of the value). Press the

and jogging keys to switch between the different parameters. After changing the

values a final test can be done by pressing the 1 Key.

PRINT MODE

The PRINT MODE sub-menu is used to set print mode. The PRINT MODE default value is ENHANCED.PRINT MODE can be set to ENHANCED or DRAFT.

The draft mode is fast but can onlybe used for linedrawings or technical drawings. For printingpictures the enhanced mode should always be used.





DIRECTION

The DIRECTION sub-menu determines during which print-carriage movement the machineactually prints. The default setting is UNI-LEFT.DIRECTION can be set to UNI-LEFT, UNI-RIGHT and BI-DIRECTIONAL.UNI-LEFT : Printing takes place while the carriage moves to the left.UNI-RIGH : Printing takes place while the carriage moves to the right.BI-DIRECTIONAL: Printing takes place while the carriage moves to the left and also when itmoves to the right. The BI-DIRECTIONAL mode is fast but requires an additional calibration(see 1.).

BI-DIR CAL

The BI-DIR(ectional) CAL(ibration) aligns the left and rightprinting movements to each other inorder to print bi-directional.

In line drawings the result of the bi-directional calibration can easily be seen.Examine whether the lines are smooth. If the lines are not in a direct line then the bi-directionalvalue has to be changed.

The values can be changed by pressing the and jogging keys. Press the key to

confirm the selection (an * appears in front of the value).

NOTE

When using the SummaPaint Control program, a special test can be activated to do thebi-directional calibrating test.

PRINT / CUT CAL.

The PRINT / CUT CAL. calibrates the position of the four cartridges in relation to the cuttinghead.

Press the 1 Key to perform a Print and Cut calibration test as illustrated below:

Result :

After printing the Print and Cut calibration test you can change the values for horizontal andvertical offset.

Select again ‘PRINT / CUT CAL.’

Press the key to change the horizontal offset.

HORZ. OFFSET





*0

Press the and jogging keys to change the value. The value must correspond with the

number of dots the printed part has to move so that printed and cut lines are exactly the same.Moving to the left increases the parameter, moving to the right decreases the parameter. Press

the key to confirm the selection (an * appears in front of the value). Press the and

jogging keys to switch to the vertical offset.

Press the and jogging keys to change the value. The value must correspond with the

number of dots the printed part has to move so that printed and cut lines are exactly the same.Moving upwards increases the parameter, moving downwards decreases the parameter. Pressthe key to confirm the selection (an * appears in front of the value).

After changing the values a final test can be done by pressing the 1 Key.






Blank Page



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 drawingsindicating the position of the parts. Use the last section of this manual for detailed assembly pictures.

Precautions

Observe simple, common sense rules and procedures whilst servicing the unit. They include, but arenot limited to the following:

Do not wipe or touch the cartridge head. The ink nozzles can be damaged.

If the contacts of either the cartridge or flex are touched, then isopropyl alcohol is the proper

cleaning fluid, because it doesn’t leave residues.

The base of the unit has been assembled on a fixture to assure straightness all along the y-axis.

To keep this :DO NOT REMOVE THE SIDE PLATES NOR THE Y-GUIDING.

Unplug the line cord 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 handlingtechniques.

Keep sensors and reflection plates free of scratches and dirt.

Keep the guiding, at least dirtfree where the wheels of the carriage pass.

Replacements Guidelines 2-1




2-2 Replacements Guidelines

1 left end cover 400-5472 right end cover 400-5483 screws +washers ND5000-9650+ND5000-9639 6 (3 +2+1)4 screws +washers ND5000-9650+ND5000-9639 6 (3 +2+1)

5 body




2.1. REMOVING THE LEFT-HAND COVER

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

1. Remove the six screws holding the left-hand cover in place. Two are located at the front, one atthe rear and three on the bottom. Pay close attention to where each of the screws goes. Theyshould 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.

2.2. REMOVING THE RIGHT-HAND COVER

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

1. Remove the six screws holding the right-hand cover in place. Two are located at the front, one atthe rear and three on the bottom. Pay close attention to where each of the screws goes. Theyshould be returned to their original location when re-installed.

! Note !

The rear screw is located in the top corner of the plate, to the left of the threever tical ly-al igned screws. Remove only the screw in the top corner because the

others serve to hold the PCB in place.

2. Gently tap the top of the cover.



1.!

CAUTION2.

3. Make sure that you do not jam any wires between the cover and the sideplate as this may cause considerable damage.4. Give special at tention to the flat cables. Protruding parts ins ide the cover can partly unconnect the flat cables and inflict serious damage to several pcb’s5.

Replacement Guidelines 2-3




2.3.


1 2 screws on each side ND5000-92772 keyboard and LCD 400-5413 safety cover 400-2044 top cover 400-147




2.4. REMOVING THE SAFETY COVER

To remove the safety cover, proceed as follows:

1. Open the topcover by pushing it upward with one hand from underneath the safety cover.

2. Remove the two screws at each side of the safety cover.

3. Remove the safety cover.

4. Be careful not to lose any of the loose parts in the side plate. If the safety covers stays of for along times, keep them apart.

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

2.5. REMOVING THE KEYBOARD - LCD

To remove the keyboard-LCD, proceed as follows:

1. Remove the right-hand cover (see Chapter 2.2. Removing the right-hand cover ).

2. Unplug the keyboard connectors.

3. Remove the two screws holding the keyboard plate.

4. Remove the nut holding the grounding wire.

5. Remove the other three nuts from the bottom of the plate.

6. Remove the keyboard and LCD assy ( fig6.3 page 6-8).

7. Remover the four nuts holding the LCD in place.

8. Remove the LCD .






2.6.


1 bottom plate 400-1482 fan assy 400-5443 fan guard MF00674 washer M4 ND5000-9315 4x5 screw M4 x 45 ND5000-9606 4x secure with loctite 2426 base7 screw ST4.2 x 9 ND5000-9795 20x




2.7. REMOVING THE BOTTOM PLATE

To remove the bottom plate, proceed as follows:


2. Disconnect the connectors of the fan.

3. Remove all the tie-wraps of the wires of the fan.

4. Remove the 20 screws holding the bottom plate in place.

6. ! NOTE !7.

8. Do not pull at the wires of the fans, but guide them gently through the hole.

9.10. Mind the vacuum baffle (p iece of cardboard which separates the service stat ionfrom the rest of the bottom cavity).11.

5. Gently pull the bottom cover from under the unit while holding it parallel between the side plates.


12.!

CAUTION13.14. Do not forget to reconnect the fan and make sure the wires cannot touchmoving parts. Also tie-wrap them in the same way as they were.15. Removing or misplacing of the vacuum baffle results in soiling the servicestation w hen cleaning of the printhead happens.

2.8. REPLACING THE FAN MOTOR

To replace the fan motor, proceed as follows:

1. Remove the bottom plate (see Chapter 2.5. Removing the bottom plate).

2. Remove the four screws holding the fan motor in place.

3. Remove the fan motor.






2.9.


The wire colour are onlyas a reference they are subjectto change without notice. They are summed up from left to right looking from there rear towards the PCB.Between 7 and 8 are two 2pins connectors unused.

