Optical System Upgrade manual

Page 1
Upgrade Manual for
Optical Positioning System on SummaSign Cutters
OPOS
Optical System Upgrade manual
Page 2
1. GENERAL INFORMATION.
1.1. Introduction
This guide has been compiled to assist you in upgrading your cutter to a cutter with an optical
system. With this system it is possible to cut preprinted signs.
The cutter can be upgraded by adding the optical system (see 1.3), or by changing the head
(see 1.4). In addition a upgrade from drag head to tangential head is also possible (see 1.5).
1.2. Minimum Requirements
* Upgrade kit : Optical sensor only. (see 1.3)
Only those SummaSign cutters built after 1 February 1995 are upgradable. The production
date is mentioned on the label at the rear of the machine (last four digits of the firs part of
the serial number give year and month of fabrication).
* Optical Head (see 1.4)
The optical head can be mounted on all SummaSign cutters.
* Upgrading from drag head to tangential head with OPOS (see 1.5)
Upgrading from drag head to tangential head can be done on all SummaSign Cutters with a
drag head.
1.3. Upgrade Kit
The following steps must be taken.
1) Upgrading cutter. ROM-change (See 2.1) only if the cutter if from before 1 Dec 95
and the ROM-revision is 9 or lower. In the other cases reflash the cutter.
2) Parameter change (See 2.2)
3) hardware change (See 2.3)
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The Upgrade Kit (Drag head : 391-785, Tangential head : 391-885) consists of the items listed
below in Table 1 :
DESCRIPTION PART NUMBER QUANTITY
Optical Sensor D
or T
391-771
391-881
1
Adjusting tool 391-635 1
Adjusting plate 391-636 1
Screw M3x7 ND5000-9693 2
Screwdriver MT9004 1
EPROM Program
LO
MW9987 1
EPROM Program HI MW9988 1
Cable Tie ND5000-0510 1
Disk firmware MD9955 1
Manual + software MD9020 1
Upgrade manual
OPOS
MI9982 1
TABLE 1.
1.4. Optical Head.
The following steps must be taken:
1) ROM-change (see 2.1)
2) Firmware change (see 2.2)
3) The hardware must partly be changed (see 2.3). Points 6 and 7 can be skipped.
4) Configuration. (see 2.4)
The optical head package (Drag head: 391-790, Tangential head:391-890) consists of the items
listed in table 2.
DESCRIPTION PART NUMBER QUANTITY
Optical head D
T
391-200 + 391-871
391-600 + 391-781
1
Adjusting tool 391-635 1
Adjusting plate 391-636 1
Screw M3x7 ND5000-9693 7
Screwdriver MT9004 1
Stop plate * 391-634 1
Screw M2x4 * ND5000-9667 2
Washer M2 * ND5000-9267 2
EPROM Program LO MW9987 1
EPROM Program HI MW9988 1
Cover head D
T
391-222
391-691
1
Cable Tie ND 5000-0510 1
Disk firmware MD9955 1
Manual + software MD9020 1
Upgrade manual OPOS MI9982 1
* Only for T750
Additional tools and parts for upgrading from D-head to T-Head (see 1.5)
TABLE 2.
Optical System Upgrade manual
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1.5. Upgrading from drag-head to tangential head.
The procedure is analogous to the procedure to install the optical head (see 1.4).
For upgrading your cutter from a drag-head to a tangential head following parts are added to
the package (see table 3).
DESCRIPTION PART NUMBER QUANTITY
Screw M3x4 ND5000-9693 1
Washer M3 ND5000-9865 5
Standard tangential
knife
390-549 2
Sandblast nose piece 391-666 1
Knife for masking stencil 390-550 1
Dragknife holder 391-668 1
Standard drag knife 391-224 1
Knife install tool 390-553 1
Ballpoint holder 391-667 1
Ballpoint pen 391-669 1
Spacer 391-637 1
T-Series Users Manual MI9985 1
TABLE 3:
TANGENTIAL UPGRADE KIT CONTENTS
Optical System Upgrade manual
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2. STEP BY STEP INSTALLATION OF
THE OPTICAL SYSTEM.
2.1. Upgrading your cutter
Attention
All Cutters build after 1 December 95 have an other PCB. Inserting the EPROMs
in these units will damage the Cutter.
If your cutter dates from after dec 1995, proceed to 2.1.b
2.1.a installation of new ROMs
Caution : Adhere to Electro Static Discharge (ESD) procedures when removing and installing
PCB boards and ROMs. Ground strap must be worn.
1. Disconnect the power cord from the power source and the unit. Disconnect the data cables
from the unit.

