Summa DC4 User Manual

USER’S MANUAL

Revision 04-04-06

IMPORTANT

Before you begin...

Please go through the online registration at

http://www.summa.be/registration.html

Failure to register might delay response to your warranty and
service inquiries.

Summa

FCC NOTICE

The DC 4 has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference when the equipment is
operated in a commercial environment. The DC4 generates, uses, and can
radiate radio frequency energy and, if not installed and used in accordance with
the instruction manual, may cause harmful interference to radio communications.
Operation of the DC4 in a residential area is likely to cause harmful interference in
which case the user will be required to correct the interference at his own
expense.

CAUTION !

Changes or modifications, not expressly approved by Summa, who is responsible
for FCC compliance, could void the user authority to operate this equipment.

DOC NOTICE

The DC4 does not exceed the Class A limits for radio noise for digital apparatus
set out in the Radio Interference Regulations of the Canadian Department of
Communications.

WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE)
DIRECTIVE

Directive 2002/96/EC of the European Parliament and of the Council
The symbol (right) is shown on this product. It indicates that the

product should not be disposed of with regular household waste,
but should be disposed of separately.
Electrical and electronic equipment can contain materials that are
hazardous to the environment and human health and therefore
should be disposed of at a designated waste facility or returned to
your retailer for the appropriate recycling to take place.

If you wish to dispose of this product and the product still functions, please
consider recycling/reusing it by donating it to a charity shop, selling it or part­exchanging it with your retailer.

NOTICE

Summa reserves the right to modify the information contained in this User Manual at
any time without prior notice. Unauthorized copying, modification, distribution or
display is prohibited. All rights reserved. All inquiries, comments or suggestions
concerning this and other Summa manuals should be directed to:

North America and Asia

Pacific

Summa, Inc

10001 Lake City Way NE
Seattle, WA 98125
USA

Main Office

+1 206.527.1050
+1 800.527.7788

Fax

+1 206.527.1046

Support

[e-mail]

Sales

[e-mail]

Web Site

www.summausa.com

Eastern United States

and Latin America

Summa East, Inc

222 Jubilee Drive
Peabody, MA 01960
USA

Main Office

+1 781.233.7494
+1 800.527.1050

Fax

+1 781.233.7495

Support

[e-mail]

Sales

[e-mail]

Web Site

www.summausa.com

Europe, Africa and

Middle East

Summa, bvba

Rochesterlaan 6
B-8470 GISTEL
Belgium

Main Office

[phone]

Fax

[phone]

Support

[e-mail]

Sales

[e-mail]

Web Site

www.summa.be

© Copyright 2006, Summa bvba.

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

1 INSTALLATION OF THE DC4............................................ 1-1

1.1 UNPACKING INSTRUCTIONS................................................................. 1-1

1.1.1 ACCESSORIES AND SUPPLIES............................................................. 1-4

1.1.2 PART NUMBERS FOR ACCESSORIES AND SUPPLIES ...................... 1-5

1.2 PRINTER PARTS AND LOCATIONS.......................................................1-7

1.2.1 FRONT SIDE.............................................................................................1-7

1.2.2 REAR SIDE............................................................................................... 1-9

1.3 IDEAL OPERATING ENVIRONMENT.................................................... 1-10

1.4 POWERING ON THE DC4...................................................................... 1-11

1.4.1 GROUNDING .......................................................................................... 1-11

1.4.2 POWER-ON PROCEDURE..................................................................... 1-12

1.5 CONNECTING THE PRINTER TO A COMPUTER................................. 1-13

1.5.1 USB CONNECTION................................................................................1-13

1.5.2 PARALLEL CONNECTION .................................................................... 1-13

1.6 MEDIA HANDELING............................................................................... 1-14

1.6.1 LOADING MEDIA.................................................................................... 1-14

1.6.2 CHANGING MEDIA WIDTH.................................................................... 1-17

1.6.3 USING MEDIA TAKE-UP ROLLERS...................................................... 1-18

1.6.4 UNLOADING THE MEDIA. ..................................................................... 1-19

1.6.5 USING THE MEDIA BASKET................................................................. 1-19

1.6.6 PREPARING THE DC4 FOR LONG PRINT-OUTS................................ 1-20

1.6.6.1 INTRODUCTION.................................................................................. 1-20

1.6.6.2 PROCEDURE...................................................................................... 1-20

1.7 LOADING RIBBON CASSETTES .......................................................... 1-21

1.7.1 LOADING AND REMOVING THE CASSETTES.................................... 1-21

1.7.2 REFILLING RIBBON CASSETTES........................................................ 1-22

1.8 CONTOUR CUTTING KNIFE INSTALLATION....................................... 1-24

TOC-i Table of Contents

DC4 User’s Manual

SECTION 2.................................................................................. 1-1

2 OPERATION INSTRUCTIONS........................................... 2-1

2.1. THE CONTROL PANEL............................................................................ 2-1

2.1.1 THE LIQUID CRYSTAL DISPLAY............................................................ 2-1

2.1.2 THE AND KEY.................................................................. 2-2

2.1.3 THE ARROW KEYS ...................................................................... 2-2

2.1.4 THE KEY.......................................................................................2-2

2.1.5 THE KEY........................................................................................2-2

2.2. MENU STRUCTURE OVERVIEW............................................................. 2-3

2.2.1 MAIN MENU.............................................................................................. 2-3

2.2.1.1 PRINTER MENU....................................................................................2-4

2.2.1.2 REPRINT JOB ....................................................................................... 2-4

2.2.1.3 CUTTER MENU..................................................................................... 2-4

2.2.1.4 SYSTEM SETUP ................................................................................... 2-4

2.2.1.5 SELECT USER CONFIGURATION....................................................... 2-4

2.2.1.6 SHUT DOWN…. .................................................................................... 2-5

2.2.1.7 RESET................................................................................................... 2-5

2.2.2 PRINTER MENU ....................................................................................... 2-6

2.2.2.1 RIBBON STATUS.................................................................................. 2-7

2.2.2.2 DENSITY................................................................................................ 2-7

2.2.2.3 PRINT SPEED....................................................................................... 2-8

2.2.2.4 DOUBLE DENSITY................................................................................2-8

2.2.2.5 DOT OVERLAP...................................................................................... 2-8

2.2.2.6 COLOR OFFSET................................................................................... 2-8

2.2.2.7 SCRATCHGUARD.................................................................................2-9

2.2.2.8 OPTITRAC COLOR............................................................................... 2-9

2.2.2.9 OPTITRAC............................................................................................. 2-9

2.2.2.10 CALIBRATE LINEFEED......................................................................... 2-9

2.2.2.11 CALIBRATE PRINT & CUT.................................................................. 2-10

2.2.2.12 HEAD ALIGNMENT TEST................................................................... 2-11

2.2.2.13 CLEAN PRINTHEAD ........................................................................... 2-11

2.2.3 CUTTER MENU....................................................................................... 2-12

2.2.3.1 KNIFE PRESSURE..............................................................................2-12

2.2.3.2 KNIFE OFFSET ................................................................................... 2-13

2.2.3.3 VELOCITY ........................................................................................... 2-13

2.2.3.4 OVERCUT............................................................................................ 2-13

2.2.3.5 DIN TEST.............................................................................................2-14

2.2.3.6 LOAD OPOS MARKERS..................................................................... 2-14

2.2.4 SETUP MENU......................................................................................... 2-15

2.2.4.1 TAKE-UP ROLL................................................................................... 2-16

2.2.4.2 RIBBON SAVE.....................................................................................2-16

2.2.4.3 CALIBRATE MEDIA.............................................................................2-16

2.2.4.4 CALIBRATE PRINT & CUT.................................................................. 2-17

2.2.4.5 CALIBRATE OPOS..............................................................................2-17

2.2.4.6 CAL. TEMP. SENSORS....................................................................... 2-17

2.2.4.7 FIRMWARE REVISION ....................................................................... 2-17

Table of Contents TOC-ii

User’s Manual DC4

2.2.4.8 ROOM TEMPERATURE...................................................................... 2-18

2.2.4.9 COIL SETUP........................................................................................2-18

2.2.4.10 SHOW PRINTER USAGE.................................................................... 2-18

2.2.4.11 COPY USER CONFIG......................................................................... 2-18

2.2.4.12 PRINT DEMO FILE.............................................................................. 2-18

SECTION 3.................................................................................. 2-1

3 GENERAL INFORMATION............................................... 3-1

3.1. MAINTENANCE & CLEANING................................................................. 3-1

3.1.1 CLEANING THE DRIVE SYSTEM............................................................ 3-1

3.1.2 CLEANING THE SENSOR........................................................................ 3-2

3.1.3 CLEANING PAD ....................................................................................... 3-3

3.1.4 CLEANING THE PRINTHEAD.................................................................. 3-4

3.1.5 CLEANING THE PRINTING SURFACE ................................................... 3-5

3.2. OPERATING VOLTAGE........................................................................... 3-6

SECTION 4.................................................................................. 3-1

4 INTERFACE...................................................................... 4-1

4.1. INTRODUCTION ....................................................................................... 4-1

4.1.1 PARALLEL INTERFACE.......................................................................... 4-1

4.1.2 USB INTERFACE NOTES ........................................................................ 4-2

TOC-iii Table of Contents

DC4 User’s Manual

SECTION 5.................................................................................. 4-1

5 PRINTING SOFTWARE..................................................... 5-1

5.1. SUMMA COLORCONTROL ..................................................................... 5-1

5.1.1 INSTALLING HASP DRIVER FOR DONGLE........................................... 5-2

5.1.2 INSTALLING SUMMA COLORCONTROL............................................... 5-3

5.1.3 SUMMA COLORCONTROL (SCC) CONFIGURATION........................... 5-4

5.1.3.1 COLORCONTROL PREFERENCES.....................................................5-4

5.1.3.2 PROCESS PREFERENCES.................................................................. 5-5

5.1.3.3 RIP PREFERENCES............................................................................. 5-6

5.1.3.4 DC4 PREFERENCES............................................................................ 5-7

5.1.3.5 REPRINT PREFERENCES ................................................................... 5-8

5.1.4 HOW TO RIP AND PRINT ........................................................................ 5-9

5.1.4.1 GENERAL TAB...................................................................................... 5-9

5.1.4.2 COLOR TAB ........................................................................................ 5-10

5.1.4.3 SCREENING TAB................................................................................5-11

5.1.4.4 LAYOUT TAB.......................................................................................5-14

5.1.4.5 ADVANCED TAB................................................................................. 5-15

5.1.5 HOW TO RIP,VIEW AND PRINT ............................................................ 5-18

5.2. PALETTE INSTALLER ........................................................................... 5-19

5.2.1 LAUNCHING PALETTE INSTALLER..................................................... 5-19

5.3. SUMMA PRINTER CONTROL................................................................ 5-20

5.3.1 INSTALLING SUMMA PRINTER CONTROL......................................... 5-20

5.3.2 SUMMA PRINTER CONTROL MENUS.................................................. 5-21

5.3.2.1 FILE MENU.......................................................................................... 5-21

5.3.2.2 VIEW MENU ........................................................................................ 5-21

5.3.2.3 CONFIGURATION MENU ................................................................... 5-22

5.3.2.4 SETTINGS MENU................................................................................ 5-22

5.3.2.5 TESTS MENU...................................................................................... 5-22

5.3.3 ACTION LIST.......................................................................................... 5-23

5.3.3.1 CONFIGURATION SETTINGS............................................................ 5-23

5.3.3.2 TOOL PROPERTIES........................................................................... 5-23

5.3.3.3 INFO..................................................................................................... 5-24

5.3.3.4 USERS.................................................................................................5-24

SECTION 6.................................................................................. 5-1

6 OPOS.............................................................................. 6-1

6.1 INTRODUCTION ....................................................................................... 6-1

6.2 MAKING AND PRINTING THE DESIGN .................................................. 6-1

6.3 SETTING THE PARAMETERS AND LOADING TO CUT........................ 6-5

6.4 CUTTING THE CONTOUR ....................................................................... 6-6

Table of Contents TOC-iv

1 INSTALLATION OF THE DC4

1.1 UNPACKING INSTRUCTIONS

The shipping box and any other items, used for packaging, must be saved in the
event the printer will need to be moved. Do not transport the DC4 without completely
repackaging it in the original packaging. For safety reasons, the unpacking of a DC4
must be done with at least 2 persons.
Before unpacking, make sure to have at least 6 meter of space at one side of the
box, because the printer will be rolled down a ramp

Remove the straps and open the flaps of the box, take out the 4 foam blocks. Then
remove the box from the pallet; this must be done in a room that is at least 2.5 meter
high.
Remove the protective bag then cut all the straps and cable ties. Next, set aside the
baskets, vinyl, take-up cores and the accessories box.