1 x-motor 1 3pins -red blank black2 x-motor 2 3pins -red blank black3 y-motor 1 (cuttercarr.) 3pins -red blank black4 power supply (30V DC) 3pins -blank red black5 ultrasonic sensor 4pins -red orange brown black6 x-encoder 4pins -black brown orange red7 y-encoder 1 (cuttercarr.) 4pins -black brown orange red8 cam switch 2pins - orange red9 media sensors 5pins -yellow green red brown orange10 LCD 14pins11 control panel 15pins12 cutter carriage 15pins -no label on flatcable

13 power supply (30V DC) 3pins -black red blank14 printerhead 15 pins flatcable labeled front14b printerhead 15 pins flatcable labeled rear15 fans 2x2pins -black red16 y-encoder 2 (printer carr.) 4pins -red orange brown black17 y-motor 2 (printer carr.) 3pins -black blank red18 motor pick up roll 3pins -black black red19 serial port20 parallel port




2.10. REPLACING THE MAIN PCB

To replace the PCB, proceed as follows:1. Disconnect the power cord, the serial cable and the parallel cable.


3. Remove the flat cables from the heads by gently pulling the flat cable out of the connector. Onboth sides of the connector cover there is a small protuberance that you can pry up using ascrewdriver. Gently pull the flat cable out of the connector.

4. Disconnect the various connectors at the top and bottom of the PCB’s. Pay close attention to theposition of the connectors. They should be returned to their original location when re-installed. If necessary, mark them

5. Remove the flat cables from the keyboard.

6. Remove the three screws in the side plate which hold the PCB. Pay close attention to the positionof the screws. They should be returned to their original location when re-installed.

7. Loosen the earthing clamp(s) so that the earthing wires can be removed. Take the cables,running towards the leg of the stand, out of their cable holders

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

16.!

CAUTION17.18. When re-ins tal ling, pay c lose at tent ion to plug the connectors into the correctplaces.19. Once the new PCB has been has been installed, it is very important that thedata (x and y cal ibrat ion factors, and the tun ing of the heads) s to red on the old PCBbe brought back in the new one. See further in the manual for how to do this.





2.11.


1 motor encoder 400-5262 screws holding motor ND5000-9694 3x3 pulley 391-198 (with setscrew)4 setscrew pulley ND5000-9380




2.12. REPLACING THE X-MOTOR WITH THE ENCODER

To replace the X-motor, proceed as follows:

1. Remove the right-hand cover ( see Chapter 2.2. Removing the right-hand cover ).

2. Remove all the tie-wraps leading from the motor to the PCB board, open the ferrite core anddisconnect the connectors.

3. Remove the Keyboard (see Chapter 2.4 Removing the keyboard LCD from 1. 4. )

4. Remove the three screws holding the x-motor.

!NOTE!

As the motor is mounted springloaded, make sure to hold the motor fi rm, whi lstunscrewing the last screw

5. Leave the belt over the big x-pulley as it is.

6. Take the small pulley from the x-motor by unscrewing the setscrew.

7. Solder off the black and red wires and the capacitor.

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

! CAUTION

Make sure to weld the black w ire to the minus (-) entry and the red wire to theplus (+) entry. The (+) and (-) signs are located in the corners of the motor label.Make sure the setscrew of the small pulley is on the flat part of the axis.





2.13.


1 motor without encoder 391-8092 screws which hold motor ND5000-9694 3x3 pulley 391-1984 setscrew pulley ND5000-9711




2.14. REPLACING THE X-MOTOR WITHOUT THE ENCODER

To replace the X-motor, proceed as follows:


2. Remove the Keyboard (see Chapter 2.4 Removing the keyboard LCD from 1. 4. )

3. Remove the three screws holding the x-motor

!NOTE!

As the motor is mounted springloaded, make sure to hold the motor fi rm, whi lstunscrewing the last screw.

4. Leave the belt over the big x-pulley.


6. Solder off the black and red wires and the capacitor.

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

! CAUTION







1 motor printer head 400-5262 screws holding motor on spacers MH0899 3x3 pulley 391-1984 spacers 391-503 3x5 nuts and washers to hold spacers MH071 and MH0291 3x +3x

6 setscrew pulley ND5000-9380




2.15. REPLACING THE Y-MOTOR FROM THE PRINTERHEAD

To replace the Y-motor proceed as follows:



3. Disconnect the flatcables from the keyboard.

4. Remove the tie-wraps holding the tubes and flatcables to the tie-wrap feet to expose the nutsunderneath.

5. Unscrew the three nuts holding the y-motor with the long spacers.

6. Remove the motor with the long spacers.7. Solder off the black and the red wire and the capacitor from the Y-motor.

8. Remove the three screws from the spacers.


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

! CAUTION






1 motor printer head 400-5262 screws to hold motor on spacers MH0899 3x3 pulley 391-1984 spacers 391-502 3x

5 nuts and washers to hold spacers MH071 and MH0291 3x +3x6 setscrew pulley ND5000-9380





2.16. REPLACING THE Y-MOTOR FROM THE CUTTERHEAD

To replace the Y-motor proceed as follows:



3. Disconnect the flatcables from the keyboard.

4. Remove the tie-wraps which hold the tubes and flatcables to the tie-wrap feet to expose the nutsunderneath.

5. Unscrew the three nuts holding the y-motor with the long spacers.

6. Remove the motor with the long spacers. Keep it aside.

7. Unscrew the three nuts holding the y-motor with the short spacers.

8. Remove the motor with the short spacers

9. Solder the black and the red wire and the capacitor off from the Y-motor.

10.Remove the three screws from the spacers.

11.Take the small pulley from the x-motor by unscrewing the setscrew.

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

! CAUTION







1 screws holding the cover ND5000-91602 cover cutter head 391-6013 cutter head 400-6004 mounting screws for cutterhead ND5000-96935 flat cable 400-1626 connector flatcable7 connector motor

8 connector encoder9 connector width sensor10 connector OPOS system11 connector coil




2.17. REPLACING THE CUTTERHEAD

To replace the cutterhead, proceed as follows:

1. Raise the inserted tool by turning to make sure it does not protrude!

2. Remove the cover of the cutter head by loosening the two screws .

3. Gently pull the flat cable out of the connector .

4.

5. 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 cutterhead, proceed as follows:

1. Place the head back onto the screws.

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

3. Adjust the height and position of the head. The height must be between 2.7mm and 3mm and thehead must be positioned perpendicular to the cutting strip. To do this one can use theadjustments tools, Partnumber are 391-635 and 391-636. The positioning of the head has to bechecked or done while the unit powered on without media in it.

! NOTE !

Aside from the standard adjustment tools used in the standard operatingprocedure, you can use an ordinary 3.1/2” disk to adjust the height and theposition of the head. To do this proceed as follows:Put the disk against the drag head (the same way as you would put an adjustmentplate against it) to veri fy that the drag head is positi oned perpendicular to thecutting surface.Sl ide the disk under the kni fe holder . If the disk touches the kni fe holder the headis mounted too low.

4. Firmly tighten the screws once the cutter head is properly positioned.

5. Put the flat cable back into the connector. To ensure good contact, the flat cable must be

positioned as deeply as possible in the middle of the connector.6. Remount the front cover of the head and firmly tighten the screws.

20.!

CAUTION21.22. Now that the head is rep laced, i t i s extremely important to bring the data sto redon the PCB in line with the head and vice-versa. See further .





2.18.


