Home

SERVICE MANUAL 60e 42e

1. Figure 3 5 Carrier Connection Locations Maintenance 51 Novajet PROe Series Service Manual 52 Figures 3 4 and 3 5 shows the locations of all the connectors on the MPCB and carrier board respectively Toremovethe ribbon cables from their connectors lift the connector s ribbon locking mechanism as shown in figure 3 6 Toreattach depress the locking mechanism back into the locking position after inserting the ribbon cable end RIBBON LOCKING MECHANISM UNLOCKED LOCKED CONNECTOR ASSEMBLY Figure 3 6 Ribbon Connector Locking Mechanism Replace Carrier Bushings The carrier bushings are rated for approximately 1500 hours of operational usage Many factors including but not limited to hours day used cleanliness of the slide shaft and general ambient environ ment make it impossible to calculate the average time that the carrier bushings to last If not replaced the wear on the bushings can result in erratic carrier motion and or carrier axis failures It can even cause the cartridge head height to become uneven To replace the carrier bushings follow the procedures for Carrier Bushing Replacement found in Chapter 5 Maintenance Novajet PROe Series Service Manual Servo Motor Winding Resistance Check aS G2 NEM BW E z m z gt Z 9 m Figure 3 7 Servo Motor
2. SERVICE MANUAL This Page Intentionally Left Blank caD PROe SERIES PRINTER SERVICE MANUAL Part Number 209053 Novajet PROe Series Service Manual Copyright 1997 ENCADs Inc All rights reserved ENCAD is a registered trademark of ENCAD Inc NOVAJET PRO is a trademark of ENCAD Inc Other trademarks and registered trademarks are the property of their respective owners No part of this manual may be copied or distributed transmitted transcribed stored in a retrieval system or translated in any human or computing language in any form or by any means electronic mechanical mag netic or otherwise or disclosed to a third party without the express written permission of ENCAD Inc 6059 Cornerstone Court West San Diego CA 92121 U S A Printing history 1st Edition Rev A April 1997 2nd Edition RevB June 1997 Novajet PROe Series Service Manual FCC Statement U S A The United States Federal Communications Commision has specified that the following notice be brought to the attention of the users of the NOVAJET PROe series printers FEDERAL COMMUNICATIONS COMMISION RADIO AND TELEVI SION
3. 57 Slide Shaft Profile Adjustment sse 57 Head Height Alignment Procedure eene 60 Color Calibration 1 aaa eia aaen 63 Deadband Alignrierit 66 Paper Axis eene 69 Diagnostics d 71 Limited Access 0 1 nnn nes 73 Firmware Dowmoading chaud 75 Internal Cabling and Signal Flow 76 Chapter 4 Troubleshooting eee 81 e EE EE ETE EDS E 81 81 Media Does Not eti recette cert teer ttes 82 Internal ERROR Carriage Axis 83 Internal ERROR Encoder Sensor Failure sss 84 Internal ERROR Paper Sensor 84 Internal ERROR Auto Sensor Failure 2 0 40 00 84 Internal ERROR Trailing Cable Failure teaiin 85 10 Novajet PROe Series Service Manual Table of Contents cont Chapter 4 Troubleshooting cont Internal ERROR MPCB 85 0066 85 Ink Cartridge
4. m gt z 9 m Figure 3 27 Diagnostics Menu All tests under the Diagnostics Menu should be performed by competent technicians only The types of tests that can be per formed are Servo PWM Test Servo Cycle Test Carriage Test Color Test Continuous Test Fan 1 Test Fan 2 Test and Legs Test The Fan 1 Test Fan 2 Test and Legs Test are located in the Accessory Menu as shown in Figure 3 28 Maintenance 71 Figure 3 28 Accessory Menu Servo PWM Test Monitors the PWM pulse width modulation signal applied to the servo motor from the driver on the MPCB to check the amount of force required to move the Carrier The test includes three complete cycles of the carrier assembly and lists the average PWM the maximum PWM and the