FIG 1-1

DC4 ON SHIPPING PALLET

The printer is secured to the base at each side with a bracket. Remove the 4 nuts
(#17mm) located at each side. Next, lift the brackets up and out by pulling the bottom
part backwards under the DC4, and then remove them.

1-1 General Information

DC4 User’s Manual

FIG 1-2

UNPACKING DC4 STAGE 2

Remove the two foam blocks from underneath the stand. Do this using the two
ramps, which are screwed to the pallet. Slide the ramp under the stand, closest to the
end with the foam suspension blocks. From this point on, two people ARE
REQUIRED for safety reasons. Lift the DC4 from each side, just high enough so the
foam blocks can be pulled out from underneath the DC4.

FIG 1-3

UNPACKING DC4 STAGE 3

General Information 1-2

User’s Manual DC4

Position the ramps so the printer can be rolled down from the pallet. Be sure the
wheels of the printer are aligned with the ramp legs.

FIG 1-4

UNPACKING DC4 FINAL STAGE 4

Open the front cover and loosen the printer carriage, then remove the foam
underneath the carriage, which is protecting the printhead.
Loosen the cutter carriage.
REMOVE THE PROTECTIVE SHEET FROM THE PRINTING SURFACE. THE
PRINTING SURFACE IS VERY FRAGILE, PLEASE READ SECTION 3.1.5.

1-3 General Information

DC4 User’s Manual

1.1.1 ACCESSORIES AND SUPPLIES

The DC4 is delivered with all the accessories and supplies necessary to start working
immediately. Some accessories are already installed in the machine and others are
in separate boxes. Please check if everything was delivered with your DC4.

Already installed in the machine:

¾ Knife holder with knife for cutting.

Packed accessories and supplies:

¾ 8 empty ribbon cassettes.
¾ Roll of 3M Summa Certified vinyl media.
¾ 4 ribbons; cyan, magenta, yellow and black
¾ 4 media core holders.
¾ 2 empty cores (76mm, 3”).
¾ CD containing Summa ColorControl, Printer Control and User’s Manual.
¾ A Summa ColorControl hardware key (sometimes called a dongle).
¾ User’s manual.
¾ Slitter cut-off knife.
¾ Power cord.
¾ USB cable and cable holders.
¾ Pair of white gloves for handling media.
¾ Spare fuse, spare knife for contour cutting, and spare knife for slitter cut-off

knife.

General Information 1-4

User’s Manual DC4

1.1.2 PART NUMBERS FOR ACCESSORIES AND SUPPLIES

The following table contains the description and the part number for DC4 accessories
and printer supplies.

Description Part number Picture

Thermal Printhead 420-400

Drag knife (set of 5) 391-360

Slitter knife 390-290

Software CD MD9957

USB cable 399-111

Power cord MC1184

Drag knife holder 391-332

Ribbon cassette 420-326

1-5 General Information

DC4 User’s Manual

DC3-602
DC3-601
DC3-600
DC3-604

Ribbon:

Cyan
Magenta
Yellow
Black

Media core holders-set 391-510

3M vinyl printing media DC-405

TABLE 1-1

TABLE OF ACCESSORIES AND SUPPLIES

General Information 1-6

User’s Manual DC4

1.2 PRINTER PARTS AND LOCATIONS

1.2.1 FRONT SIDE

FIG 1-1

DC4 FRONT VIEW

1. Control Panel and LCD: All printer activity can be initiated from the 8 key
control panel. The LCD informs the user on the current status of the printer, or
actions, which need to be taken. A detailed explanation can be found in section

2.

2. Front Cover: The front cover protects the media from dust and also the operator
from any moving parts during operation. Therefore, the front cover must be kept
closed during operation. To open the front cover, you must first pause the
machine.

3. Pinch Rollers: The pinch rollers clamp the media to the drive system and insure
necessary tracking. The pinch rollers are electrically powered from the keypad.
The right pinch roller can be set in 3 different positions.

4. Printer Carriage: The printer carriage holds the ribbon cassette and the thermal
printhead. The thermal printhead is made from fragile ceramic glaze; DO NOT
TOUCH THE PRINTHEAD as oil or moisture can corrode the surface. The
printhead can also be VERY HOT, just after printing.

1-7 General Information

DC4 User’s Manual

5. Cleaning Plate: The cleaning plate is used to clean the thermal printhead. While
printing, the printhead cleans itself automatically and at regular intervals.

6. Front Wheels: The front wheels of the DC4 are equipped with locking brakes.
Secure the brakes, once the DC4 is permanently installed, by pressing the
locking wheel brake down with your foot.

7. Media Take-up Sensor: The media take up sensor enables the take-up rollers.
Do not place any objects in front of the sensor.

8. Take-up Rollers: The two front rollers are part of the motorized media take-up
system, used for unattended printing.

9. Cutter Carriage: The cutter carriage is the mount for the contour cutting knife
holder.

General Information 1-8

User’s Manual DC4

1.2.2 REAR SIDE

FIG 1-2

DC4 REAR VIEW

1. Power Entry Module: The fuse box, the AC power cord receptacle and the
on/off switch are located in the power entry module. See section 1.4. for power
up procedure and section 3.2. for information about changing the fuse.

2. Media Load push buttons: On the right side there are two push buttons,
conveniently located to make the loading process easy. For further explanation,
see section 1.6.

3. Parallel Port: This connector (IEEE1284-B) provides a communication link
between the DC4 and the host computer. It can be used as a connection with a
LAN, in combination with an Ethernet to parallel converter.

4. USB port: This interface is based on the standards specified in Universal Serial
Bus Specifications Revision 1.1. It allows for high-speed bi-directional serial
communication between the host computer and the DC4.

5. Cable clamp: These two cable clamps provide a neat path for the
communication cables.

6. Cassette station latch: Two latches are located at the back, in order to open up
the cassette station. Open only when the machine is paused or switched off.

7. Media supply rollers: The two back rollers are part of the media supply system.

8. Media Supply Sensor: The media supply sensor enables the motorized media
supply rollers. - Do not place any objects in front of the sensor.

1-9 General Information

DC4 User’s Manual

1.3 IDEAL OPERATING ENVIRONMENT

Environmental conditions can significantly affect the printer’s performance. High
humidity, high temperatures, direct sunlight and airborne contamination (dust) can
adversely affect print quality. The printer should be located away from windows and
doors, preferably within a clean interior room of a building.

Check for the following conditions when installing the DC4:

¾ Surface must be level without vibration
¾ Operating temperature should be stable, between 15 - 27 degrees Celsius

(60 to 80 degrees Fahrenheit).

¾ Operating humidity should be stable, between 30% and 75%.
¾ Area should not be prone to static electricity (no carpeted floors).
¾ Be sure to allow enough space surrounding the printer for changing media

rolls and ribbons. At least 500mm (24 inches) on both sides, and 1000mm (40
inches) behind and in front of the printer.

¾ The printer uses a universal power supply that can operate from 100 to 240

volts with a line frequency of 50 or 60 Hz.

General Information 1-10

User’s Manual DC4

1.4 POWERING ON THE DC4

1.4.1 GROUNDING

!

SAFETY WARNING

An insulated ground conductor must be installed as part of the
branch circuit that supplies power to the wall outlet to which the
printer is connected. The ground conductor must have the same
size, insulation material and thickness as the grounded and
ungrounded branch-circuit supply conductors, but the insulating
seat should be green, or green with yellow striping.

The ground conductor described above must be grounded at the
electrical distribution board, or, if power is supplied by a separate
system, at the power supply transformer/motor generator set.

The wall sockets into which the cutter is plugged must be of the
grounded type. The grounded conductors serving the wall sockets
must be properly connected to ground.

For emergency access the machine should be installed near to the
socket-outlet for easy access.

See section 1.4 for the minimum and maximum operating voltage.
For information about operating voltage and the exact fuse ratings, see Section 3.2.

:

USA

EUROPE:

THREE-PIN
OUTLET

MAKE SURE THIS
IS CONNEC TED TO A
KNOWN EARTH

THREE-PIN
PLUG

MAKE SURE THIS IS
CONNECTED T O A
KNOWN EARTH

FIG1-4:

GROUND CONNECTION

1-11 General Information

DC4 User’s Manual

!

IMPORTANT OPERATIONAL TIP

This printer must only be used with a power outlet that is properly
grounded to earth. Use of an ungrounded outlet exposes the
operator to risk of electric shock, and will also lead to
malfunctioning of the printer.

1.4.2 POWER-ON PROCEDURE

Î To power on the DC4, proceed as follows:

!

CAUTION

Be sure the power switch of the printer is turned off before connecting the
power cord. To be sure, press on the “0” side of the ON/OFF rocker
switch.

Do not switch the machine on unless the cassettes contain ribbons or core
holders contain vinyl media.

1. Plug one end of the AC power cord into the AC power cord receptacle, located at
the printer’ s rear panel.

2. Plug the other end of the AC power cord into the wall socket.

3. Press the "I" side of the ON/OFF rocker switch, located at the rear next to the
power inlet switch, in order to power ON the DC4.

4. The LCD display will activate and an initializing process will begin. Depending on
whether there is media loaded or not, the process will be different. When there is
no media loaded, the DC4 will prompt the user for a media load procedure.
When media is loaded, the DC4 will measure the media width and check the
presence of the cassettes and estimate how much usable ribbon is remaining on
the roll. After loading a small letter indicating will appear on the top row second
last digit of the LCD. S for small M for medium and L for large. The letters
indicate for which media width the line calibration was done.

General Information 1-12

User’s Manual DC4

1.5 CONNECTING THE PRINTER TO A COMPUTER

The DC4 supports two types of date transfer: USB and Parallel.