1 cover printer head 400-1552 screws to hold cover ND5000-9785 2 on each side3 screws to hold the printer head ND5000-9693 the 4 outer ones4 printer head 400-5505 upper screw to tilt the head ND5000-92726 connector for flatcables CHECK THE LABELS ON IT7 connector linear encoder

1: 6.7mm between carriage and base =9.7mm frombase plate till top of plate printerhead (3) 2: 6.8mmbetween carriage and base =9.8mm from base plate till top of plate printerhead (3)




2.19. REPLACING THE PRINTHEAD

To replace the printhead proceed as follows:

1. Remove the safety cover (see Chapter 2.4. Removing the safety cover ).

2. Close the tubes near to the filling bottles with the attached clamp.

3. Remove the cartridges from the head and put the cartridge clamp on the cartridge. Put thecartridge aside..

! NOTE !

DO NOT LOOSEN THE TUBE CONNECTION. If you do, you’l l have to go throughthe filling procedure again

4. Remove the cover by unscrewing the four screws at the side.

5. Remove the two flat cables from the PCB.

6. Remove the connector from the encoder.

7. Remove the printer head by unscrewing the four outer most screws holding the plate from theprinter head to the carriage.

To re-install the cutterhead, proceed as follows:

1. Put the carriage right beside the capping station.

2. Screw the printhead on the printer carriage with four screws.

3. Measure the distance between the carriage and the plate. It should be 6.8 (0.15)mm at the frontand 6.7(0.15)mm at the back. This can easily be measured with a vernier calipers taking intoaccount that the thickness of the plate is 3mm (9.8 and 9.9mm).

4. If the carriage isn’t tilted for .0.1mm upwards, then this can be adjusted with the two mountingblocks at each side of the carriage (unscrew the top screw and adjust with the slotted specialscrew inside the block).

5. If the printhead is mounted correctly, then continue in the reverse order of removing it starting at6.





2.20.


1 drive drum 400-5112 screws to hold the drum ND5000-9695 22x3 x-pulley 391-152

det1 push all the bearing blocks in the same direction

det2 equal distances




2.21. REPLACING THE DRIVE DRUM

To change the drum-drive proceed as follows:

! NOTE !

Because al l the sleeves of the drive drum are accurately matched, i t is not possibleto replace just one sleeve.

1. Disconnect the power cord and the various cables. Pay close attention to the position of thecables. They should be returned to their original location when re-installed.


3. Disconnect the connectors of the fan (at the bottom of the PCB).

4. Remove all the tie-wraps of the wires of the fan.

5. Unscrew the four wingnuts fixing the machine to the stand.

6. Remove the unit from the stand and turn it upside down.

7. Remove the 20 screws holding the bottom plate in place, remove the bottom plate.

23. ! NOTE !24.

25. Do not pull at the wires of the fans, but guide them gently through the hole.

8. Gently take the belts from the big pulley (do this by pushing the respective motor to the drum andturn the pulley while gently guiding the belt to one side of the big pulley). Put one belt in front of and one behind the big pulley.

9. Remove the pulley by unscrewing the setscrews.

10.Remove the 22 screws from the bearing blocks.

11.Disconnect the front sensor from the rear sensor and cut the tie-wraps, if any.

12.Take the drum out of the unit.

To re-install, proceed as follows:

1. Place the drum in the base plate.

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






1 drive drum2 screws to hold the drum 22x3 x-pulley

det1 push all the bearing blocks in the same directiondet2 equal distancesdet3 push the pillow blocks against the sleeve




26.!

CAUTION27.

28. It is very important that the drive drum be stable and stationary to prevent themedia from shift ing about. To achieve this, proceed as follows:29.

1. Secure the block to the left (or right) of the large sleeve by tightening itsscrews. Make sure the block is pos it ioned perpendicu lar over the ho les and that thelong 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 thesleeve and tighten the screws of the block.

30.31. Also make sure all the blocks are pushed in the same direction while beingfastened (either up or down).

32.

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

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





2.22.


1 rear sensor 400-513

2 spacer ND5000-96173 screw ND5000-96944 front sensor 400-5155 screw ND5000-96946 spacer ND5000-9617




2.23. REPACING THE MEDIA SENSORS

The unit is equipped with two media sensors. One is locatedatthe front and the other one atthe rearof the machine.

! NOTE !

When one sensor is malfunctioning it is advisable to replace both sensors.Exper ience shows that soon after rep lacing the broken sensor, the other sensor tends to star t mal funct ioning as wel l. Therefore, to avoid having to per fo rm thesame repair tw ice w ithin a short span of time, it is advisable to replace bothsensors at the same time.

To replace the media sensors proceed as follows:


2. Remove the bottom plate (see Chapter 2.5. Removing the bottom plate).

3. Remove all the tie-wrap from the media sensor cable and disconnect the cable from the PCB.

4. Remove the screws holding the two sensors in place. Pay close attention to the position of thespacers. They should be returned to their original location when re-installed.

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

6. Remove the sensors.


33.!

CAUTION34.35. Make sure the sensor wire does not touch the drum. The rotat ing drum maydamage the wire and cause malfunctioning.36.37. Also check whether the sensors aren’t sticking out.38.






1 screw for reflection part ND5000-9780

2 reflection part camroller 400-1023 setscrew ND5000-9196 2x4 shaft camroller 390-1425 camroller 391-3266 start here to peel of pink strip




2.24. 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. 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 onto the unit.





2.25. REPLACING THE CAMROLLERS

To replace the camrollers, proceed as follows:

1. Remove the safety cover. (see Chapter 2.4. Removing the safety cover ).

2. Remove the reflector block from the camroller assy.

3. Remove the setscrew on both sides of the camroller.

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

5. Remove the camroller.

! NOTE !

Camrollers come in pairs. When one is mal function ing or broken, both the outer camrollers need to be replaced.

The centre camroller does not matched with the two edge camrollers and can beinstalled independently.


39.

! CAUTION40.

41. It is extremely important that the camroller be stable and stationary. Toachieve this, press one side of the camroll shaft w hile tightening the setscrews.42.






1 cover cutterhead2 screws and washers which hold steel strip3 screws which hold flatcable holder4 flatcable and steel strip glued along here




2.26. REPLACING THE FLATCABLE OR STEEL STRIP FOR THECUTTER HEAD

To replace the flat cable or steel strip, proceed as follows:

1. Remove the left-hand cover (see Chapter 2.1. Removing the left-hand cover ).


3. Open the top cover.

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

5. Pull the flatcable free as far as the side plate.

6. Remove the two screws holding the steel strip (Mind the order of washers !).

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

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


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

11.Remove two screws from flatcable holder.

12.Remove the two screws holding the flatcable and steel strip in place.

! NOTE !Pay c lose at tent ion to the way the f latcab le has been folded . The f lat cab le wil lneed to be folded exactly the same way when re-installed.


1. Put the flatcable and steel strip in the flatcable holder .

2. Mount the flatcable clamp back on the carriage. Make sure that the flatcable and steel strip runsparallel to the top beam .

3. Slide the carriage a couple of times from left to right to see if the flatcable and steel strip runsmoothly.

4. Proceed in the reverse order of removal starting at 10 .

43.!

CAUTION44.45. Make sure the loop is neither too long nor too short. A very long loop mayget caught behind other par ts and break. A very short loop may break as the headmoves along the length of the unit.





2.27.


1 hole feeding the tubes to the outside2 nut holding shielding strip MH00713 chain lift 400-1794 3 screws between the tubes ND5000-96935 screws chain lift ND5000-9786

1 tubes 400-1462 grey tube3 steel strip 400-1784 flatcables 400-1625 chain 400-1446 assy tubes 400-556




2.28. REPLACING THE TUBE ASSY FOR THE PRINTER HEAD

To replace the flat cable or steel strip, proceed as follows:

1. Remove all the ink from the tubes. Close the clips on the tubes of the bottles

2. Disconnect the tubes from under the tray .


4. Remove the safety cover (see Chapter 2.5. Removing the safety cover ).

5. Remove all the tie-wraps from around the tubes.

6. Disconnect the three flatcables on the PCB board.

7. Unscrew the nut holding the big washer holding the steel strip.

8. Put the flatcable of the cutter head aside.

9. Remove the chain lifts.

10.Unscrew the chain from the top beam (small screw is at the front).