2. Remove the unit from the stand if applicable. Set the cutter on a flat level surface.

3. Remove the 5 screws that retain the right end cover, paying close attention to where each
of the screws goes. They will need to be returned to their original location when the cover is
re-installed. Remove the right end cover.

4. Remove the screw on the power entry module just besides the power switch.

5. Loosen by two turns only, the screw on the power entry module just besides the voltage
selector.

6. Remove the 2 screw nuts (3/16) that retain the 9-pin D connector.

7. Remove the 2 screws that attach the parallel plate to the parallel connector.

8. Remove the 3 screws at the rear of the right end plate that holds the main PCB. Pay close
attention to where each of the screws goes. They will need to be returned to their original
location when re-installed.

9. Remove the 2 screws on the main PCB assy which have become visible now as a result of
the previous step.

10. Remove the two screws that hold the small PCB to the main PCB.

11. Unplug the small PCB.
The ROMs should be exposed now. Pay attention to the orientation of the ROMs before
carefully removing them and replacing them with the new ones.
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Note : A right angle flat blade screwdriver can be helpful in removing the ROMs. Dont damage
the main board with the screwdriver!

12. Pay special attention to plug the connectors into the correct holes.
Re-install all items in reserve order of removal.

13. When powering up the Cutter, there will be ask for the language (choosing with the ,
-keys and select with the -key) and the menu units (select by pressing 1 or 2).
2.1.b Flash EPROM
To Upgrade a cutter built after 1 December 1995 follow instructions on sheet MI9994.
2.2. Parameter change.
The parameter change is to enable some specific functions for the optical system in the cutter.
The cutter control program on the CDROM is especially written for this (Press 'Ctrl' 'Alt' 'Shift
and 'O' simultainsly) .
2.3. Hardware change.
* When installing the upgrade kit, each step of this section must be followed.
* When installing the optical head, points 6 and 7 can be skipped.
* When upgrading your cutter from drag head to tangential head, execute the 5 first
points of 2.3.1 and proceed with point 8 in 2.3.2.
Hardware change is different for the drag head and tangential head. (Tangential head see
section 2.3.2.)
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2.3.1. HARDWARE CHANGE FOR A DRAG HEAD.
CAUTION
Before starting the hardware installation, make sure the cutter is powered down.
1. Power down the cutter.
2. Take the knife holder out of the head.
3. Remove the cover from the head by loosening the 2 screws.
FIGURE 1.
REMOVING DRAG HEAD COVER.
4. Loosen the flat cable by first pulling up the flat cable connector cover (on both sides of the
connector cover there is a small protuberance you can pry up using a screwdriver). Then
gently pull the flat cable out of the connector.
5. Remove the head by loosening the 3 screws (two turns Counter-Clockwise) using the
screwdriver as shown in Figure 2, and lift the head upwards to take the head off the screws.
Optical System Upgrade manual
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FIGURE 2
REMOVING THE DRAG HEAD.
When upgrading your cutter from drag head to tangential head proceed now with point 8 in
section 2.3.2.
6. Fix the OPOS assembly at the bottom of the head with 2 screws, so that the sensor is
underneath the head and piece of black vinyl is visible (see figure 3).
FIGURE 3.
ASSEMBLING THE OPTICAL SYSTEM.
7. Twist the 3 wires so that they become one strand. Guide this strand through the notch at the
right of the heads bottom plate. Guide it further under the print from behind the right
spacer to the front (see figure 3). Click the 3 pin connector of the optical system in the free
connector on the top of the head. Make sure that the connector is not upside down. Fasten
the three wires to the right spacer with the cable tie.
8. Put the head in place and tighten the screws a little more (See figure 2).
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9. Place the standard knife holder back without knife. Slide the adjustment tool ( the middle