1.5.1 USB CONNECTION

The USB connection provides bi-directional communication between the printer and
the computer. This connection must be used when using the software utility program
called Summa Printer Control (see section
When the DC4 is connected for the first time to a computer, the computer will detect
it and ask for the USB drivers. The drivers are located on the CD with the manual.
Insert the CD and follow the instructions given by the Microsoft Windows installation
wizard.

5.3.1.).

FIG 1-5

USB CONNECTION

1.5.2 PARALLEL CONNECTION

The parallel connection is a standard IEEE1284 connection. This connection can
either be used for a direct parallel connection with the computer, or in combination
with a miniature print server to connect the printer to a network.

FIG 1-6 FIG 1-7

PARALLEL CONNECTION CONNECTION USING PRINT SERVER

!

CAUTION

Turn the printer and computer OFF before connecting the parallel cable.
To protect both devices, follow the on/off sequence for the computer. Refer
to the computer’s operating instructions.

1-13 General Information

DC4 User’s Manual

1.6 MEDIA HANDELING

1.6.1 LOADING MEDIA

The DC4 is designed to work with rolls of media, not sheets.
It is advised to use cotton gloves while loading the media, otherwise the surface of
the media becomes contaminated by oil from fingers, and the beginning of the
printout will be unusable.
Four media core end holders are delivered with the machine, two for the supply side
and two for the take-up roll. The printer aligns the media automatically during
operation. Therefore, the left side of the vinyl roll must be straight (seen from the
front of the DC4).
To load the media proceed as follows:

While loading the media, do not touch the gray printing surface
(platen)! Doing so might permanently damage the delicate printing
surface.

Switch the printer on.
Insert a media core holder in each end of the media roll. Check first if they are
loosened. If not, loosen them with the black knob at the side. Figure 1-7 shows a
loosened (1) core holder and an expanded (2) core holder.

FIG 1-7

MEDIA CORE HOLDER

Insert the loosened core holders into each end of the roll. Then tighten them with the
black knob, be sure both core holders are secured.

General Information 1-14

User’s Manual DC4

Place the media roll on the DC4 rollers. The right core holder guide is at a fixed
position on the supply rollers bar. The left guide is adjustable. Make sure the media
roll is positioned as in figure 1-8. Guide the beginning of the vinyl around the second
supply roll (1). Then make a big loop underneath the two roller bars, and pull it
upwards and into the machine.

FIG 1-8

POSITION OF THE SUPPLY ROLL ON THE DC4

To unwind the media roll, press the pushbutton (1), located on the right side. Hold the
media so it does not touch the floor. Insert the vinyl between the cassette station and
the base. As soon as the vinyl covers a sensor, the rear clamps will come down and
hold the vinyl.

FIG 1-9

LOADING ROLL AT THE BACK OF DC4

1-15 General Information

DC4 User’s Manual

Next, return to the
front of the machine.
Hold the vinyl and

push

.

The rear clamps will
release the vinyl.
Now pull the vinyl
forward, while
pulling the media all
the way to the front,
make sure it is
guided underneath
the left clamp.

Align the edge of the media using the alignment
markers (1), on the front of the base, then press

. Just before the DC4 starts to print, it will test
the media alignment and the position, relative to the
origin, before it starts printing. If the media is to far from
the origin, then the DC4 will “Park” the media on the
starting point (origin). If it is not loaded straight, it will
align it automatically.

FIG 1-10a TO 1-10c

LOADING ROLL AT THE FRONT OF THE DC4

The pinch rollers will now come down and the media is properly loaded. The machine
will remain paused until the front cover is closed. After closing the front cover, the
DC4 will measure the media width. If the media width has changed, then the printer
will prompt the user to check if the right pinch roller is set correct.

General Information 1-16

User’s Manual DC4

1.6.2 CHANGING MEDIA WIDTH

The DC4 has three positions for the right pinch roller. The recommended roll widths
are: 61, 76, 137cm (24, 30, 54 inch).
The printer remembers always the last loaded media width (even when machine is
switched off) regardless of the chosen user. If a different size of media is loaded,
then the DC4 will prompt the user to check the right pinch roller position (MEDIA
SIZE CHANGED CHECK RIGHT PINCH ROLLER POSITION). Press to
continue and change pinch roller position if necessary.
The line feed calibration (see section
The line feed parameters are stored per user and it always indicated with a letter in
the upper right corner of the LCD for which media width the current user is calibrated.
(L for 137cm - 54inch; M for 76cm - 30inch; s for 61cm – 24inch.

If a job is sent to the DC4 and the loaded media width is not calibrated with the
correct line feed, then the DC prompts the user with the message: WARNING:

USER IS NOT CALIBRATED FOR THIS MEDIAWIDTH.

Pressing continue will clear this remarks and the DC4 will continue printing, however
it is recommended to quit the job and either calibrate this user with the correct line
feed test for the loaded media or to change to a user wit the correct settings for the
loaded media.

It is recommended to calibrate certain users for specifics widths of vinyl and to
change user when media width is changed. Not changing user when changing media
width will finally result in wrongly calibrated users and bad print quality.

When calibrating a certain user for a specific width, then do the print and cut
calibration (see
depended of the loaded media width.

2.2.2.11) right after the line feed calibration. This calibration is also

2.2.2.10) depends on the loaded media width.

1-17 General Information

DC4 User’s Manual

1.6.3 USING MEDIA TAKE-UP ROLLERS

The DC4 is equipped with an automatic (motorized) roll take-up system. The take-up
rollers are only active if the DC4 is printing.
If a printed image is to be contour cut, the take-up rollers MUST be set to DISABLE
to PRINT AND CUT JOB.
To use the take-up rollers, follow procedure below:
Using an empty media core, insert media core holders into each end and attach a
piece of scrap vinyl to the core with adhesive tape (minimum 1 meter long). Place
this core and vinyl on the DC4 as shown in the picture.

FIG 1-11

PREPARING TAKE-UP ROLL

Attach the scrap media to the edge of the vinyl. Allow for some slack so the DC4 can
align and park the media if necessary. If the take-up rollers are enabled, and if the
DC4 is printing, then the media will be rolled up.

FIG 1-12

USING THE TAKE-UP ROLL

General Information 1-18

User’s Manual DC4

1.6.4 UNLOADING THE MEDIA.

First, detach the media from the take-up roll (if used).
Then push on the

Go to the back of the machine and press on the top switch. The machine will rewind
the media supply roll and move the media from under the clamps.

Each time the media type is changed, the user must perform
the media calibration (see section 2.2.4.3) and the line feed
calibration (see section 2.2.2.10). Failing to do so may result in
poor print quality.

1.6.5 USING THE MEDIA BASKET

It is strongly recommended to always use the baskets while printing. The basket
prevents the vinyl from touching the ground or the base of the DC4, thus preventing
the vinyl from collecting dust.
When the DC4 is used for print and cut, then the media baskets, front and rear,
MUST be used, otherwise the vinyl will pick up dust, damaging the print.
The front and rear baskets are designed to hold at least 6 meter of vinyl. Depending
on the type of vinyl, it is possible to hold up until 10 meters.

(up arrow) key until the media does not move any further.

FIG 1-13

REAR BASKET

1-19 General Information

DC4 User’s Manual

1.6.6 PREPARING THE DC4 FOR LONG PRINT-OUTS

1.6.6.1 INTRODUCTION

The DC4 has a fixed position at the rear for the rollerguiding of the flange.
It is possible that some types of vinyls are not wound up even (e.g. the core sticking
out). This results in a forcing of the path of the vinyl in a wrong direction. Following
procedure can help to solve that problem.

1.6.6.2 PROCEDURE

1. Load media in the machine as described in section 1.6.1.

2. Print out a small test of 2 or 3 band-passes high.

3. Check the path of the media. The distances, marked with the white arrows and the
same number, should all be the same. The middle arrow of the second photo
points to the roll itself

4. If not, check first if the media has moved
from its place of origin. If so reload with a
maximum loop at the back.

5. If it did not move, then reposition the
rollerguide (3) so that the path of the vinyl is
as shown above. Make also sure that the
flange is flush to the core.

General Information 1-20

User’s Manual DC4

1.7 LOADING RIBBON CASSETTES

1.7.1 LOADING AND REMOVING THE CASSETTES

The DC4 is delivered with 8 empty cassettes. The cassettes can be loaded or
removed from the cassette station at any time, even during printing. If the printer is
missing a color, then it will give a message on the LCD just before it needs the color.
The machine automatically detects the end of a ribbon. If the machine runs out off a
certain ribbon color while printing, then it will pause until the operator inserts a new
ribbon. As soon as the machine detects a new ribbon roll, it will continue to print and
complete the image.
ALWAYS load or remove cassettes from behind the printer. To remove a cassette,
open the rear cover by puling down both latches simultaneously.

FIG 1-14

REAR CASSETTE STATION COVER

To remove a cassette, lift it enough to pass over the rubber bumper, then pull it
backwards and out of the printer.
To load a cassette, push it gently into an open location, until it just passes the rear
bumper, then press it down and pull it backwards against the bumper.

FIG 1-15 FIG 1-16

REMOVING A CASSETTE LOADING A CASSETTE

Close the rear cover. After the media is loaded, DC4 will take the cassette and
estimate the amount of ribbon in the cassette available for printing.

The printer will not check the cassettes if no media is loaded

! CAUTION !

Do not insert empty cassettes, without ribbon.

1-21 General Information

DC4 User’s Manual

1.7.2 REFILLING RIBBON CASSETTES

The DC4 prints by transferring pigmented vinyl resin directly onto vinyl media. Each
color is printed separately in strips (appx. 10cm wide), printing yellow first, then
magenta, cyan and sometimes black. The media is then advanced (feed) an exact
distance in order to print the next strip (band), carefully aligning each pixel.
The ribbons are wound onto plastic cores, which are unique to the DC4 cassette and
printer carriage. First, remove the protective ribbon wrapping and place the RI (ribbon
identification) chip aside. This ribbon chip contains information about the ribbon’s
color formulation and transfer energy, necessary for printing. The RI chips are color­coded for easy identification.

1. Open the cassette by pressing the release tabs on each side (1), and then lifting
upward the top hinges, in the back, to the bottom part.

FIG 1-17

CASSETTE TOP RELEASE TABS

2. Insert the RI chip into the bottom of the cassette (orientation is shown in figure 1­17 – the arrow indicates the direction for inserting).

3. Place the ribbon into the cassette, as shown below. There is also a small
diagram inside the cassette bottom, to help remind the loading direction.

FIG 1-18

LOADING RIBBON AND RIBBON INFORMATION CHIP INTO THE CASSETTE

General Information 1-22

User’s Manual DC4

4. When closing the cassette, make sure the hinge pins (top piece) fit securely into
the notched out bottom part of the cassette (2).

FIG 1-19

CLOSING THE RIBBON CASSETTE

1-23 General Information

DC4 User’s Manual

1.8 CONTOUR CUTTING KNIFE INSTALLATION

!

SAFETY WARNING

The DC4 uses razor-sharp vinyl cutting knives. The knife blades may
cause serious personal injuries if handled without proper caution.
Use extreme care when operating the cutter; and when installing,
removing or handling the cutter’s knife blade!