11.Remove the assy from the printer head carriage (3 screws between tubes).

12.Remove the ferrite cores from the flatcables.

13.Gently pull the cables and tubes and steel strip out of the chain.

! NOTE !

Pay close attention to the way everything has been folded. Everything will need to

be folded exactly the same way when re-installed.On older models, the steel str ip is between side plate and upper pul ley holder, justpull it from between or cut it real close to the upper pulley holder.


1. Gently lead the flatcables, tubes and steel strip through the chain .

2. Proceed in the reverse order of removal starting at 12.

46. ! NOTE !47. Before refitting the steel strip to the upper pulley holder, cut it the same

way the old one was.48. If the tubes or flatcables are changed separately, the same procedure canbe used, however it advisable to change them all at the same time.49.





2.29.


Blank page



SECTION 3

GENERAL INFORMATION

3.1. MAINTENANCE & CLEANING

The SummaPaint PC1500X has a number of sliding surfaces made of smooth metals and

plastics. They are virtually friction-free and require no lubrication. They will, however, collectdust, which may affect the performance of the machine. Keep the SummaPaint PC1500X asclean as possible by using a dust cover. When necessary, clean the unit with a soft clothdampened with isopropyl alcohol or mild detergent. Do not use abrasives.

3.1.1 CLEANING THE SERVICE STATION.

NOTE

When the machine is used intensively the service station must be cleaned daily.

The service station contains ink reservoirs. The head will spit in these reservoirs periodically toprevent the nozzles from blocking. If the service station is not cleaned regularly, the ink willoverflow and cause difficulties.

To clean the service station, proceed as follows:

1. Set the cutter's power switch to OFF.

2. Move the two carriages manually away from the service station.

Maintenance and Cleaning 3-1




FIGURE 3 -CLEANING THE SERVICE STATION

3. Lift the service station moving it a little to the side so that it comes free from the machinebody.

4. First hold the complete service station under water allowing most ink to flow away, thenclean it more carefully with a soft dampened cloth.

5. Dry the service station as well as you can to prevent corrosion.

6. Place the service station back in place.

7. Move the service station as far as possible to the left.

3.1.2 CLEANING CARTRIDGES

When a cartridge has blocked nozzles, try the following suggestions to make them work again.Repeat the first suggestion a few times before trying the other suggestions.

3-2 Maintenance and Cleaning




Copper

Contacs

Print nozzles

FIGURE 3 -CLEANING INK CARTRIDGE

Clean the nozzles with a soft dampened cloth. Pressing the sides of the cartridge will forceink to come out of the nozzles. Do this while holding the print nozzles downwards.

Clean the copper contacts of the cartridge with a soft cloth.

Clean the copper contacts of the print carriage with a soft cloth.

To find out whether a cartridge is not working properly anymore due to blocked nozzles orbad contacts, switch two cartridges from place and repeat the prime test.

If the cartridge is still not working fine, force some ink to come by pumping air in the inkbottles with the priming bulb while printing. However, do not do this when printing finalpictures. The cartridge could start leaking for a while.

If the cartridge is still notworking fine, place iton top of a wet(destilled water)cloth during afew minutes so that the water has time to dissolve the blocked nozzles.

3.1.3 CLEANING THE DRIVE SLEEVES

After a time, the sleeves of the drive drummaybecome clogged with accumulated residue fromthemedia. This situation mayaffect the traction as the media will tend to slip between the pinchrollers and the drive sleeves.

To clean the drive sleeves, proceed as follows:

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

2. Place the cutter in local operation. (See Section 1.2.2.) Local operation will allow you touse the control panel jogging keys, even when no media is loaded.

3. 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.





4. Use the and jogging keys to move the piece of vinyl backward and forward

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

5. Raise the pinch roller arm and remove the piece of vinyl.

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

7. Set the machine’s power switch to OFF.

SLEEVE

VINYL STRIP PINCH ROLLER

TACKY SIDE ON BOTTOM

FIGURE 3 -

CLEANING OF THE DRIVE SLEEVES

3.1.4 CLEANING THE SENSORS.

3.1.5After a certain time, the sensor may become dirty with accumulated residue from the media. This situation may cause malfunctioning of the unit.

To clean the sensor area, proceed as follows:

1. The sensors are located on the machine’s right side. One sensor is located on the frontplaten, the other sensor is located on the rear platen.





FIGURE 3 -

LOCATION OF THE SENSORS

2. To keep the sensors clean, it is sufficient to wipe them out now and then with a cottonswab.

3.1.6 CLEANING THE NOSE PIECE.

3.1.7

The nose piece may become dirty with accumulated residue fromthe vinyl, which will result inpoor cut quality.

To clean the nose piece, proceed as follows:

1. Gently take out the knife or ball-point pen by turning the knife holder anticlockwise.

2. Observe the orientation of the nose piece first and then push it out of its holder.

3. Remove any remaining vinyl residue using a brush or a pair of tweezers.

4. Place the nose piece back.

5. Install the knife or ball-point pen holder.





3.1.8 CLEANING THE Y-GUIDING.

After a certain time, the y-guiding may become dirty with dust and accumulated residue from

the carriage wheels. This may lead to bad printing and bad cutting quality.

To clean the y-guiding, proceed as follows:

1. Set the machine’s power switch to OFF, and open the safety cover.

2. The Y-guiding is the guiding on which the two carriages (print en cut carriages) are moving.

FIGURE 3 -

CLEANING THE Y-GUIDING

3. Clean thesurfaces that are under a 45 degree angle with a soft dampened cloth(both on topand underneath).

4. Move the carriages manually so that you can clean the complete guiding.

3.1.9 CLEANING THE ENCODER STRIP.

After a certain time, the encoder strip may become dirty, which may cause the drawing to shiftwhile printing.

CAUTION

The encoder strip is an essential and very fragile part. Handle it with extreme care.





To clean the encoder strip, proceed as follows:

1. Set the machine’s power switch to OFF.

2. Open the safety-cover partly with one hand, and reach with the other hand under the safetycover to open the top cover.

FIGURE 3 -CLEANING THE ENCODER STRIP

3. The encoder strip is situated about 2,5 cm (1”) behind the Y-guiding .

4. Clean both sides of the strip extremely carefully with a soft dampened cloth.

Move the carriages manually so that you can clean the complete strip.

3.1.10 CLEANING THE OPOS SYSTEM.

The optical systemwill collect dust. It is therefore advised to clean the sensor regularly with acotton bud. The sensor has a small hole so that it can be cleaned easily.





Hole

Cutting

Head

OPOSSYSTEM

FIGURE 3 -CLEANING THE OPOS SYSTEM





3.1.11

3.1.12

3.1.13





3.2.

3.3. OPERATING VOLTAGE CONVERSION

Before operating the machine for the first time it is advised to check the fuse rating for securityreasons.

To check the fuse(s), remove the fuse(s) fromthe fuse boxbehind the cover plate of the powerentry module. Changing to another operation voltage also implies a change of the fuse rate.