position of the carrier where the maximum PWM occured Servo Cycle Test Tests the servo motor by moving the carrier back and forth across the slide shaft The number of cycles is selectable and the available options are 10 100 1 000 10 000 100 000 1 000 000 Carriage Test Prints 5 sets of 3 parallel lines to test the vibration characteristics of the carrier assembly Color Test The Color Test prints a wide swath of color total of four to test for banding The test is selectable in the amount of ink that is to be printed The available are 10 25 35 50 65 75 and 100 Continuous Test The Continuous Test sends the printer into a test loop tha
5. PARTS LIST Figure 6 6 Power Feed and Take Up Parts Breakdown 159 Parts List This Page Intentionally Left Blank Index A adapter J Tag 75 alignments head height 60 slide shaft 57 axis drive carrier 28 paper media 27 banding 56 bushings carrier replacing 127 C cabling 76 calibration color 63 deadband 66 X axis 69 carrier 117 cartridges 47 63 cautions 20 control panel 40 E encoder strip 133 ESD 19 fan cooling 108 firmware downloading 33 75 G general block diagram 25 ink delivery system 114 J jack connections carrier 51 MPCB 51 L linear encoder strip 46 M main printed circuit board 30 49 media feed and take up system 29 memory SIMMs 33 installation 103 menu accessory 72 calibration 70 calibration deadband 68 color calib 65 diagnostics 71 main 40 service 67 utility 65 motor media feed take up resistance check 55 161 Novajet PROe Series Service Manual Servo controller 36 removal installation 111 resistance check 53 stepper media controller 34 removal installation 139 resistance check 54 104 notes 20 O optical encoder strip 28 36 P pinch rollers 135 power supply 41 108 R related publications 19 S
6. 126 5 18 Carrier Bushing 128 5 19 Carrier Bushing Installation 000000 ana 128 5 20 Service Station Exploded 129 5 21 Stabilizer Bracket Installation Removal sse 134 5 22 Y Arm 1 136 5 23 Pinen ROST E RT 137 5 24 Inner Platen Assembly Disassembly 140 5 25 Stepper Motor Removal Installation 2 142 5 26 Inside Platen Right 144 5 27 Media Take Up and Feed Sensor 146 5 28 Media Take Up and Feed Motor 149 Chapter 6 Parts List 6 1 Left Side Parts Breakdown 0 244 1 154 6 2 Platen and Above Parts Breakdown 0000 155 6 3 Right Side Parts Breakdown 156 6 4 Inner Platen Parts Breakdown 157 6 5 Carrier Assembly Parts Breakdown 1 044 444204 0 0 158 6 6 Power Feed and Take Up Parts Breakdown 159 15 Novajet PROe Series Service Manual List of Tables Table Page Chapter 1 General Description Chapter 2 Theory of Operation Chapt
7. atur 41 Chapter Maintenance 43 ied 43 Scheduled Maintenance ai 43 Cleaning Procedures 040 0441 1 AARTEEN nnns nennen 44 External GIA MING cs uuu citet 44 Slide Shaft Cleaning 44 Novajet PROe Series Service Manual Table of Contents cont Chapter 3 Maintenance cont Service Station Cleaning esses 45 Linear Encoder Strip 46 Cartridge Dimples nnn 47 Flex Cable Contact Cleaning irre 48 Clean and Inspect Stepper Motor Gears n 48 Cleanand Inspect MPO B erii axi 49 Clean and Inspect Carrier Assembly sss 49 Reseat Connectors on MPCB and Carrier Board 50 Replace Carrier 52 Servo Motor Winding Resistance 53 Stepper Motor Winding Resistance 54 Power Feed and Take Up Motor Winding Resistance 55 Banding Hardware vs Software 2 56