Î To set up the knife, proceed as follows:

1. As shown in Figure 1-20, insert the knife blade into the knife holder.

FIGURE 1-20

KNIFE BLADE INSERTION FOR CONTOUR CUTTING

2. Set the knife blade length to zero by aligning the blade tip with the tip of the
holder. An easy way of performing this is by holding the knife holder against your
fingertip and gradually increasing the blade length, by turning the adjustment
knob, until you feel the knife tip touching your fingertip.

3. Extend the tip of the blade the distance required for exact cutting depth into the
vinyl media, as shown in Figure 1-21. The blade should only extend beyond the
knife holder’s tip, sufficient only to completely cut through the film and adhesive
layers, yet avoiding penetration of the polyester liner (backing) material. Cutting
deeply into the backing will damage the blade, and cutting through the backing
will damage the cutting strip.

FIGURE 1-21

BLADE LENGTH ADJUSTMENT

General Information 1-24

User’s Manual DC4

4. Turn the cutting depth adjustment screw clockwise to increase the cutting depth.
Turning the cutting depth adjustment screw anticlockwise will decrease the
cutting depth.

FIGURE 1-22

SETTING KNIFE DEPTH

5. To install the knife into the tool carriage:

- Loosen the clamping screw and insert the knife holder. Press the holder down,
firmly seating it.

- Tighten the clamping screw.

6. Set the knife pressure as follows:

• Power ON the DC4 and load a piece of media (See 1.7.).

• Press the

key.

• Press the

key, until ‘CUTTER MENU’ appears on the second line of the

LCD screen.

• Press the

key once.

• The parameter displayed is the knife pressure, which can be changed
between the range of 0 to 400gr.

• Click the

key to perform a knife depth test, as illustrated below.

FIG 1-23

KNIFE DEPTH TEST PATTERN

1-25 General Information

DC4 User’s Manual

The knife depth is correctly set when the test pattern is visible on the front

side of the media backing, but not on the rear side of the media backing.

Increase the knife pressure using the

visible on the front side of the media backing. Decrease the knife pressure
with the

key when the cut pattern is visible on the rear side of the media

key when the cut pattern is not

backing. Press the
setting.

In general, you should increase the knife depth and knife pressure when

using thicker vinyl types.

The ideal knife pressure setting depends upon the thickness and the type
of media to be cut; adjusting the knife pressure will require some practice.
Typically, you should increase the pressure when cutting thicker types of
vinyl. For thinner types of vinyl, you will normally have to reduce the knife
pressure.

!

CAUTION

After setting the cutting depth and/or the knife pressure, perform a
thorough visual check of the knife blade, which can be seen protruding
from the knife holder, and then test cutting on a scrap of vinyl media for
proper results.
DO NOT OPERATE THE CUTTER if the knife blade cuts through the
media backing, as this will seriously damage the rubber cutting strip and
cutting knife blade.

key or the key to save the changed

NOTE

General Information 1-26

User’s Manual DC4

!

CAUTION

To prevent damage to the cutter, check the depth of the knife blade tip and
the quality of the cut each time you load a different type of vinyl media into
the DC4.

7. To change the knife offset, proceed as follows:

• Power ON the cutter, load a piece of media into the cutter (See 1.7.).

• Press the

key.

• Press the

key three times.

• Press the

key once.

• Press the

key once.

• The parameter displayed is the knife offset, which can be changed in the
range of 0.00 to 1.00mm.

• Click the

key to perform a knife-offset test, as illustrated below.

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.

Increase the knife offset with the

at the corners. Decrease the knife offset with the

key when the squares seem rounded

key when the squares

seem to have little spikes at the corners. Press the

key or the

key to save the changed setting.

1-27 General Information

SECTION 2

2 OPERATION INSTRUCTIONS

2.1. THE CONTROL PANEL

Figure 2-1 shows the control panel of the DC4. The main functions of the LCD and
the control panel keys are explained in the following paragraphs.
It is advised not to touch the control panel while the machine is printing or cutting,
except for canceling the current job.

SUMMA DC4 L

SUMMA DC4 L

PRINT WIDTH:1275 mm

PRINT WIDTH:1275 mm

PREMIUM WHITE VINYL

PREMIUM WHITE VINYL

[MENU] [PAUSE]

[MENU] [PAUSE]

FIG 2-1

DC4 CONTROL PANEL

2.1.1 THE LIQUID CRYSTAL DISPLAY

The liquid crystal display (LCD) contains 4 lines of 20 characters. The LCD provides
DC4 status information during operation and displays menu options for the
configuration of the DC4.

The various menu and submenu items are always presented in a loop, which means
when the last menu or submenu item is displayed, pressing the appropriate key will
automatically take you back to the first item of the same menu or submenu.

2-1 Operating Instructions

DC4 User’s Manual

2.1.2 THE AND KEY

The function of the
DC4. The bottom line of the LCD displays the function of the keys.

and key depends on the current status of the

2.1.3 THE ARROW KEYS

The use of the arrow keys varies according to the operation in progress.
For, example when working with different sub menus, the

the next or the previous submenu.
Values in a submenu can be changed by pressing the

When the DC4 is in normal operation, pressing
and forward.

or moves the media backward

or arrow keys select

or arrow keys.

2.1.4 THE KEY

The
level of the menu, press this key three times. The DC4 will also then be ready for
printing.

key returns back a step in to the previous menu level. To get at the top

2.1.5 THE KEY

The
is in a ready state. There are three “Clamps”.
The double rear clamp, the left clamp and the pinch rollers. All three serve to hold
the media in place while printing and transport media forward and backward.

The LCD prompts the user for a loading procedure when all the clamps are raised.

key toggles the status of the clamps. This key works only when the DC4

Operating Instructions 2-2

User’s Manual DC4

2.2. MENU STRUCTURE OVERVIEW

2.2.1 MAIN MENU

The main menu can be entered when [MENU] is visible on the bottom line of the
LCD. Pressing 3 times on the
machine is loading. Press the

key will bring the DC4 to this state unless the

key to enter the main menu. The main menu

items give access to submenus or commands. Press the
one menu item to another.

..

.......

.

.. .

.............

.

.. .

.............

.

.. .

.............

or key to go from

.

.. .

.............

.

...

.............

.

.. .

.............

.

..

.............

FIG 2-2

MAIN MENU

2-3 Operating Instructions

DC4 User’s Manual

2.2.1.1 PRINTER MENU

Pressing
and small routines to optimize the printing quality; it is explained in section 2.2.3.

2.2.1.2 REPRINT JOB

The DC4 stores every sent job on hard disk. If the hard disk is almost full, the oldest
jobs will be deleted. After pressing

the saved jobs. Push the
reprinted. Push the

removes all jobs from the hard disk.

2.2.1.3 CUTTER MENU

Pressing

2.2.3.

2.2.1.4 SYSTEM SETUP

Pressing
section 2.2.4.

enters the printer menu. The printer menu contains all parameters

, press the or key to scroll through

or key to change the amount of copies that need to be
key to start reprinting the chosen job. Pressing

enters the cutter menu. The cutter menu is explained in section

enters the system setup. The system setup menu is explained in

2.2.1.5 SELECT USER CONFIGURATION

The DC4 stores 16 user configurations. Push the
configuration. Push the

knife pressure is marked with an * (asterisk).
The user configurations are setup to quickly change several parameters depending

on the type of vinyl or kind of job.
Settings include:

• Energy setting (e.g. Density see

• Line feed calibration parameters (see

• Media calibration parameters (see

• Print & Cut calibration parameters (see

• OptiTrac(see

(see

2.2.2.5) parameters

• Knife pressure (see
and overcut (see

• Internal parameters.

Some predefined users can be found on the DC4 CD under the subdirectory ‘users’
send them to the DC4 with Summa Printer Control. Open Summa Printer Control,

Click on

, select the appropriate file and send it.

2.2.2.7 and 2.2.2.9), Color Offset (see 2.2.2.6) and Dot overlap

2.2.3.4)

key to confirm the selection. On the LCD, the active

2.2.2.2)

2.2.2.10)

2.2.2.10)

2.2.4.4)

2.2.3.1), Knife offset (see 2.2.3.2) , velocity(see 2.2.3.3)

or key to change the

Operating Instructions 2-4

User’s Manual DC4

2.2.1.6 SHUT DOWN….

After pressing
open files on the hard disk and raises the pinch rollers. It is advised to use this key
when shutting down the DC4, especially for minimizing wear on the pinch rollers. If
the pinch rollers are left down for a long period of time, a flat spot is created on the
wheel and tracking becomes a problem and is not guaranteed any more. The pinch
rollers are automatically raised when the DC4 is idle for more than 4 minutes.

2.2.1.7 RESET

When pressing
completely reset the machine, perform a cold reset (switch off and on the power to
the machine). This reset is usually used for canceling current print jobs or canceling
non-fatal errors or alarms.

, the DC4 removes any cassette from the carriage, closes any

, the DC4 will reset. This reset is not a full reset. To

2-5 Operating Instructions

DC4 User’s Manual

2.2.2 PRINTER MENU

The printer menu contains parameters and small routines to optimize the printing
quality.

.

.. .

.. .

.............

.............

..

..
...

...

.. .

.. .
...

...

.

.

.

.......

.......

.

.

.

.. .

.. .
...

...

.............

.............

..

..
...

...

.............

.............

.

.

.

.

.

.

..

..
...

...

.. .

.. .
...

...

.............

.............

.. .

.. .
...

...

.............

.............

..

..
...

...

.

.

.

.

.

.

.

FIG 2-3

PRINTER MENU

.

.. .

.. .
..

..

.............

.............

..

..

.. .

.. .
...

...

.............

.............

.. .

.. .

.............

.............

.

.

.

.

.

.

.

Operating Instructions 2-6

User’s Manual DC4

2.2.2.1 RIBBON STATUS

The RIBBON STATUS sub-menu is used to check the status of the cassettes and
their locations. Press the

cassette and location can be checked. Press the

key to enter the sub menu. Now the status of each

or to scroll through the

different locations.

..

.+

FIG 2-4

STORE STATUS

The first line shows the current selected location. When there is no cassette in the
station, instead of ” OK ”, the LCD will read ” EMPTY ” and the remaining LCD will be
empty. The third line displays the color of the ribbon. On the bottom line, the amount
of ribbon remaining in the cassette can be read. This amount is only an
approximation of the actual length in the cassette.

2.2.2.2 DENSITY

Print density refers to the level of energy being sent to the printhead. Print densities
change between different media types because energy is absorbed differently,

depending on the vinyl formulation, liner, etc. With the

or key the density can
be raised or lowered. If the density is too low, the transfer will be incomplete (less
than 100%). If the density is too high, the colors will become matted and washed out.
Or, the ribbon may start to wrinkle.
On the LCD display, the active setting is marked with an * (asterisk).

Press the
Then press the
press the

12 34

key.

key for a test of the density setting for standard printing or

key for a test of the density setting for high resolution printing.

FIG 2-5

INTERNAL DENSITY TEST

1: If the density is set too high then in area 1 the ribbon will stick too long to the
media while printing and leave matt areas behind.
2: If the density is set too low, then this area will not be 100% black
3: If the density is set too high, then this area will darker then 95% cyan, the white
holes will become filled randomly.
4: If the density setting is too low, then the lines will not be printed evenly.
The density test is optimized for cast vinyls. Other types of vinyl might result in
conflicting results, which means that the media is probably less suited for thermal
transfer printing.