For 100 or 120 V AC operation, use only T 4 A,250V fuses, 5 x 20 mm (MF9004).For 220 or 240 V AC operation, use only T 2 A,250V fuse, 5 x 20 mm (MF9003).

FIGURE 3 -POWER ENTRY MODULE

Fuse change ( see Figure 3 - ) :

- Unplug the power supply cable- Remove the fuse block- Replace the fuse with the correct fuse that corresponds with the nominal voltage- Re-install the fuse block

NOTE

Always make sure that you are using the correct fuses for your voltage selection.






BLANK PAGE



SECTION 4

Calibration

General

This section contains information on calibrating replaced parts or recalibrating worn down parts. Eachtime a unit is serviced, check this section to see which calibration has to be or can be done.

Calibration 4-1




4.1. MEDIA CALIBRATION

I. CALIBRATION OF THE X-AXIS

1. 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 dif ferentthickness of media give different results w hile calibrating in the x-direction. So if a high accuracy is needed, the unit has to be

recalibrated when di fferent thickness of material are used.However recalibrating is not needed for normal usage

2. Calibration:

Load media in the machine (the wider the media, the more accurate the calibration).

Start the SsummaPaint Control program.

Select “calibration” in the “configuration” menu.

Select “Calibrate x-axis”.

measure the test pattern and enter it in the dialogue box.

Switch the machine on and off so that the new calibration parameters will come intoeffect (the borders will also be corrected).

4-2 Calibration




II. CALIBRATION OF THE Y-AXIS

1. The unit has to be recalibrated when :

the linear encoder strip has been replaced the camrollers have been replaced

the PCB has been replaced or defaulted

!NOTE!

This calibration is very important when using the cut and print feature of the machine.

2. Calibration:

Load media in the machine (the wider the media, the more accurate the calibration willbe).

start the SummaPaint Control program.

Select “calibration” in the “configuration” menu.

Select “Calibrate y-axis”.

measure the two test patterns and enter the measurements in their respective dialoguebox.

Calibration 4-3




4.2. CUTTERHEAD CALIBRATION

I. KNIFE CALIBRATION

It is recommended to recalibrate the knife, each time it is changed. See section 1.6.1. forthe calibration procedure.

II. COIL CALIBRATION

1. The coil has to be recalibrated when:

the head is changed

the PCB is changed

when the cut quality is dubious

2. Calibration:

Power the machine up when there is no media loaded and while the knife is turned up. Go to to internal system tests - coil set-up. Press the key.

The following message is displayed on the LCD :

40 g PRESSURE19

In the upper line of the LCD the desired pressure isdisplayed and the bottomline showes the value that has tobe sent to the head to reach the pressure displayed.

Press the key. The following message is displayed on the LCD :

600 g PRESSURE110

If you have a tension gauge of ±600g you can check if the pressure is 600 gr. You canadjust the 600gr pressure with the pot-meter located right besides the connector for theLCD en keyboard on the main PCB.

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 PRESSURE19

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

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 tangential head.

4-4 Calibration




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

DRAG LANDING14

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 down (value around11).

Press the key another three times.

Insert the ball-point holder into the tangential head.


PEN LANDING

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 (valuearound 11)


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


PEN LANDING14

Press the key repeatedly until the ball-point pen goes in the up position (valuearound 2).

Press the key repeatedly until the ball-point pen holder moves down (value around11)


Press the (ONLINE) key and power the machine down.

! NOTE!For a good cutting quality, the values of the landings have to be at least 3 less thenthe 40g pressure

Calibration 4-5




4.3. PRINTERHEAD CALIBRATION

I. CARTRIDGE CALIBRATION

!NOTE! Al though the cartr idge cal ibration is already descr ibed in section 1.8. fo llows ashort explanation on how to cal ibrate the cartr idges with the SummaPaint Controlprogram. It i s recommended to do the tests with this program instead of using theinternal tests.

1. The cartridge calibration has to be done when:

Each time the cartridges have been out of their holders.

The controlbox has been replaced (the values are stored in the control box)

The cutterhead has been replaced (only the print/cut calibration) The cutterhead has been replaced

2. Calibration and selftest

Load media. Put the cartridges in place and insert a tool in the cutterhead.

Start the test “Tune Heads” on the SummaPaint Control program.

Use the Prime Test to check the print-head and the cartridges.

4-6 Calibration




When all nozzles are working fine, the four slanting lines will be continuous. If one colourline is interrupted, one ore more nozzles will be blocked. Repeat this test a second time.If some nozzles are still blocked, the cartridge needs to be cleaned.

Start the Alignment Pattern test

After printing the colour calibration test you can change the values for the horizontal andvertical offset of the printed colour with reference to the black.

Click on Check Pattern to verify the alignment.

Start de Offset Test. Type the value, that has the smoothest line with it ,in.

Make sure the installed tool in the cutterhead is mounted correctly.

Start the Print & Cut.

The printed and cut out pattern depends on the way the tuning of the heads test wasstarted up. If the box was normally clicked then the following pattern is shown.

Check which pattern is correct and fill in the values.

If the box was clicked while holding down the Shift key then the following pattern isshown.

Result :

If the normal test was not sufficient then this test is necessary. Now the offset can be

changed drastically. One step is 1/300 of an inch Start the test again to check the result.

Calibration 4-7




4.4. OPOS CALIBRATION

I. NORMAL CALIBRATION

Normal calibration of the OPOS system is explained in section 1.6.6. until 1.6.8. However,when this doesn’t work there is an extra calibration method for fine tuning.

II. FINE TUNING

1. The Opos system has to be fine tuned when:

the normal calibration didn’t do the job.

the Opos system has been removed from the head.

The markers are extremely glossy (sometimes with photoquality with thermal waxtransfer).

2. Calibration:

Calibration of the Pot meters: There are two pot meters on the Opos assy. Normally they are hidden behind a blackpiece of vinyl at the front of the assy. The left potmeter adjusts the gain of the sensor. The right one adjusts the “white level”. To accomplice a good calibration you must useshiny white media and mat black (mat: a black square printed with SummaPaint ink onCalComp mat media with a SummaPaint, shiny: a piece of CalComp laminate onCalComp mat media) The procedure is as follows:

a) Start the internal “OPTICAL SENSOR” test. (power on the machine, press

key twice to go to “INTERNAL TEST” - press the key twice to go to

“SYSTEM TESTS” - press the key - press the key three times to got to

“OPTICAL SENSOR” - press the key.

b) Turn the left pot meter completely to the right (CW) until you hear or feel a click(maximum 15 turns CW). The gain is now at its minimum

c) Place a piece of shiny white media under the Opos sensor (make sure the sensoris perpendicular to the media). Turn the right pot meter CCW until the value on theLCD clearly increases (up until 300 if possible). Now turn the right pot meter CWuntil the value does not decrease any more. This has to be set very precise. TurnCCW and again CW if you think you have turned too far. Now move the mediaunder the sensor (making sure the sensor stays perpendicular) and watch whether

the value does not increase any more. If the value increases, place the sensorabove this section of the media and adjust the right pot meter again following theabove procedure.

d) Place a piece of matte black under the sensor and turn the left pot meter CCWuntil the value on the LCD screen reaches 1800.

e) Check the white value again.

f) Go to “CAL. MEDIA” test (one sub menu lower – not in system test). Press -

choose option “1=SET” and enter value 30.Now the machine can calibrate itself on the media. This means then the unit calculatesthe best value for one combination of ink-media-laminate. With this test the machine firstmeasures a piece white and then a piece of black (a square of app. 4cm is large enough- then put the sensor in the lower right corner). If the difference between black and whiteis big enough then a value for this media will appear on the LCD screen. If however this

combination is not stable then the machine will give a message.