and thickest part ) under the standard knife holder (see figure 4) and use the adjustment
plate to place the head perpendicular to the surface (see figure 5). Then tighten the screws.
FIGURE 4.
ADJUSTING TOOL.
FIGURE 5.
ADJUSTING PLATE TO PERPENDICULARLY POSITION THE HEAD.
10. The best cut quality will be obtained when then height of the standard knife holder is
between 2.7 and 3 mm. Perform the following steps to check the height:
1. Power the cutter on without media.
2. Check whether the thinnest but shortest side (2.7 mm) of the adjusting tool fits under the
standard knife holder (see figure 6). If this part hits the holder, the head is mounted too
low. In that case readjust the mounting of the head as described in point 9.
Optical System Upgrade manual
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FIGURE 6.
CHECKING THE HEIGHT OF THE HEAD
3. Check whether the other side (second smallest and longest) of the adjusting tool fits
under the knife holder. This part should hit the nose piece. If not, go back to point 8 to
lower the head a little.
11. Put the flat cable back in the connector and close the connector. The flat cable must be
positioned in the middle of the connector as deep as possible to give good contact.
12. Normally the sensor is calibrated in the factory. This calibration can be checked as follow:
1. Power the cutter on and load white media with black markers.
Click the sensor down by turning the front knob.
2. Press the key (MENU) key until the message INTERNAL TEST is displayed on the LCD.
INTERNAL TESTS K
3. (This step is only for cutters with flash eprom firmware.) Press the jogging key until the
message System TESTS is displayed.
INTERNAL TESTS K
SYSTEM TESTS
. Press the key to confirm the selection
4. Press the jogging key until the message OPTICAL SENSOR is displayed.
INTERNAL TESTS K
OPTICAL SENSOR
Press the key to confirm the selection
5. SENSOR OUTPUT will appear on the display.
SENSOR OUTPUT
SENSOR 1678
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6. The value of the sensor readings are now shown on the second line of the LCD. You can
also move the head freely with your hands. Position the sensor on top of a white part of
the media. The sensor output must be low (less than 700 ). Position the sensor on top of a
marker. The sensor output must be higher (more than 1300).
7. For finer tuning, follow next procedure:
There are two pot meters on the Opos assy. Normally they are hidden behind a black
piece of vinyl at the front of the assy. The left pot meter adjusts the gain of the sensor. The
left one adjusts the white level. To accomplice a good calibration you must use shiny
white media and mat black (e.g. a black square printed with summapaint ink on
summapaint mat media with a summapaint - as a matter of advertising our products)
The procedure is as follows:
Start the internal OPTICAL SENSOR test.
Turn the left pot meter completely to the right until you hear or feel a click (maximum
15 turns CW). The gain is now at its minimum
Place a piece of shiny white media under the Opos sensor (make sure the sensor is
perpendicular to the media). Turn the right pot meter CCW until the value on the LCD
screen reaches 300. Now turn the right pot meter CW until the value doesnt decrease
any more. This has to be set very precise. Turn CCW and again CW if you think you have
turned too far. Now move the media under the sensor (making sure the sensor stays
perpendicular)and watch whether the value doesnt increase any more. If the value
increases, place the sensor above this section of the media and adjust the right pot meter
again following the above procedure.
Place a piece of matte black under the sensor and turn the left pot meter CCW until
the value on the LCD screen reaches 1800.
Check the white value again.
13. Place the head-cover back (Figure 1). The sensor is now completely installed. The Users
Manual for the optical system on SummaSign Cutters describes calibration and further use
of the SummaSign cutter.
14. When you have upgraded your cutter with the Optical Positioning System as described in
the Upgrade Manual, and calibrated the system as described in the Users Manual (for
higher Precision calibrate twice consecutively), the OPOS final test will do a final check.