2-7 Operating Instructions

DC4 User’s Manual

2.2.2.3 PRINT SPEED

Print speed refers to the speed of the printhead. With the

or key the speed can

be raised or lowered. Press the

key to confirm. Lowering speed will reduce
banding. Raising speed will reduce wrinkling on certain (usually non-approved)
media.

2.2.2.4 DOUBLE DENSITY

Double density is a special printing mode. This mode enables the DC4 to print on a
much wider range of materials. When printer is in double density mode, then the
speed settings have no effect on the printing speed any more. Double density can be

set to ON or OFF by pressing the

or key. Then press to confirm.

2.2.2.5 DOT OVERLAP.

The DOT OVERLAP sub-menu is used to activate or deactivate the dot overlap.
When the DC4 prints the next pass of an image, the last dot on the edge of the
previous pass is reprinted. Dot overlap can be set to ON, OFF or HALF by pressing

the

or key. Then press to confirm. It is advised to set dot overlap to ON.

When printing with a mask (see

5.1.4.5), set it to HALF.

On the LCD display, the active setting is marked with an * (asterisk).

2.2.2.6 COLOR OFFSET

The COLOR OFFSET sub-menu is used to set the color offset feature. While
printing, the DC4 shifts each color plane 8 dots (STANDARD). This is to blend the
printed strips together more gradually. The figure below shows how offset color plane
strips are printed. Color offset can be increased (16 dots: HIGH) or disabled (0 dots:

DISABLED) by pressing the arrow keys. Then press

to confirm. It is advised
to set color offset to STANDARD.
On the LCD display, the active setting is marked with an * (asterisk).

Second Pass

First Pass

FIG 2-6

COLOR OFFSET

Operating Instructions 2-8

User’s Manual DC4

2.2.2.7 SCRATCHGUARD

The option Scratch guard makes it possible to put a layer of protective coating on the
printed images. Scratchguard can be set to ON or OFF by pressing the

or key.

Then press

2.2.2.8 OPTITRAC COLOR

The DC4 prints and measures small lines, located at each side of the print, to
optimize the tracking performance. The color of these lines can be changed within
this menu. Be sure to use colors that are in contrast with the vinyl color. The menu
option to change color is useful when printing monochrome, or on colored vinyl. The
default value for white vinyl is cyan.
If white, gold or silver is chosen as OptiTrac color, then the DC4 will raise the head
between the left and right OptiTrac mark if the color is not used. With all other colors,
it will keep the head down.

Each time the color of the OptiTrac lines is changed, perform a
recommended line feed calibration (see section 2.2.2.10).
Failing to do so may result in poor print quality.

2.2.2.9 OPTITRAC

This menu allows setting the OptiTrac feature to automatic or ON. The default setting
is automatic, which means the OptiTrac lines are omitted when the height of the
design is less than one print pass wide (98mm). Setting this option to ON means the
lines are always printed.

to confirm.

2.2.2.10 CALIBRATE LINEFEED

The calibrate linefeed test is used to calibrate the media feed. It is advised to do this
test each time a vinyl roll is changed. This test is fully automatic. After pressing

, There is a choice between a recommended line feed test [TEST 1] and a
simple line feed test[TEST 2]. The recommended line feed test combines the simple
line feed test together with a media calibration test (see

After pressing
calibrates the OptiTrac sensor and then completes the line feed test. The printed
lines are measured and then internal parameters are adjusted automatically. If the
DC4 has to compensate too much, it will ask the operator to redo the test.

After pressing
and then internal parameters are adjusted automatically. If the DC4 has to
compensate too much, it will ask the operator to redo the test.

After the calibration, the printer returns from the menu and into the ready state. Fig 2­6 shows the pattern that is printed using this test.

, a test pattern is printed and then cut out. Now the DC4

, a test pattern is printed and the printed lines are measured

2.2.4.3).

2-9 Operating Instructions

DC4 User’s Manual

FIG 2-7A

RECOMMENDED LINE FEED CALIBRATION TEST

FIG 2-7B

SIMPLE LINE FEED CALIBRATION TEST

Always perform a recommended line feed test when the
OptiTrac color is changed or when the media type is changed.
The simple line feed test is used when just changing the roll or
when the DC4 prompts the user to redo the line feed test.

2.2.2.11 CALIBRATE PRINT & CUT

The print and cut cal. test calibrates the position of the cutting head in relation to the
printhead. Press the

key to perform the calibration test. The DC4 first prints
and cuts out a test pattern similar to the one below. Weed out the large rectangle,
and then search in each set for the small square where the printed lines are not
visible. Now insert the values, which correspond to those squares into the DC4 via
the control panel.

+8

-8

+8

-8

+7

-7

+7

-7
+6

-6

+6

-6
+5

-5

+5

-5
+4

-4

+4

-4
+3

-3

+3

-3
+2

-2

+2

-2

+1

-1

+1

-1
0

0

0

0

FIG 2-9

PRECISION PRINT AND CUT TEST PATTERN

+8

-8

+8

-8

+7

-7

+7

-7
+6

-6

+6

-6
+5

-5

+5

-5
+4

-4

+4

-4
+3

-3

+3

-3
+2

-2

+2

-2

+1

-1

+1

-1
0

0

0

0

CAUTION
Perform the basic test only on 3M white cast vinyl, using cyan

as the marker color, for optimal calibration results.

Operating Instructions 2-10

User’s Manual DC4

2.2.2.12 HEAD ALIGNMENT TEST

The head alignment test is used to check if the carriage is aligned (mounted)
correctly on the DC4. This test should only be performed after a head or a carriage
change. Fig 2-10 shows the pattern that is printed using this test.
The lines must meet, in the middle, within a certain tolerance.

FIG 2-10

HEAD ALIGNMENT TEST

2.2.2.13 CLEAN PRINTHEAD

This routine cleans the printhead. If the transfer of the ribbon has degraded this
cleaning procedure will clean the printhead automatically. Also, the printhead is
periodically cleaned while printing. Do not use this cleaning routine too often as it can
prematurely wear down the printhead surface. This procedure cleans any build-up
from the heat resistant layer, which is coated on the backside of the ribbon.

2-11 Operating Instructions

DC4 User’s Manual

2.2.3 CUTTER MENU

The cutter menu contains parameters and small routines to optimize the cutting
quality.

.. .
...

.. .

... .

..

... . .

.............

..
...

.............

.. .

.............

.. . .

.

.......

.

.......

.

.

.

.

.............

FIG 2-11

CUTTER MENU

2.2.3.1 KNIFE PRESSURE

The KNIFE PRESSURE parameter is used to set the cutting pressure of the knife.
Press the

then press

or arrow keys until the desired pressure is displayed on the LCD,

to confirm.

The knife pressure can be set between 0 and 400 grams.
Knife pressure set-up is explained in detail in section 1.9.
On the LCD, the active knife pressure is marked with an * (asterisk).

Operating Instructions 2-12

User’s Manual DC4

2.2.3.2 KNIFE OFFSET

The KNIFE OFFSET parameter is used to set the distance between the knife blade
tip and the center axis of rotation.
The default knife offset value is .45 mm.

Press the

or arrow key until the desired knife offset is displayed on the LCD

and press
The value can be set between 0 and 1 mm.

Make sure that the selected knife offset value matches that of the knife blade. Some
fine-tuning may be necessary because of the mechanical tolerances on the knife. To

verify the knife offset, a test can be cut by pressing the
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.
On the LCD display, the active setting is marked with an * (asterisk).

2.2.3.3 VELOCITY

The VELOCITY submenu is used to set or modify the cutting velocity.
The default velocity is 500 mm/s (20 ips).

Press the
press

The velocity can be set between 50 mm/s (2 ips) and 600 mm/s (24 ips).
On the LCD, the active plotting speed is marked with an *(asterisk).

to confirm.

key.

or arrow keys until the desired speed is displayed on the LCD and

to confirm.

2.2.3.4 OVERCUT

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

to confirm.
The default overcut is set to 2.
The overcut setting can be disabled (=0) or set to any value between 1 and 10. Each
unit is about 0.1 mm or 0.004 ".
On the LCD, the active value is marked with an *(asterisk).

or arrow keys to change the value and press

2-13 Operating Instructions

DC4 User’s Manual

2.2.3.5 DIN TEST

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

This test cut is always a DIN A4 portrait/A-size image. This cut is always executed in
the sequence prescribed by the ISO DIN standard.

Press the

2.2.3.6 LOAD OPOS MARKERS

This initiates the special load procedure to read the pre-printed markers. This feature
is completely explained in chapter 6 of this manual.

Press the

key to execute.

key to execute and follow the instructions on the LCD.

Operating Instructions 2-14

User’s Manual DC4

2.2.4 SETUP MENU

The setup menu contains parameters, tests and info on the DC4 that are not often
used.

.

.. . .

... . .

.............

.
.. .
...

.............

.
..
.

.............

..

.............

.

.

.
.. .

.............

.

.. . .

.............

.
.. .

.............

.
.. .

.............

.
.. .

.............

.

.. . .

.............

.

.. . .

.............

.

.. . .

.............

FIG 2-12

SETUP MENU

2-15 Operating Instructions

DC4 User’s Manual

2.2.4.1 TAKE-UP ROLL

The TAKE-UP ROLL sub-menu is used to activate or deactivate the take-up rollers.
The take-up rollers can be set for print job only, print and cut job or disabled by

pressing the
On the LCD display, the active setting is marked with an * (asterisk).

2.2.4.2 RIBBON SAVE

The RIBBON SAVE sub-menu is used to set the ribbon save mode. In STANDARD
mode, a ribbon is used over the full width of the print job as soon as one dot is
required in the print pass. No ribbon will be used if no ink is required in the print pass.
In ribbon save mode HIGH, no ribbon will be used if no ink is required in the print
pass and ribbon will also be saved as soon as no ink is required anymore on the
right-hand side of the image.

With ribbon save mode HIGH, the printhead is raised inside the
image. This may leave an impression in the vinyl causing print
quality issues in the next print passes.

The ribbon save mode can be set by pressing the
confirm. The default setting is STANDARD.
On the LCD display, the active setting is marked with an * (asterisk).

or key. Then press to confirm.

or key. Then press to

2.2.4.3 CALIBRATE MEDIA

Calibrate media is used to optimize the parameters of the OptiTrac sensor. Press the

to perform the calibration. The DC4 prints out the pattern below and then cuts
out a rectangle. Then it measure the reflection values of media and Optitrack color.
These values are very important for troubleshooting. Rest of the calibration is
automatic.

FIG 2-13

CALIBRATE MEDIA TEST

Operating Instructions 2-16

User’s Manual DC4

2.2.4.4 CALIBRATE PRINT & CUT

The print and cut cal. test calibrates the position of the cutting head in relation to the
printhead. Press the

key to perform the calibration test. The DC4 first prints
and cuts out a test pattern similar to the one below. Weed out the large rectangle,
and then search in each set for the small square where the printed lines are not
visible. Now insert the values, which correspond to those squares into the DC4 via
the control panel.