4-8 Calibration




Remember this test must only be performed if the default value of 30 does not suffice(which means that you have a stubborn combination of media-ink-laminate)

!NOTE!When the OPOS system still fails to work properly, do the fine tuning on the mediagiving trouble. Change the “ matt white media” with the troublesome media andchange “ glossy black media” with the marker on the troublesome media.If everything else fails just try to make the difference, between the readout abovethe markers and the media, more then 800.The left pot meter changes the gain and the right po t meter changes the thresholdlevel between black and white.

Calibration 4-9




4.5. SENSOR TESTS AND CALIBRATION

I. MEDIA SENSORS

The front and rear media sensors can be tested with internal test as described in section1.7.4. . 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 hasto be at least 2 positions further than the top arrow for the unitto function properly.

There is a possibility to change the positions of the bottom arrow with the left and right arrowon the keyboard.

II. CAM SENSOR

If the machine doesn’t sense the position of the camrollers anymore, follow the followingprocedure:

1. Power the machine up without any media.

2. Go to the test “CAM SENSOR”

3. Lower the camrollers, put the sensor of the cuttinghead above a reflection part of acamroller.

4. Lower or raise the sensor until you get a value higher than 300.

5. Check whether the reflection block doesn’t touch the sensor in the up position.

III. LINEAR ENCODER SENSOR

When the machine makes all the movements it is supposed to do but does not print, then thelinear encoder sensor may be defective. To check whether it functions properly, do thefollowing:

1. Turn the machine off but leave the controller box on.

2. Gently slide the printercarriage from the left to the right manually while checking the LEDmarked “y” on the controller box. If it flickers from red to green then everything is OK.

3. If it doesn’t work either replace or reposition it.

!NOTE!If the sensor is repositioned or replaced make sure that the encoder is mounted asshown on the fig below (encoderstrip 1/3 from the back)

4-10 Calibration

-------------------------------->

>




4.6. SERVICE STATION CALIBRATION

I. MECHANICAL CALIBRATION

1. The mechanical calibration has to be done when:

The printerhead has been replaced.

the service station has been replaced.

2. Calibration:

Make sure the machine is powered off.

Check whether the capping cushions are mounted correctly (see fig).

Move the printerhead first to the left then to the right until the printerhead touches theright stop of the service station. The inkjethead should now be exactly above the cappingcushions. If not, reposition the right stop with the screws on the front. Then set the leftstop as high as possible and in such a way that there is a little play for the printer head.

Check whether all the wipers touch the inkjet heads, when the printer head is movedcompletely to the right.

Calibration 4-11




3. Fine tuning:

There is an internal calibration to change the cleaning and capping position. Howeverthis test can only be accessed via FactorySetupMode (FSM or 3-key).

1.!

CAUTION2. FSM is normally a mode just used in factory. Be extremely careful while in thatmode and follow the given guidelines to the letter. You can inflict serious damagebeyond repair to the machine if the wrong parameters are changed.

(1) Power on the machine while holding down the ,1 and key.

(2) Wait until the display shows .

FSM<- STANDARD INIT->

(3) Press the key(4) Load media.(5) Goto internal test - system test.

(6) Press the key.(7) Goto internal tests - capping set-up.

(8) Press the key.

(9) Press the or key until the black printhead is in the middle above the right inkdump reservoir

(10) Press the key.

(11) Press the or key until the printcarriage is in the middle of the twomaximum pressure points of the capping cushions against the cartridges.

(12) Press the key.

(13) Press the key.(14) Power the machine down.

4-12 Calibration




Calibration 4-13

Blank Page



SECTION 5

Troubleshooting - Error codes

General

This section contains information onthe errorcodes whichcan appearonthe LCD screen. A step-by-step procedure is provided in this section to ensure this error doesn’t occur any more.

Troubleshooting-Error Codes 5-1




5.1. MOTOR HOT

Cause:

Heavy media can overload the motors, especially the X-motor. The µP on the PCBcalculates the power dissipated in the motors. When this dissipation becomes too high, themessage MOTOR HOT appears. This is not a fatal error. After a while this message willdisappear and the machine will continue its operation.

Action:

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

2. Lower the speed using the menu and use a lower knife pressure if possible.

3. Use lighter or smaller media.

4. Check the cam rollers, replace any damaged cam rollers.

5. Call CalComp 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 cam rollers in the up-position). Replace motor and/or drum.

5.2. ERROR IN X-AXIS

Cause:

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

Action:

1. Remove the crashed media and restart the machine. Should this happen ratherfrequently, 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 knowwhich 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 thecam rollers in the up-position).

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

5. Replace the X-motor encoder.

6. Replace the PCB.

5-2 Troubleshooting-Error Codes




5.3. ERROR IN Y-AXIS POSITION

Cause:

The motordriving the machine headcannotmove to the position wanted. This is a fatal error.It can onlybe solved by turning the power off and then onagain. This error is usually causedby 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 poweroff and position the camrollers on the outer edges of the media).

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

5. If this error occurs during media loading and the head bashes against the left, then itcould be that the media sensor doesn’t work any more.

-> Check media sensor with internal test. Replace if necessary.

6. Replace the Y-motor of the machine head.

7. Replace the PCB.

5.4. ERROR IN Y-2 AXIS POSITION

Cause:

The motordriving the printerheadcannotmove to the position wanted. This is a fatal error. Itcan onlybe solvedbyturning the poweroff and thenonagain. This error is usuallycausedby

a media crash.

Action:

1. Remove the crashed media and restart the machine.

2. Check whether the head moves smoothly (first turn the power off).

3. Check the y-axis motor of the printer head and the encoder cables.

4. Replace the Y-motor of the printer head.

5. Replace the PCB.





5.5. LOW LINE VOLTAGE

Cause:

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

Action:

1. Measure the line voltage. The line voltage should be between 88V and 132 V or 176Vand 264 V.

2. Checkthe secondary voltage of the powersupply. Itshouldbe atleast27VAC. If that isnot the case, replace the power supply.

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

4. Disconnect the motor cables, the encoder cables, the flat cable going to the head, thefan cable, the sensor cables and the 28V power cable going to the machine interfaceboard, and switch the machine on again.

5. When you have done this, plug in the cables one by one until the energy consumer isfound. Replace it.

6. Replace the main PCB.

5.6. HIGH LINE VOLTAGE

Cause:

The secondary voltage of the transformer is measured by the µP on the PCB. When itmeasures a valuehigher than the upper limitsetting, themachinewill give this error. This is afatal error. Switching the power off and making a corrective action is the only solution.

Action:

1. Measure the line voltage. The line voltage should be between 88V and 132 V or 176Vand 264 V.

2. Check the secondary voltage of thepowersupply. It shouldbe less than37VAC. If thatis not the case, replace the power supply.

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






5.7. ILLEGAL PLOT COMMAND

Cause:

For DMPL, when a wrong set of instruction is sent to the machine. This message onlyappears when the machine is configured to report DMPL ERRORS.

Action:

1. Set DM/PL ERRORS to IGNORED in the MENU to avoid this message.

2. If the cut result is not satisfactory, lower the baud rate at the machine side and at thecomputer side. If the parallel interface is used, make the cable shorter.

3. Check the cut file for unknown dm/pl commands.

5.8. ILLEGAL CLIP & SCALE SETTINGS

Cause:

Appears when wrong parameters are sent after a W command in DMPL. This message onlyappears when the machine is configured to report DMPL ERRORS.