The test paper contains 27 tests and the Summa Cutter control software includes the
matching file.
We recommend making a copy of the test paper, so that you can do new tests, should the
test paper be damaged or should you run out of tests.
Load the test paper as described in the SummaSign Users Manual. Make sure that the
camrollers are positioned outside the markers.
Set the knife pressure low (60 gr.) so that it does not cut through the test paper.
You can now send the OPOSTEST.PLT file with Summa Cutter control. ( press on the figures
button).
The cutter will ask to SET SENSOR ABOVE FIRST MARKER. Use the arrow keys to set the sensor
above a marker at the bottom right of a rectangle an press enter to confirm.
The cutter will now sense four markers and cut out the rectangle.
You can now check whether OPOS is working properly. If there is an offset error, we
recommend to calibrate the system again as described in the OPOS User,s Manual. For
higher precision, calibrate twice consecutively.
Optical System Upgrade manual
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2.3.2. HARDWARE CHANGE FOR A TANGENTIAL HEAD.
CAUTION
Before starting the hardware installation, make sure the cutter is powered down.
1. Power down the cutter.
2. Take the knife holder out of the head.
3. Remove the cover from the head by loosening the 3 screws.
FIGURE 7.
REMOVING THE TANGENTIAL HEAD COVER.
4. Loosen the flat cable by first pulling up the flat cable connector cover (on both sides of the
connector cover there is a small protuberance you can pry up using a screwdriver). Then
gently pull the flat cable out of the connector.
5. Remove the head by loosening the 3 screws (two turns Counter-Clockwise) using a
screwdriver as shown in Figure 2, and lift the head upwards to take the head off the screws.
Optical System Upgrade manual
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FIGURE 8.
REMOVING TANGENTIAL HEAD.
6. Fix the OPOS assembly at the bottom of the head with 2 screws, so that the sensor is
underneath the head and the two potentiometers are visible (see figure 9).
7. Click the 3 pin connector of the optical sensor in the free connector on the front of the
head. Make sure that the connector is not back to front.
FIGURE 9.
ASSEMBLING THE OPTICAL SYSTEM.
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8. When upgrading from drag head to tangential head proceed by executing the following
two steps, in the other case proceed by point 9.
a) Move the flatcable holder as far as possible to the right by loosening the 2 small screws.
Then you may tighten the screws again as shown in Figure 10.
FIGURE 10
MOVING THE FLAT CABLE HOLDER
b) Insert the 3 screws of the upgrade kit with washer attached (ND5000-9693) into the
carriage plate at the positions shown in Figure 11. These are not the same positions as for
the drag head!
Fasten these screws with a 1 1/2 turn clockwise to allow the head to be hang from these
screws. Remove the three used screws.
FIGURE 11
POSITION OF THE 3 SCREWS ON THE CARRIAGE PLATE.
9. In case you have a SummaSign T750 cutter (or an upgraded D750), refer to Figure 12. The
T750 head differs from the other T-models in that it has an extra stop plate that has to be
affixed to the head with screws ND5000-9667 and ND5000-9267.
Optical System Upgrade manual
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FIGURE 12
POSITIONING THE T750 TANGENTIAL HEAD
10. Put the head in place and tighten the screws a little bit.
11.Place the standard nose piece (NOT THE BLACK ONE) back under the head. Slide the
adjustment tool ( the middle and thickest part ) under the standard nose piece and use the
adjustment plate to place the head perpendicular to the surface as shown in figure 13 and
14. Then tighten the screws.
FIGURE 13.
ADJUSTING TOOL.
Optical System Upgrade manual