-8

+8

-8

+8

-7

+7

-7

+7

-6

+6

-6

+6

-5

+5

-5

+5

-4

+4

-4

+4

-3

+3

-3

+3

-2

+2

-2

+2

-1

+1

-1

+1

0

0

0

0

FIG 2-9

PRECISION PRINT AND CUT TEST PATTERN

-8

+8

-8

+8

-7

+7

-7

+7

-6

+6

-6

+6

-5

+5

-5

+5

-4

+4

-4

+4

-3

+3

-3

+3

-2

+2

-2

+2

-1

+1

-1

+1

0

0

0

0

CAUTION
Perform the basic test only on 3M white cast vinyl, using cyan

as the marker color, for optimal calibration results.

2.2.4.5 CALIBRATE OPOS

This test is used to calibrate the phisical distance between the marker sensor and the
knife tip. Press the

key to start the test. The DC4 will cut out three

rectangles. After that the machine will prompt the user to weed the three rectangles.
Do so and press continue (key

). The DC4 will now measure the difference of
the reflection level of the backing and the media. Then it will search the edges of the
two outer rectangles. If the vinyl is not appropriate for the test, then the DC4 will give
a message. Then the test has to redone with a vinyl which has a high contrast
between the media and the backing color.

2.2.4.6 CAL. TEMP. SENSORS

This test is used when a printhead is changed. This test is fully automatic after the

key is pressed twice. Do this test only when the head is at room temperature.

2.2.4.7 FIRMWARE REVISION

Pressing the

key will furnish the details on the DC4’s firmware revision. This
information is often helpful to technicians when diagnosing problems over the
telephone.

2-17 Operating Instructions

DC4 User’s Manual

2.2.4.8 ROOM TEMPERATURE

Press the

2.2.4.9 COIL SETUP

This test is used to calibrate knife pressure and to set the knife “Landing”.
After adjustment, the value is saved in the system’s memory.
To execute this test, a tension gauge of ± 100 gr. and ± 500 gr. is required.

Press the

CAUTION

Do not perform the coil test when the machine is working
properly. Changing the parameters to incorrect values may
seriously affect the quality, and may even damage the DC4.

2.2.4.10 SHOW PRINTER USAGE

Pressing the
carried through the unit during printing. Pressing the

counter to zero.

key and the DC4 will display the room temperature.

key to enter the test and follow the guidelines on the LCD screen.

key will furnish the square meter / square feet amount of vinyl

key will reset this

2.2.4.11 COPY USER CONFIG.

This menu enables the operator to copy the parameters from one user to another
user (see

user name is not changed. Pres the

key the source user can be chosen. With the or key the target user can be

chosen. Then press the

2.2.4.12 PRINT DEMO FILE

On the hard disk of the DC4 there are two demo files. A print and cut file of 800mm
by 380mm and a color chart. Pres the

or key choose the demo file. Then press he key to execute. The color
chart was made with Corel 11, then exported using the generic CMYK printer profile
and then ripped with the screening option set to printer default. Colors might differ
slightly when using other settings in either CorelDraw or SummaColorControl.

2.2.1.5for detail on which parameters). When copying the parameters, the
key start the copy process. With the or

key to confirm or the key to cancel.

key to enter the menu. Then with the

Operating Instructions 2-18

SECTION 3

3 GENERAL INFORMATION

3.1. MAINTENANCE & CLEANING

The DC4 has a number of sliding surfaces made of smooth metals and plastics. They
are virtually friction-free and require no lubrication. They will, however, collect dust
and lint, which may affect the performance of the DC4. Keep the DC4 as clean as
possible by keeping the front cover always closed. When necessary, clean the unit
with a soft cloth dampened with isopropyl alcohol or mild detergent. Do not use
abrasive cleaners.

!

WARNING

The printing surface is made out of a special cellular material. Do not
touch it! Cleaning it with any kind of fluid will permanently damage it.
Also if pressure is applied to the surface with anything other than the
printhead, the printing surface could also be permanently damaged.

3.1.1 CLEANING THE DRIVE SYSTEM

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

Î To clean the drive sleeves, proceed as follows:

1. Power down the DC4 and remove media and cassettes. Switch it back on.

2. Wait until it is initialized and open the front cover.

3. Cover the front and rear sensor with a piece of paper. 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.

4. Close the cover, press the

5. Open the cover and press the
adhesive side down, back and forth. Be careful not to lose the strip within the

machine. Press the

key again to release the pinch rollers.

key twice, and wait until the machine is ready.

or arrow keys to move the vinyl strip,

The figure shows the front sensor covered and the vinyl strip between the pinch roller
and the sleeve.

3-1 Maintenance and Cleaning

DC4 User’s Manual

FIGURE 3-1:

CLEANING THE DRIVE SLEEVES

3.1.2 CLEANING THE SENSOR

After a time and usage, the sensor may become dirty with accumulated residue from
the media. This situation may cause malfunctioning of the DC4.

Î To clean the sensor area, proceed as follows:

1. The front sensor is located on the DC4’ s left side, right next to the pinch roller.
The rear sensor is located in the neighborhood of the rear clamp (see figure
below).

2. To keep the sensors clean, it is sufficient to wipe them out with a cotton swab.

FIG 3-2

Position of the front and rear sensors

Maintenance and Cleaning 3-2

User’s Manual DC4

3.1.3 CLEANING PAD

Located on the left side of the DC4 is a printhead cleaning pad. The printer cleans
the head periodically on this pad. It is possible that after a while some dust will
accumulate on this pad. Therefore it is advised to clean this pad from time to time.

Î To clean the cleaning pad, proceed as follows:

1. Take a piece of scrap vinyl that is a bit larger than the cleaning pad. Remove the
backing and stick it on the cleaning pad.

2. Gently apply equal pressure on the vinyl, pressing the adhesive on the pad.

3. Remove the vinyl and check the back of the vinyl. If it is dirty do the procedure
again, until the vinyl does not show dirt from the cleaning pad.

If the cleaning pad starts turning white, it is worn out and should be replaced.

NOTE

The cleaning plate should be cleaned every week or after each change of
roll vinyl which ever come first.
Every five rolls of vinyl, the cleaning pad should be replaced (or turned
once – mark used side so it is not used twice).
Using not approved material can raise the need to perform these actions.
Cleaning pad should be changed if the printhead is changed.

FIG 3-3

CLEANING PAD

3-3 Maintenance and Cleaning

DC4 User’s Manual

3.1.4 CLEANING THE PRINTHEAD

The printhead accumulates dust, debris and resin residue, which can all degrade the
print quality. The printer will automatically self-clean the printhead (see
section
debris, the printhead will sometimes require manual cleaning, particularly after a
ribbon breakage because large pieces of ribbon material might be caught underneath
the carriage.
Do not clean the printhead just after printing. The printhead is still hot after printing.
Touching it too soon after printing might cause injuries.
Do not clean the printhead above the printing surface.

Î To clean the printhead, proceed as follows:

1. Power off the DC4. Open up the rear cover and take out the cassette.

2. Use a lint free cloth, or gauze, moistened with isopropyl alcohol.

3. Gently wipe the printhead (1), the release plate (2) and the rollers (4).

2.2.2.13. and 3.1.3). While this procedure removes much of the residue and

4. Note the position of the ribbon end sensor (3).

NOTE

Clean the printhead after every change of roll of ribbon.

FIG 3-4

CLEANING THE PRINTHEAD

Maintenance and Cleaning 3-4

User’s Manual DC4

3.1.5 CLEANING THE PRINTING SURFACE

The printing surface is very delicate. It is made out of cellular material. Oil and
moisture from fingers damages the surface, therefore great care should be taken
when the printing surface is uncovered. DO NOT TOUCH SURFACE.
In rare cases it might be necessary to clean the printing surface. It is not
recommended to do it, but sometimes it is the only safe way to remove dirt.

Î To clean the printing surface, proceed as follows:

1. Power off the DC4 and remove the vinyl.

2. Cut a piece of vinyl, the size of the printing surface (1 x 0.14m) and stick it onto
the printing surface.

3. Power on the DC4 and load the media. Print out a rectangle full width and height,
consisting out of two colors app 20% coverage.

4. Remove the media from the DC4 and turn off the power.

5. Carefully remove the vinyl from the printing surface.

This test has been done with 3M cast white vinyl. Do not attempt to use any other
vinyl to clean the printing surface. The reaction of the adhesive on the printing
surface might damage it. Do not leave the vinyl on the printing surface longer than is
necessary for this test.

3-5 Maintenance and Cleaning

DC4 User’s Manual

3.2. OPERATING VOLTAGE

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

The fuse is at the back, next to the power inlet.
The fuse rating is a 4.0A Slo-Blo, for all voltage ratings.

!

SAFETY WARNING

Before changing the fuse be sure to completely disconnect the DC4.

NOTE

Always make sure that you are using the correct fuse rating.

1. Power entry module

2. Fuse holder

3. Fuse

FIGURE 3-5

POWER ENTRY MODULE

Maintenance and Cleaning 3-6

SECTION 4

4 INTERFACE

4.1. INTRODUCTION

This section describes the communication interfaces between your DC4 and the host
computer.

A Parallel and USB connection is available with DC4. When both ports are connected
at the same time, only the port that receives the data first will stay active, and this will
deactivate the other port. Switching to the other port to send information can only be
achieved when both ports get no data for at least 30 seconds.

4.1.1 PARALLEL INTERFACE

A standard shielded, twisted-pair parallel cable should be used on the parallel port.
The recommended length of the cable should be less than 3 meters (10 ft).

Setting up:
Make sure both the DC4 and the computer are turned off.
Plug the cable connector securely into the DC4’s interface connector. Then squeeze
the wire clips together, on both sides, until they lock in place.
Plug the other end of the cable into the computer’s parallel interface.

4-1 Interface

DC4 User’s Manual

4.1.2 USB INTERFACE NOTES

The DC4 has a built–in USB interface and is based on the standards, specified in
Universal Serial Bus Specifications Revision 1.1
The recommend cable length is 5 meters (16 ft.) or less.
The adaptable connector type is USB Series “B”
The specifications of the cable should be USB Series A 4-pin for the computer side
and USB Series B 4-pin for the DC4 side.

USB is “Hot swappable”, which means the connection between the computer and the
printer can be established or interrupted without switching of computer or printer.
However with Windows 2000, Windows ME and Windows XP, it is advised to first let
MS Windows “Unplug the hardware”.

Î To disconnect or switch printers, proceed as follows:

1. Double click on the “Unplug hardware” icon in the system tray

2. Click on

3. A new window appears, click on

4. Wait for the message, which confirms that it is now safe to unplug the device,
then either unplug it or switch it off.

, click on

, then click on .

.

Interface 4-2

SECTION 5

5 PRINTING SOFTWARE

5.1. SUMMA COLORCONTROL

ColorControl is a Windows based program that processes Postscript files (“EPS”,
“PS”, “EPSF” and “PDF” files). ColorControl provides the RIP (Raster Image
Processor) to enable the operator to output vector and raster images to the DC4.

Included functions are:
Print to DC4: A high-speed image rasterizer that processes postscript files using a

postscript level 3 interpreter.
View ripped files: Allows the operator to view images before printing them.
The RIP retains all aspects of file size, rotation and color depth, which is assigned in

the design software.
The program uses a hardware key (Dongle), which attaches to the host computer’s

port.