Action:

1. Set DM/PL ERRORS to IGNORED in the MENU to avoid this message.

2. If the cut result is not satisfactory, lower the baud rate at the machine side and at thecomputer side. If the parallel interface is used, make the cable shorter.

3. Check the cut file for unknown dm/pl commands.

5.9. SYNTAX ERROR

Cause:

Syntax errors occur when an incorrectHPGL 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.

Action:

1. Change the data sent to the machine.

2. Refer to the HPGL supported commands.

5.10. NVRAM FAILURES AND MESSAGES





Non fatal errors:

SYSTEM NVRAM HAS BEEN DEFAULTED DUE TO ROM CHANGE,USER NVRAM HAS BEEN DEFAULTED DUE TO ROM CHANGE

Action:

1. Message appears when rebooting the machine for the firsttime afteran upgrade of theROM’s. The configuration of the machine will be defaulted. After answering thequestions on the display, this message should no longer appear when the machine isswitched on.

2. If it does replace PCB.

Fatal errors:

SYSTEM NVRAM CHECKSUM FAILURE - SYSTEM NVRAM HAS BEEN DEFAULTED

TRY TO REBOOT MACHINE,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 informationcan be lost, such as calibration, landing pressure.


5.11. RS232 ERROR

Cause:

These errors can only happen when the RS232 test is being executed. A special loopbacktest cable is necessary to do this test. (This cable connects pin 2 to pin 3 and pin 7 to pin8).Possible errors:

COULD NOT TRANSMIT DATACOULD NOT RECEIVE DATADATA RECEIVED DID NOT MATCH DATA TRANSMITTEDPARITY/FRAMING/OVERRUN ERRORCOULD NOT TOGGLE RTS HARDWARE HANDSHAKE LINE.

Action:

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

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






5.12. INTERNAL ERRORS

Cause:

Happens when there is a Firmware problem or a problem with the main board (address busor data bus), the following list gives an overview:

Error Number Meaning

1 bus error2 address error3 illegal instruction4 zero division5 chk instruction6 trapv instruction7 line 1010

8 line 1111

Action:1. This is an internal error. The cause of this error maybe an unknown firmware problem

in the machine's EPROM’s. Do the internal confidence test. If this test is OK, check thedata sent to the machine.

2. Reflash the ROM’s on the main board.


5.13. FLASHING ERRORS AND MESSAGES

Non fatal errors:

ERASING FLASH, PROGRAMMING,READING IN FLASH FILE

Action:

Message appears when the internal ROM’s are being reflashed. J ust wait untill theoperation is done.

Fatal errors:

ORDER ROMCOULD NOT ERASE FLASHCORRUPTED UPGRADE FILE

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.

5.14. ROM ERROR





Cause:

ROM’s are going bad. Action:

1. Reflash the ROM’s.


5.15. RAM ERROR

Cause:

RAM’s are going bad. Action:

Replace the main PCB.

5.16. MACHINE UNABLE TO FIND THE KNIFE HOME POSITION

Cause:

The machine doesn’t find the home position for the tangential knife.

Action:

1. Check whether the knife holder turns smoothly when the power is switched off. If not,

something is wrong with the T-head. Replace the head or check the mechanical partsof the head.

2. Check the connection cable, which runs from the head to the PCB.

3. Check the machine with another head.

4. Replace the flat cable which runs from the head to the PCB.






5.17. MARKERS NOT SENSED PROPERLY

Cause:

The machine has trouble during its special load sequence.

Action:

1. Check whether there is dust on the sensor tip.

2. Make sure that the markers are black on a white surface.

3. Run the "OPTICAL SENSOR " testand use black and white vinyl to check the differentreflection levels.

4. Make sure that the right settings are sent to the machine to sense the markers.

5. Check the flat cable going from the head to the PCB.

6. Should there still be problems, change OPOS.

5.18. TIMEOUT ERROR ON CONTROL PORT B, CHECK CONNECTION

Cause:

The main PCB doesn’t communicate with the printer controller.

Action:

1. Turn the machine off. Wait10s. Power on the machine. Doa print and cut test to checkif everything works.

2. Replace the printer controller.


5.19. COULD NOT START INTERNAL TEST, PLEASE RETRY

Cause:

The internal test, started from the main PCB could not reach the printer controller.

Action:

1. J ust push 1 and retry (works if there was a timeout error).

2. Turn the machine off. Wait10s. Power on the machine. Do a print and cut test to checkif everything works.






Blank Page



Figures 6-1

6. FIGURES

This section contains the detailed drawings of several assys of the Summapaint. There are no detailed drawings of the base. Since the base (containing rear andfrontplate assys and the topbeamassys) are consideredas a whole and mayneverbedisassembled. If the should ever be taken apart (e.g. heavy transportdamage, then thebase has to be reassembled in the factory or by a CalComp technician).

Figures 6-1




6-2 Figures

1 400-113 sliding plate front2 400-115 sliding plate rear3 400-114 end piece capping station4 ND5000-9789 spacer M3x355 ND5000-9283 spcer M3x26 ND5000-9785 screw M3x10 ISO73807 ND5000-9490 cable guard8 ND5000-9787 spring9 ND5000-9693 screw M3x7

fig. 6-1aservice station




1 400-112 mounting profile2 428-610 rubber prinhead cap3 428-620 rubber wiper4 ND5000-9786 screw M3x405 ND5000-9788 spacer 3x6x206 ND5000-0670 nut M3 DIN 985

Figures 6-3

fig. 6-1bservice station




6-4 Figures

1 400-112 mounting profile2 ND5000-9781 spacer M43 ND5000-9377 screw M4x84 ND5000-9231 lockwasher M45 ND5000-9568 teflon strip6 ND5000-9784 clip M57 ND5000-9676 o-ring 4.1x1.68 ND5000-9806 o-ring 5.23x2.629 ND5000-9782 pen 5x50

fig. 6-1cservice station




fig. 6-2aprinter head

Figures 6-5

1 400-170 flexibele platine2 400-152 main plate printhead3 400-171 gummikusen4 ND5000-9801 nylon washer M25 ND5000-9668 screw M2x5




6-6 Figures

fig. 6-2bprinter head

1 ND5000-9244 pressure piece2 400-153 cartridge holder3 ND5000-9802

ND5000-9668screw M2x10screw M2x5

4 ND5000-9800 kartelknob M55 ND5000-9327 screw M5x12 DIN9126 ND5000-1188 washer M57 400-154 cartridge clamp




Figures 6-7

1 400-151 base profile printhead2 ND5000-9685 Spacer M3x53 400-935 print inkjet head4 ND5000-9686 screw M3x45 ND5000-9581 screw M2.5x6

fig. 6-2cprinter head




6-8 Figures

1 391-168 keyboard2 ND5000-9657 skiffy bus3 384-656 LCD module4 ND5000-9283 nylon washer5 ND5000-9269 nut M26 ND5000-9358 sealing strip 9x2mm7 400-143 keyboard fixing plate8 384-751 assy LCD module

9 MC92122 connector10 391-362 grouding cable12 ND5000-9265 lockwasher M313 ND5000-0856 nut M3

fig. 6-3keyboard-LCD display




Figures 6-9

1 MB0275 bearing2 400-124 idler pulley3 400-122 mount idler pulley4 400-123 shaft idler pulley5 ND5000-9382 truarc 3.2mm

fig. 6-4aidler pulley

fig. 6-4bidler pulley

1 400-518 assy, idler wheel2 400-121 holder idler assys3 400-123 shaft4 ND5000-9382 truarc 3.2mm5 ND5000-9714 nylon washer