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FIGURE 14.
ADJUSTING PLATE TO PERPENDICULARLY POSITION THE HEAD.
12. The best cut quality will be obtained when the height of the standard nose piece is
between 2.7 and 3 mm. Perform the following steps to check the height:
1. Power the cutter on without media.
2. Check whether the thinnest but shortest side (2.7 mm) of the adjusting tool fits under the
standard nose piece. If this part hits the holder or nose piece, the head is mounted too
low. In that case readjust the mounting of the head as described in point 10.
3. Check whether the other side (second smallest and longest) of the adjusting tool fits
under the standard nose piece. This part should hit the nose piece. If not, go back to
point 10 to lower the head a little.
FIGURE 15.
CHECKING THE HEIGHT OF THE HEAD.
Optical System Upgrade manual
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13. Put the flat cable back in the connector and close the connector. The flat cable must be
positioned in the middle of the connector as deep as possible to give good contact.
14. Normally the sensor is calibrated in the factory. This calibration can be checked as follow:
1. Power the cutter on and load white media with black markers.
Click the sensor down by turning the front knob.
2. Press the key (MENU) key until the message INTERNAL TEST is displayed on the LCD.
INTERNAL TESTS K
3. (This step is only for cutters with flash eprom firmware.) Press the jogging key until the
message System TESTS is displayed.
INTERNAL TESTS K
SYSTEM TESTS
.
Press the key to confirm the selection
4. Press the jogging key until the message OPTICAL SENSOR is displayed.
INTERNAL TESTS K
OPTICAL SENSOR
Press the key to confirm the selection
5. SENSOR OUTPUT will appear on the display.
SENSOR OUTPUT
SENSOR 1678
6. The value of the sensor readings are now shown on the second line of the LCD. You can
also move the head freely with your hands. Position the sensor on top of a white part of
the media. The sensor output must be low (less than 700 ). Position the sensor on top of a
marker. The sensor output must be higher (more than 1300).
7. For finer tuning, follow next procedure:
There are two pot meters on the Opos assy. Normally they are hidden behind a black
piece of vinyl at the front of the assy. The left pot meter adjusts the gain of the sensor. The
left one adjusts the white level. To accomplice a good calibration you must use shiny
white media and mat black (e.g. a black square printed with summapaint ink on
summapaint mat media with a summapaint - as a matter of advertising our products)
The procedure is as follows:
Start the internal OPTICAL SENSOR test.
Turn the left pot meter completely to the right until you hear or feel a click (maximum
15 turns CW). The gain is now at its minimum
Place a piece of shiny white media under the Opos sensor (make sure the sensor is
perpendicular to the media). Turn the right pot meter CCW until the value on the LCD
Optical System Upgrade manual
Page 18
screen reaches 300. Now turn the right pot meter CW until the value doesnt decrease
any more. This has to be set very precise. Turn CCW and again CW if you think you have
turned too far. Now move the media under the sensor (making sure the sensor stays
perpendicular)and watch whether the value doesnt increase any more. If the value
increases, place the sensor above this section of the media and adjust the right pot meter
again following the above procedure.
Place a piece of matte black under the sensor and turn the left pot meter CCW until
the value on the LCD screen reaches 1800.
Check the white value again.
15. Place the head cover back (see figure 7). The sensor is now completely installed. The
Users manual for the optical system on SummaSign cutters describes calibration and
further use of the SummaSign cutter.