NOTE

Do not install the dongle before that the HASP driver is installed (see later).

5-1 Printing Software

DC4 User’s Manual

5.1.1 INSTALLING HASP DRIVER FOR DONGLE

1. Insert the CD into the computer.

2. The CD should start automatically. If the installation does not begin
automatically, launch the routine manually from the “Run” command line in the
Windows Start menu. Type “D:\autostart.exe” (where D is the DVD/CD-ROM
drive).

FIG 5-1

START CD MANUALLY

3. Start up screen.

FIG 5-2

INSTALLATION OF HASP DRIVER

4. Click on “Install HASP driver for dongle “.

5. Then follow the instructions on the screen.

Wait to connect the dongle until the driver for it is installed (see next paragraph).

Printing Software 5-2

User’s Manual DC4

5.1.2 INSTALLING SUMMA COLORCONTROL

1. Insert the CD into the computer.

2. The CD should start automatically. If the installation does not begin
automatically, launch the routine manually from the “Run” command line in the
Windows Start menu. Type “D:\autostart.exe” (where D is the DVD/CD-ROM
drive).

FIG 5-3

START CD MANUALLY

3. Start up screen.

FIG 5-4

INSTALLATION OF SUMMA COLORCONTROL

4. Click on “Setup Color Control “.

5. Then follow the instructions on the screen.

The ColorControl installation procedure is self-explanatory.

5-3 Printing Software

DC4 User’s Manual

5.1.3 SUMMA COLORCONTROL (SCC) CONFIGURATION

The software is now ready to use, but the operator might wish to adjust certain
preferences. Launch ColorControl.

5.1.3.1 COLORCONTROL PREFERENCES

FIF 5-5

COLORCONTROL PREFERENCES

1. Temp directory: Indicates where SCC writes temporary files during processing.
SCC uses the default MS Windows temp directory.

icense key: In this box the dongle license number appears. If this box is

2. L
blank, then either the HASP drivers are not installed or the dongle is missing,
defective or the printer is turned off. The printer must always be turned on

before launching Summa ColorControl.

Printing Software 5-4

User’s Manual DC4

5.1.3.2 PROCESS PREFERENCES

FIG 5-6

PROCESS PREFERENCES

1. Units: sets the units of measurement for pixel resolution, page size and rulers
within the preview menu.

2. Drag ‘n’ Drop RIP: identifies the printer being used.

5-5 Printing Software

DC4 User’s Manual

5.1.3.3 RIP PREFERENCES

FIG 5-7

RIP PREFERENCES

1. Lib directory: where SCC’s library files reside. The default is “C:\Program
Files\SummaCC\lib\psrip3”. If during an installation the files are stored
elsewhere, then change this setting appropriately. If the settings are incorrect,
SCC will give a fatal error when ripping.

IP memory (MB): the amount of RAM SCC uses while processing files. The

2. R
default is the minimum 16MB. The maximum memory used by SCC is 256MB.

3. Default page size: provides the default page size if the imported Postscript file
does not contain page size information.

Printing Software 5-6

User’s Manual DC4

5.1.3.4 DC4 PREFERENCES

FIG 5-8

DC4 PREFERENCES

1. Destination printer: select the interface port, most commonly used is the USB
port.

2. Check if printer type is set to Summa DC4. This is important for maximum
printing width and tile size.

3. RIP output directory: specify the directory where ripped files will be stored.
Please BE VERY CAREFUL and watch this directory as large ripped files can
accumulate and fill your computers hard disk quickly.

4. Custom m
recommended to use bitmaps with a height that is a multiple of 16 pixels.

5. I

mport Spot ID’s: allows new spot color ID’s to be created and imported when

a new spot color is released.

6. R

eset Spot ID’s: resets spot ID’s to factory default.

asks: import custom-made masks for the Vision Print feature. It is

5-7 Printing Software

DC4 User’s Manual

5.1.3.5 REPRINT PREFERENCES

FIG 5-9

REPRINT PREFERENCES

Reprint d
to store ripped files.

irectory: select to use the RIP output directory or choose another location

Printing Software 5-8

User’s Manual DC4

5.1.4 HOW TO RIP AND PRINT

To begin, enter the menu and click on . In the
subsequent dialog boxes, browse to the file that needs to be printed and click on the

button. The print dialog box will appear, there are 5 tabs.

5.1.4.1 GENERAL TAB

FIG 5-10

GENERAL TAB

1. Force Black Overprint: overprints all black elements, which help to prevent
small black text from dropping out the background color.

TEXT TEXT

FIG 5-11

FORCE BLACK OVERPRINT ON FORCE BLACK OVERPRINT OFF

2. Mirror: reverses the image, which is useful for some backlit and window
graphic applications.

egative: creates a negative image, which is useful for screen-printing

3. N
applications.

4. RIP & Print: select which operation to perform.

5. Rotate: rotates an image 90°, 180° or 270°.

6. Save PS/EPS/PDF file after successfully Ripping: Select whether to save or
delete the file that has just been ripped.

7. Save RIP’ed file after printing: Select whether to save or delete the ripped file,
after printing. The location of the ripped files can be set in the preference
menu. If this option is set to on, then this subdirectory has to be checked
regularly in order not to flood the hard disk.

8. Number of c

opies: specify the number of copies to print.

5-9 Printing Software

DC4 User’s Manual

5.1.4.2 COLOR TAB

FIG 5-12

COLOR TAB

1. Colorspace: select 3 color (CMY), 4 color (CMYK), Monochrome (Grey scale)
or spot color only. Printing in 4 colors is chosen to deepen shadows and to
provide a true black. Printing in 3 colors reduces the cost of the output. (See
fig below – only visible in color)

FIG 5-13

PRINTED CMYK PRINTED CMY

2. Reverse print order: reverses the print order. This option is used for reverse
backlit applications to preserve the lightest color being printed first. Choosing
this option also has as a result that the masking colors are printed last. The
best print order is always YMCK.

3. Type: CMYK information in the file will default to “Process”. If spot color
information is assigned in the design software, then they will appear here as
“Spot”. The spot colors can be changed to “As process” if the spot color
ribbons are not available. The spot color “COUNTOUR” is an exception. SCC
will cut out any information in spot color “CONTOUR”. There can only be one
‘contour color’.

4. Cassette Number: refers to the ribbon ID number. Numbers are assigned
automatically if SCC recognizes the color name.

5. Print order: specify the order in which the color planes will be printed. Ideally,
process colors always print in YMCK order, lightest color first.

Printing Software 5-10

User’s Manual DC4

5.1.4.3 SCREENING TAB

FIG 5-14

SCREENING TAB

1. Use printer’s default screens: the frequency, angle and dot shape that are
specified in the EPS file will be used while ripping and printing. If this box is
unchecked, then those parameters can be changed for different effects.

2. I

nk: Use the same shape and frequency for all colors, otherwise unexpected

patterns will appear in the design.

requency: The frequency is the ‘line frequency’ (lpmm or lpi). This parameter

3. F
determines the size of the cell in which dots are put together to create the
colors. Do not confuse this term ‘dots per mm’ (dpmm or dpi). Dpmm is the
resolution of the printer. The head of a DC4 has a fixed resolution of 12 dpmm
(304 dpi). The number of shades depends on the relation between dpmm and
lpmm (lpi and dpi). The formula is (dpmm/lpmm)² or (dpi/lpi)². It is
recommended to use only frequencies between 0.8 and 2 lines /mm (20 to 50
lines/inch). Below is an example of printing out a gradient from 100 to 0%
black with respectively 1,1.55, 2.35 lpmm (25, 40 and 60 lpi) and a smooth
gradient

FIG 5-15

DIFFERENCE BETWEEN LINE FREQUENCIES

5-11 Printing Software

DC4 User’s Manual

4. Angle: To get various shades to reproduce an image, the RIP uses a process
called screening. Screening breaks an image down into series of dots. Each
screen is set to a certain angle. Thus creating intersecting rows that form a
pattern as dot shapes, know as rosettes. The default angles are carefully
chosen in order to minimize the ‘moiré’ effect. Changing those angles will
normally not reduce moiré. Moiré usually emerges in scanned pictures; add
noise in the picture to solve the moiré problem.

FIG 5-16

SCREEN ANGLES

5. Shape: Here the shape of those dots can be chosen. Below is an illustration of
the various available dot shapes.

ROUND SQUARE

CROSS DIAMOND

Printing Software 5-12

User’s Manual DC4

ELLIPSE LINE

RHOMBOID DOUBLE DOT

SINGLE DOT

The shape, shown in the enlarged section, is a result of the combination of
postscript pattern and angle and frequency.

Ellipse is the recommended default shape. Rhomboid, Double Dot and other
shapes are can be chosen for special effects, but are not generally recommended.
Summa cannot guarantee print quality using any shape other than Ellipse.

Tips:
For difficult colors, use Rhomboid 0.8 to 1.1 lines /mm (20 to 30 lines/inch)
For more steps in gradients, use Double Dot 1 line/mm (25 lines/inch)
A standard setting for mid to large designs is Rhomboid 2 lines/mm (50

lines/inch)

Do Not Use Double Dot with line frequencies higher than 1.3 lines/mm (35 lines/inch), and
only for relatively small images (smaller the one band width). Severe banding can occur

when improperly using the Double Dot shape.

5-13 Printing Software

DC4 User’s Manual

5.1.4.4 LAYOUT TAB

FIG 5-17

LAYOUT TAB

1. Output size: scale the EPS file to any size or specify a page size. To
determine the exact output size, click first on

change to the desired size in the width or height box. Enable
constrain the proportions during resizing.

2. Tiling: If the image needs to be tiled, specify the tile size and the amount of
overlap between each tile. Check the

box to use the
maximum print width. There is also the option to print out each tile separately.
If the weed box option is chosen, then the DC4 cuts a border around the print
out.. If there is print and cut information, in the file, then SCC will automatically
cut a border around the design.

, then

box to

Printing Software 5-14

User’s Manual DC4

5.1.4.5 ADVANCED TAB

FIG 5-18

ADVANCED TAB

1. Horizontal offset: specify the offset from the origin of a normal printout.
ob name (optional): specify the name the printer will use in the printer’s

2. J

queue.

3. Space a

fter job: set the required distance between subsequent jobs, This

value is ignored by the DC4.

4. Use c

ompression: compresses raw printer data to reduce the time it takes to

transfer the data.

se ColorControl UCR/GCR: a process that determines the amount of black

5. U

ink used to replace CMY in areas where those three inks overlap. (Under
Color Removal and Grey Component Replacement). It is highlighted only
when working in 4-color mode. (See fig below – only visible in color)

FIG 5-19

PRINTED NO UCR/GCR PRINTED WITH UCR/GCR

5-15 Printing Software

DC4 User’s Manual

6. Use Improved CMYK to CMY: a choice between two different embedded color

profile tables. Used when CMY images appear too dark.

FIG 5-20

IMPROVED CMYK TO CMY NO IMPROVED CMYK TO CMY

7. Use High resolution mode is an option to print in high resolution. When this

mode is used, then the DC4 prints with a resolution of 304x608 dpi which
results in higher color contrast and scharper images.