8. Use only isopropyl alcohol on the slide shaft of the printer Damage to the stainless steel slide shaft may result if cleaned with water and not completely dried off 44 Maintenance Novajet PROe Series Service Manual Printer problems can be caused by an accumulation of dirt or other contamination on the slide shaft This contamination may lead to drag on the carrier Extreme drag results in a carrier axis failure fault and will stop the carrier motion These problems may be eliminated by maintaining and deaning the slide shaft at intervals determined by the environmental conditions Do not use any lubrication To dean the slide shaft 1 Turn the printer OFF and remove the power cord 2 Raisethe printer lid 3 Moisten a clean cloth or paper wipe with isopropyl alcohol 4 Wipethelength of the slide shaft with the moistened doth or wipe 5 Manually movethe carrier assembly from side to side z gt Z 9 m 6 Wipethe shaft again to remove any deposits left from the carrier 7 Close the cover and reconnect the power cord turn the printer ON and perform the PRIME plot Besurethat the carrier moves freely on the slide shaft Service Station Cleaning Ink and dust may build up on the service station resulting in contamination which may smear the prints The service station is deaned as follows 1 Turn the printer OFF Disconnect the power and interface cable 2 Raisethe prin
9. w lt 2 Perform steps 2 through 6 of the Remove the Ink Delivery System procedures to remove the Ink Delivery System 3 Perform the Remove the Carrier Assembly Carrier Belt and the Frame Tensioner procedures to remove the Carrier Assembly from the Slide Shaft Assembly Disassembly 135 Novajet PROe Series Service Manual 4 Perform steps 3 and 4 of the Remove the Trailing Cable Assembly procedures to remove the Trailing Cable Assembly 5 Perform steps 5 and 6 of the Remove the Stabilizer Bracket and Encoder Strip procedures to remove the Stabilizer Bracket Assembly 6 Disconnect the Load Sensor connector at the J 4 location on the MPCB Grasp the Load Sensor connector with the thumb and forefinger and pull straight out 7 Remove the seven screws that secures the Y Arm Assembly to the Platen See Figure 5 22 Figure 5 22 Y Arm Installation R emoval 8 The pinch rollers are held on by a small C damp located on the back of the Y Arm Assembly See Figure 5 23 While holding the pinch roller remove the C damp and move the pinch roller towards the front of the Y Arm Assembly until it dears the back of the Y Arm Bracket 136 Assembly Disassembly Novajet PROe Series Service Manual Figure 5 23 Pinch Roller 9 Spin the back of the pinch roller to either side and remove the back spring 10 Carefully tilt the back of the pinch roller upwards This brings the front of the pinch roller down away from
10. Chapter 4 Troubleshooting Chapter 5 Assembly Disassembly 14 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 10 5 11 5 12 Right Cover Assembly Removal Installation 2 97 Left Cover Assembly Removay Installation 98 Keypad and Display Removal Installation 101 Keypad Grounding Connection 2 2 102 Extra Memory SIMM Removal Installation eese 103 MPCB REMOVAL Free 106 Power Supply B moVval cutee iced tpe coo fere ideas zov cd Pao de SES Rada 109 Cooling Fan AC Entry Module 110 Slacken Carrier TNT ER he 112 Electronics Cover Removal nne 115 Disconnect Ink Delivery System 116 Strain Relief Removal Installation 2 118 Novajet PROe Series Service Manual List of Illustrations cont Figure Page Chapter 5 Assembly Disassembly cont 5213 8 uua 119 5 14 Carrier Belt Clamp 119 5 15 Carrier PCB Removal Installation 123 5 16 Paper and Encoder Sensor Removal sees 125 5 17 Paper and Encoder Sensor
11. Novajet PROe Series Service Manual 13 Connect the Power Supply connector to J 15 on the MPCB 14 Reinstall any additional memory into J 17 by performing steps 1 and 2 of the Install Extra Memory SIMM procedure 15 Perform steps 4 through 10 of the Install the Left Top and Right Covers procedure to install the Right and Top Covers Remove Power Supply Cooling Fan and AC Entry Module 1 Perform steps 1 through 9 of the Remove the Left Top and Right Covers procedure to remove the Top and Right Covers 2 Perform steps 3 through 15 of the Remove the MPCB Main Printed Circuit Board procedure to remove and protect the MPCB 3 Reach between the