16. When you have upgraded your cutter with the Optical Positioning System as described in
the Upgrade Manual, and calibrated the system as described in the Users Manual (for
higher Precision calibrate twice consecutively), the OPOS final test will do a final check.

The test paper contains 27 tests and the Summa Cutter control software includes the
matching file.
We recommend making a copy of the test paper, so that you can do new tests, should the
test paper be damaged or should you run out of tests.
Load the test paper as described in the SummaSign Users Manual. Make sure that the
camrollers are positioned outside the markers.
Set the knife pressure low (60 gr.) so that it does not cut through the test paper.
You can now send the OPOSTEST.PLT file with Summa Cutter control. ( press on the figures
button).
The cutter will ask to SET SENSOR ABOVE FIRST MARKER. Use the arrow keys to set the sensor
above a marker at the bottom right of a rectangle an press enter to confirm.
The cutter will now sense four markers and cut out the rectangle.
You can now check whether OPOS is working properly. If there is an offset error, we
recommend to calibrate the system again as described in the User,s Manual. For higher
precision, calibrate twice consecutively.
2.4. Configuration
* Follow the procedure described below when a new head has been mounted
The configuration the drag head en tangential head is different. (Tangential
head see section 2.4.2.)
Optical System Upgrade manual
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2.4.1. CONFIGURATION FOR A DRAG HEAD.
Proceed as follows to configure the drag head.
1. Power the cutter on. Make sure that the standard holder and knife are installed and that
the knife does not protrude.
2. Press the key (MENU) key until the message INTERNAL TEST is displayed on the LCD.
INTERNAL TESTS K
3. Press the jogging key until the message System TESTS is displayed.
INTERNAL TESTS K
SYSTEM TESTS
.
Press the key to confirm the selection
4. Press the jogging key until the message COIL SETUP is displayed.
INTERNAL TESTS K
COIL SETUP
Press the key to confirm the selection
5. 40 g PRESSURE will appear on the display.
40 g PRESSURE K
110
6. Press the jogging key until the message DRAG LANDING is displayed.
DRAG LANDING
K
13
The value line of the LCD can be changed by pressing the , jogging keys . Set this
value to zero. The knife holder will now be raised. Press the jogging key so that the
value increases one at the time until the knife holder is completely down. Press another
three times on the jogging key and confirm selection by pressing two times the -
key.
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2.4.2. CONFIGURATION FOR A TANGENTIAL HEAD.
1. Power the cutter on. Make sure that the standard nose piece and knife are installed. Load
media
2. Power the cutter on while pressing the key (MENU) until the message STARTING
UPGRADE PROCEDURE is displayed on the LCD. The cutter will start the automatic loading
procedure.
Normally, the message INSERT TANGENTIAL KNIFE will appear on the display.
Insert a knife holder with knife. Make sure the knife tip is not protruding from the nose piece
rollers.
If no vinyl has been loaded, the message ERROR: NO MEDIA OR NO SUCCESSFUL LOAD will
be displayed.
If the message COULD NOT DETECT TANGENTIAL HEAD appears, power the cutter down
and check if the flat cable has been properly plugged in (see section 2.3.2 ). Retry powering
the cutter on while pressing the menu key.
3. Once the media is loaded a COIL SETUP is carried out. The following message is displayed
on the LCD :
40 g PRESSURE K
10
The upper line of the LCD displays the desired pressure and the bottom line displays the
value that has to be sent to the head to obtain the pressure.
I. If you have a tension gauge of 100g you can check if the pressure is 40 gr. When
less than 40 gr. is recorded on the tension gauge press the key to adjust. When
more than 40 gr. is recorded on the tension gauge, use the key to adjust.
If you dont have a tension gauge, set the value on the second line to 10 by pressing
the key or the key.
II. Press the key to adjust the 600 gr. pressure. The following message will be displayed
:
600 g PRESSURE K
85
When you have a tension gauge of 600g you can check if the pressure is 600 gr.
When less than 600 gr. is recorded on the tension gauge press the key to adjust.
When more than 600 gr. is recorded on the tension gauge use the key to adjust.
If you dont have a tension gauge, set the value to 85 by pressing the key or
the key.
III. Press the key to adjust the drag knife landing pressure. The following message will
be displayed :
Optical System Upgrade manual
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DRAG LANDING K
8
Press the key repeatedly until the drag knife goes in the up position (value around
2).
Press the key repeatedly until the drag knife holder moves down (value around 5)
Press the key another three times.
IV. Press the key to adjust the ballpoint pen landing pressure. The following message
will be displayed :
PEN LANDING K
8
Press the key repeatedly until the ballpoint pen goes in the up position (value
around 2).
Press the key repeatedly until the ballpoint pen holder moves down (value around
5)
Press the key another three times.
V. Press the key to adjust the tangential knife landing pressure. The following message
will be displayed :
TANG. LANDING K
Press the key repeatedly until the tangential knife goes in the up position (value
around the 2).
Press the key repeatedly until the knife holder moves down (value around 5)
Press the key another three times.
4. Press the (ONLINE) key, the following message will be displayed.
FACT. ORIGIN K
0
Set the value on the second line as the value indicated on the sticker (the ORIGIN value) of
the head by pressing the key or the key. Press the 2 key to confirm, the head will
rotate.
To verify the correctness of the value, check whether the nose piece is parallel to the drive
drum and verify whether the two drilled holes are invisible.
Press the key.
Power the cutter down.
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ATTENTION
For all machines built before 1 July 1995, the following steps must be taken if the cutter
continuously resets after having installed OPOS. ( LOWER CAMROLLERS is displayed when the
camrollers are down):
Caution : Adhere to Electro Static Discharge (ESD) procedures when removing and installing
PCB boards and ROMs. Ground strap must be worn.
1. Disconnect the power cord from the power source and the unit. Disconnect the data cables
from the unit.

2. Remove the unit from the stand if there is one . Place the cutter on a flat level surface.

3. Remove the 5 screws that retain the right end cover, paying close attention to where each
of the screws goes. They will need to be returned to their original location when the cover is
re-installed. Remove the right end cover.

4. Remove the screw on the power entry module just beside the power switch.

5. Remove the 2 screws that attach the parallel plate to the parallel connector.

6. Remove the 3 screws at the rear of the right end plate that holds the main PCB. Pay close
attention to where each of the screws goes. They will need to be returned to their original
location when re-installed (the longest screw sits at the top).

7. Now you can move the PCB unit to the side. If you gently push the metal back plate, the
small PCB can be seen. The resistance R 29 must be removed with a wire-cutter (see figure)