8. Masking is an option to print color layers underneath other colors. Commonly

used for printing on clear vinyl. Choose between ColorM
coverage), P

rimer dot (printed dot on dot, or pixel on pixel) and VisionPrint
(perforated hole patterns). The patterns in VisionPrint can be chosen with
‘Mask n
‘S

ame’. The size of the pattern can be changed with ‘Mask size’ and

hape size’. The small window next to the shape option, displays the pattern
that will be printed out. The black area indicates area to be printed and the
white area indicates what will not be printed. There is a choice of one, two or
three masking layers. Fill in the cassettes numbers for selected layers as
needed.

ask (complete

FIG 5-21

MASKING

Printing Software 5-16

User’s Manual DC4

FIG 5-22

PRIMER DOT

FIG 5-23

VISION PRINT

5-17 Printing Software

DC4 User’s Manual

5.1.5 HOW TO RIP,VIEW AND PRINT

Follow next procedure to RIP, View and print.

Enter the
In the print dialogue box choose

Set the rest of the printing preferences as explained in previous section.

menu and click on .

.

Click on
Enter the

The ripped file can be checked, it can not be altered any more.
Spot colors do not show in the preview.

Click on the

.

menu and click on .

icon to print out the file.

Printing Software 5-18

User’s Manual DC4

5.2. PALETTE INSTALLER

This program installs a custom ColorControl spot color palette for Adobe Illustrator,
CorelDraw or Macromedia Freehand. The spot colors in this palette have unique
names, which ColorControl can recognize.

5.2.1 LAUNCHING PALETTE INSTALLER

1. Insert the CD into the computer.

2. The CD should start automatically. If the installation does not begin
automatically, launch the routine manually from the “Run” command line in the
Windows Start menu. Type “D:\autostart.exe” (where D is the CD-ROM drive).

FIG 5-24

START CD MANUALLY

3. Start up screen.

INSTALLATION OF PALETTE

1. Click on “Install Color Palette “.

FIG 5-25

2. Then follow the instructions on the screen.

3. The program launches and looks for installed versions of Adobe Illustrator,
CorelDraw or Macromedia Freehand. Click on the button

palettes will be installed automatically.

and the

5-19 Printing Software

DC4 User’s Manual

5.3. SUMMA PRINTER CONTROL

The Summa Printer Control Program for MS Windows is a software utility to optimize
the overall printing and cutting capabilities of the DC4.
The Summa Printer Control program basically has the same functions as the control
panel. It is up to the user to decide which way he will work most efficiently. The users
who will work with the Summa Printer Control program will notice that it is a very
powerful and practical tool.

5.3.1 INSTALLING SUMMA PRINTER CONTROL

1. Insert the CD into the computer.

2. The CD should start automatically. If the installation does not begin
automatically, launch the routine manually from the “Run” command line in the
Windows Start menu. Type “D:\autostart.exe” (where D is the CD-ROM drive).

3. Start up screen.

FIG 5-26

START CD MANUALLY

FIG 5-27

INSTALLATION OF SUMMA PRINTER CONTROL

4. Click on “Setup Printer Control “.

5. Then follow the instruction on the screen.

Printing Software 5-20

User’s Manual DC4

5.3.2 SUMMA PRINTER CONTROL MENUS

FIG 5-28

SUMMA PRINTER CONTROL START SCREEN

5.3.2.1 FILE MENU

With the file menu, configuration settings can be save on the
computer and loaded from its hard disk. The options are

only highlighted if a connection between the DC4 and the

computer has been established.

The last item in this menu will exit the program.

5.3.2.2 VIEW MENU

With the view menu, the appearance of the program

can be changed. Some options are only highlighted

if a connection between the DC4 and the

computer has been established.

5-21 Printing Software

DC4 User’s Manual

5.3.2.3 CONFIGURATION MENU

With the configuration menu, the language and units

of measurement, which Summa Printer control uses,
can be changed. With the option menu more or less

parameters can be made visible.

5.3.2.4 SETTINGS MENU

The settings menu can be used to display

certain DC4 parameters on your
computer. These parameters can be

changed and saved on the computer

hard disk, and also in DC4’s memory.

5.3.2.5 TESTS MENU

The test menu is used for starting

internal DC4 tests, updating the DC4
firmware and to check how many

prints the printhead has printed.

Printing Software 5-22

User’s Manual DC4

5.3.3 ACTION LIST

With the action list, or the setting menu, DC4’s parameter settings can be displayed
on the computer.

5.3.3.1 CONFIGURATION SETTINGS

Below is a screen capture of the parameters that can be changed using Summa
Printer Control (option’ show hidden parameters’ is set to on). An explanation of
these parameters is located in section 2.2. When a parameter is changed, then the
parameter and the value are displayed in bold on the computer and the cancel and
apply button are highlighted. Click on ‘apply’ to send the new value to the DC4.

FIG 5-29

CONFIGURATION SETTINGS

5.3.3.2 TOOL PROPERTIES

The tool properties are typical parameters used for the contour cutting knife blade.
The coil settings are for service use only.

FIG 5-30

TOOL PROPERTIES

5-23 Printing Software

DC4 User’s Manual

5.3.3.3 INFO

FIG 5-31

INFO

Info gives the operator the most important parameters at a glance. The printed media
area can be set to zero with the eraser tool right next to it.

5.3.3.4 USERS

FIG 5-32

INFO

With this the operator can change the active user and also change the user name. By
default user 01 and user 02 are factory set for premium cast white and premium clear
vinyl. Click right on the user to show the parameters of that user, set active or change
the name of that user.

Printing Software 5-24

SECTION 6

6 OPOS

6.1 INTRODUCTION

The DC4 has an accurate Optical Positioning System. This can be used when it is
impossible to contour-cut right after the printing. For instance when the design has to
be laminated and then cut afterwards. OPOS is based on the principle of registrating
black or cyan printed squares around the design. The registration of those markers is
done by a sensor on the font of the printer carriage (same sensor that is used for the
optitrac system). To be sure that OPOS works accurately, the distance between the
sensor and the knife tip must be calibrated (see section

2.2.4.5 )

6.2 MAKING AND PRINTING THE DESI GN

The orientation shown in this figures is as it will be seen on the computer screen
when the design is created. When the design is exported and printed out wit SCC,
then orientation on the printer is rotated by 180%.

1. Create the design and contour line. For easier handling, place the contour lines

on a different layer (they will have to be cut out afterwards).

Contour line

FIG 6-1

DESIGN WITH CONTOUR

When defining contours, do not define them right on the border of the

2.
design. It is advised to leave either a white space between the contour and
the design, or to define the contour inside a thick outline. Or better jet, just

6-1 OPOS

DC4 User’s Manual

X

inside the design. If the contour is designed right on the edge of the
drawing, then the slightest misalignment will result in a bad result.

Contourline ContourlineContourlineContourline

Recommended

FIG 6-2

ADVISED PLACES FOR CONTOUR PLACEMENT

• Place all the contour objects on a different layer.

3. Put the OPOS markers around the drawing. In your design the top right corner is
the origin of the design that will be printed out.

-size

Y-size

FIG 6-3

PLACEMENT OF THE FIRST MARKER

• The marker must be a rectangle that has sizes which are exactly known. The

advised size is 3mm and the line style of the marker is best set to none (line
styles with a certain thickness affect the precision).

• Make sure that around every marker a ‘white space’ which is 3-4 times the

size of the marker.

• Make sure that the origin marker is situated at the right side and above all

contours that need to be cut.

• Remember the marker size, its value will have to send in a later step of the

procedure to the DC4.

OPOS 6-2

User’s Manual DC4

X

4. Place the markers.

-distance

Y-distance

FIG 6-4

PLACEMENT OF THE REST OF THE MARKERS

• Place copies of the original marker at a regular distance in the X-direction.

The last marker at the bottom must be under all contours that need be cut.

• Make sure there is enough white space around every marker.

• The advised X-distance depends on several items. Normally 30 to 40 cm is a

satisfying distance.

• If the marker size is smaller then 3mm lower the X-distance.

• If the white margin is critical, lower the X-distance.

• The bigger the distance between the markers, the faster the registration of

the markers works. The smaller the distance between the markers, the
more accurate OPOS works, however the influence on the accuracy is
rather small.

• The exact distance between the markers must be known. Do not measure

the distance on the print-out, measure the distance in the design
software. The exact distance is the distance from the lower left corner of one

marker to the lower left corner of the marker just underneath it.

• Remember the X-distance and the number of markers in the X-axis, these

values will have to be sent to the DC4 in a later stadium.

• Make a copy of the row of markers indicating the X-axis and place them left to

the design.

• Make sure the rows are not shifted.

• The exact distance between the markers must be known. Do not

measure the distance on the print-out, measure the distance in the
design software. The exact distance is the distance from the lower left

corner of one marker to the lower left corner of the marker just underneath
it.

• Remember the Y-distance, this value will have to be sent to the DC4 in a later

stadium.

5. Print the design.

• Make the layer on which the contour lines are invisible and not printable.

6-3 OPOS

DC4 User’s Manual

• Print the markers and the design on the DC4. Make sure not to scale the

design any more.

• When printing make sure not to rotate the design any more and leave at least

30cm after the design.

• It is advised to group the jobs on a roll, since with each sheet there needs to

be rear margin of +/- 30cm.

• Leave the front edge also to the design

FIG 6-5

PRINTED DESIGN

OPOS 6-4

User’s Manual DC4

6.3 SETTING THE PARAMETERS AND LOADING TO CUT

After the 5 steps explained in the paragraph above, the design is ready to apply the
extra procedure (like laminating) to it. The rest of this paragraph describes what then
needs to be done to cut the contours. Skip this paragraph if WinPlot is used to
contourcut (recommended)

• Load the media in the DC4 as described in section 1. Make sure it is loaded

in the same orientation as it came out of the DC4

• Start Summa Printer Control

FIG 6-6

START SCREEN SPC

• Change the 5 Opos parameter to the values that were used in section 6.2

step 4. The marker distance X-direction, the marker distance y-direction, the
marker size X-direction, the marker size Y-direction and the marker count
(number of markers in the X-direction). Send those values to the DC4.

• Registrate the markers. To registrate the markers, enter the cutter menu.

• Look for ‘LOAD OPOS MARKERS’ in the cutter menu and press ’ENTER’.

• The DC4 will prompt the user to put the knife tip above the first marker. If all

previous steps were followed, then this means that the first marker is in the
lower left corner of the design that was just loaded in the DC4. Do so and
press ’ENTER’. Wait until the DC4 has read all the markers.

WinPlot automates this task so that it is not necessary to fill in the OPOS
parameters manually.

6-5 OPOS

DC4 User’s Manual

6.4 CUTTING THE CONTOUR

• Make the layer on which the contour lines are visible and printable. Do the

opposite with the print data.

• Make sure that he origin marker (top right) is also defined as a contour. This

will be used as the origin for the cutting.

• It is recommended to use WinPlot for sending cutting data to the DC4.

WinPlot also send the OPOS parameters automatically to the DC4. Just click
on the OPOS cut icon and the parameters will be send to the DC4 and the
special load will be activated (the machine will ask the user to put the knife tip
above the first OPOS marker. When using WinPlot, then the orientation of the
design loaded in the DC4 must be the same as the orientation on screen in
WinPlot.

Complete design Cutting data

FIG 6-7

SELECTING CUT DATA

OPOS 6-6