6-10 Figures

fig. 6-4cidler pulley

1 400-119 extra plate2 400-120 spacer 1033 ND5000-9694 srew M4x104 391-503 spacer 675 MH0291 lockwasher n°6

6 MH0289 screw 6/32




Figures 6-11

fig. 6-4didler pulley

1 400-120 spacer2 ND5000-9694 screw M4x10




6-12 Figures

fig. 6-5y-motors

1 400-526 motor assy2 384-478 pulley3 ND5000-9380 setscrewM4x44 fxture 3.2mm from top shaft to pulley for printer carriage motor

3.2mm between pulley and plate for cutter carriage5 400-126 holder dbl pulley6 391-502 spacer147 391-503 spacer678 MH0071 nut6/32

9 MH0291 lockwasher n° 6




Figures 6-13

fig. 6-6

Carriage cutterhead

1 400-128 plate cutterhead2 400-522 vinyl width sensor3 ND5000-9952 screw M3x104 391-365 excentric shaft assy5 398-497 special spacer6 ND5000-9540 hexnut M47 ND5000-9231 lockwasher M4

8 ND5000-9269 hexnut M29 421-350 clamp belt10 400-525 belt cutterhead11 391-313 concentric shaft assy12 ND5000-9791 screw M2x1013 ND5000-9401 nylon washer

1 excentric nut to calibrate-every wheel should touch2 approx 1.5mm




6-14 Figures

1 400-155 cover printhead2 ND5000-9785 screws M3x103 ND5000-9686 screws M3x44 400-550 printhead5 400-540 carriage printhead (without tube holder)6 distance between printhead and baseplate 6.7mm

fig6-7printerhead + cover

1 ND5000-9683 standoff M4x30 (4x)2 ND5000-9643 standoff M4x40 (3x)3 ND5000-9683 standoff M4x30 (3x)4 ND5000-9711 schroef M4x12 DIN9655 ND5000-9694 schroef M4x10

fig6-8standoffs right platefig6-9

printer carriage

1 400-132 carrige plate printhead2 400-532 up wheel system right3 400-527 assy tubes + flatcable holder4 ND5000-9693 screw M3x7 +washer5 400-140 sensor plate lin. encoder6 400-537 assy sensor linear encoder7 ND5000-9602 screw M2x6

8 400-539 up wheel system left9 ND5000-9827 screw M2x12 RVS

10 ND5000-9401 nylon washer11 421-350 clamp belt12 ND5000-9269 nut M213 400-533 lower wheel system14 400-142 headfix right15 390-198 special screw16 ND5000-9272 screw M3x1617 ND5000-9587 lockwasher M318 400-141 headfix left

1 400-526 assy motor+encoder2 391-809 assy motor without encoder3 400-905 transformer 16” leads4 391-362 assy grounding cable

5 ND5000-9775 screw M4x406 MH0899 screw 6/327 400-521 assy y axis dbl drive8 side primair leads

fig6-10x-motors-transfo




Figures 6-15

fig6-11

printercontrolbox

1 400-952 parallel board2 400-956 serial board3 400-953 processor board4 400-954 encoder board5 400-955 print head controller board6 400-951 power supply box



Appendix A

List of recommended spare parts

Product number Description Qty/unit

384-682 LCD cable 1390-549 standaard T knife 36° 1391-152 pulley 72t -x drive shaft 1391-168 keyboard 1391-198 pulley 24t- motor 4391-224 knife offset 0.45 1391-326 pinch roller 3391-342 switch assy - pinch roller 1

391-500 core holder 75mm 2391-601 cover tangential head 1391-663 tang knife holder 1391-664 nose piece long 1391-667 ball point holder 1391-668 drag knife holder-tang.head 1391-669 ball point pen 1391-809 assy, X-motor without encoder 1391-885 OPOS tang head 1398-210 Assy, power entry 1398-235 Assy, On / off switch 1400-131 steel guiding strip -flat cable 1400-145 end connection tube chain 1400-598 8 inks-tube 1400-147 top cover 1400-149 rolller lenght 1867mm 3400-150 roler brake 1400-155 cover ink jet head 1400-162 flatcable - 15 lines 3400-170 flexible platine 4400-174 diven roller lenght 1867mm 1400-204 safety cover silkscreened 1400-281 Assy cap blue 1

400-282 Assy cap yellow 1400-283 Assy cap red 1400-284 Assy cap black 1400-511 drive drum assy 1400-513 media sensor rear, assy 1400-515 media sensor front, assy 1400-516 assy Y-guiding+ lin.enc.strip 1400-517 assy capping station 1400-521 assy Yaxis double pulley drive 1400-522 assy, vinyl width sensor 1400-525 assy belt cutterhead 1

400-526 assy motor + encoder 3400-535 assy belt print head 1

Appendix A A-1




400-537 sensor lin.encoder 1400-541 assy keyboard-display 1400-544 fan with cable 2400-547 assy left cover 1

400-548 assy right cover 1400-549 assy carriage cutterhead 1400-550 assy ink jet head 1400-551 fixingknob inkjet cartridge 4400-552 priming bulb 1400-555 cable ultrasonic print 1400-556 tube chain assy 1400-559 assy carriage printhead 1400-560 assy core holder 2inch 2400-565 cutting strip PUR with tape 1400-581 Assy bottle cyan 1400-582 Assy bottle yellow 1

400-583 Assy bottle magenta 1400-584 Assy bottle black 1400-590 Assy, 4 bottle ink system 1400-592 ink connection kit carriage 1400-593 ink connection kit bottle tray 1400-600 tangential head + OPOS 1400-601 ink cartridge yellow ( empty) 1400-602 ink cartridge magenta (empty) 1400-603 ink cartridge cyan (empty) 1400-604 ink cartrigde lack (empty) 1400-611 SummaInk kit - yellw UV-dur 1

400-612 SummaInk kit - magen UV-dur 1400-613 SummaInk kit - cyan UV-dur 1400-614 SummaInk kit - black UV-dur 1400-662 print T-head 1400-905 transformer 1400-910 linear encoder strip 1400-914 cable serial, 9p - 9p, 400mm 1400-915 enc.cable, 15p - 15p, 550mm 1400-925 cable serial, 9p - 25p, 400mm 1400-926 print head cable, 26p - 26p, 570mm 1400-935 print ink jet head 1400-951 power supply box 1400-952 parallel board 1400-953 processor board 1400-954 encoder board 1400-955 print head controller board 1400-956 serial board 1400-970 print ultrasonic sensor 1400-985 controller PCB -motor-Thead 1404-102 parallel print cable 1421-198 bearing block drive drum 11423-155 serial interface cable kit 1428-610 rubber printhead capping 4

428-620 rubber wiper 4MB0380 belt 150t - Y motor 2

A-2 Appendix A




MB0389 bearing drive drum 11MB9124 belt 110t - X motor 2MF0017 Fuse 0.6A slow 5 x 20 1MF1000 Fuse 1.25A slow 5 x 20 1

MF9000 Fuse 0.6A slow 6.3 x 32 1MF9001 Fuse 1.25A slow 6.3 x 32 1MI9935 User manual PC1500 1MI9936 Quick start manual PC1500 1ND5000-9371 spring guide roller 1ND5000-9826 Cardboard roll L=1m45, dia=76mm 1

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Summa Bigpaint 1500 Maintenance Manual