Power Supply Bracket and the AC Entry Module and carefully pull out the quick disconnect assembly attaching the Power Supply input to the AC Entry Module Disconnect the Power Supply input from the AC Entry Module 4 Disconnec the dip securing the power supply wires to the top of the support bracket 5 While holding the Power Supply in place remove the four screws securing it to the Power Supply Bracket See Figure 5 7 6 Slide the Power Supply out of the Power Supply Bracket 108 Assembly Disassembly Novajet PROe Series Service Manual Figure 5 7 Power Supply Removal To remove the Cooling Fan and AC Entry Module 7 Using a 2 Phillips screwdriver remove the four screws located below the Right Baseplate securing the Power Supply Bracket to the Right Baseplate
12. scheduled maintenance 43 service station 45 129 signal flow 76 specifications 21 T technical support ENCAD BBS 24 ENCAD website 24 help desk FAX 24 telephone 24 test carriage 72 color 72 162 continuous 72 fan 73 legs 73 loopback 73 parallel port 73 serial port 73 servo cycle 72 servo PWM 72 tools required 95 trailing cable 131 troubleshooting 81 banding 87 degraded line quality 90 does not print 85 fan not operating 91 faulty keypad 88 ink cartridge failure 85 internal error auto sensor failure 84 carriage axis failure 83 encoder sensor failure 84 MPCB failure 85 paper sensor failure 84 trailing cable failure 85 media both motors inoperative 92 feed motor inoperative 92 sensor inoperative 93 take up motor inoperative 91 media does not move 82 no power 81 noisy operation 89 paper skewing 87 vacuum fan 139 W warnings 20
13. 207615 6 5 3 CARRIER PCB tice 207469 6 5 4 STRAIN RELIEF 208276 6 5 5 ENCODER SENSOR W FLEX 206823 6 5 6 PAPER SENSOR W FLEX 207095 6 5 7 CARRIER BUSHING 207961 6 5 8 CARRIER FRAME ASSY 207527 6 6 1 GUIDE PAPER ADJUSTABLE 207644 6 6 2 CLAMP GUIDE PAPER 207659 6 6 3 CRADLE IDLER 207667 6 6 4 GEAR MOTOR DRIVE 207666 6 6 5 MOTOR DRIVE rines 207767 6 6 BRACKET ASSY SENSOR 207656 6 6 7 BRACKET ASSY SENSOR 207752 6 6 8 SENSOR ASSEMBLY 207727 6 6 9 HARNESS WIRING LEG DRIVE 207731 6 6 10 ASSEMBLY DRYER 207725 6 6 11 FILTER DRYER FAN 207729 HARDWARE eret 208810 LOOPBACK TEST CABLE 205462A J TAG ADAPTER ieri nnne 209219 U gt X o Parts List 153 Figure 6 1 Left Side Parts Breakdown Novajet PROe Series Service Manual U gt wn Figure 6 2 Platen and Above Parts Breakdown Parts List 155 Figure 6 3 Right Side Parts Breakdown Novajet PROe Series Service Manual PARTS LIST Inner Platen Parts Breakdown Figure 6 4 157 Parts List Figure 6 5 Carrier Assembly Parts Breakdown Novajet PROe Series Service Manual
14. 0 85 Paper SKEWING 87 Printer Output is Banding 1 87 Keypad Locked Up or Not Functioning 88 NOISY Operation susrusa eter etna beg tu ced qat La or ete 89 Line Quality Degraded rue a a ca esit undo 90 Fan Does Not Power ener nennen nnn nens snnt nnns sens 91 Media Take Up Motor Not Operating Sensor 91 Media Feed Motor Not Operating Sensor 92 Media Feed and Take Up Motors Not Operating Both Sensors Working 92 Media Feed or Take Up Sensor s 93 Chapter 5 Assembly Disassembly 95 PR aa 95 Remove the Left and Right Covers 96 Install the Left Top and Right Covers 99 Remove the Keypad Display and Display Power Converter 100 Install the Keypad Display and Display Power Converter 102 Remove Extra Memory SIMM ener entr
15. 3 Attach the Keypad grounding flex cable to the cover standoff as shown in Figure 5 4 4 Secure the Display Power Converter onto the Display standoffs using four kepnuts with a 1 4 socket or wrench Torque to 6 in Ibs 102 Assembly Disassembly Novajet PROe Series Service Manual Remove Extra Memory SIMM Integrated circuits may become weakened or dam aged by electrical discharge Do not touch or work near integrated circuits without wearing an ESD wrist strap 1 Perform steps 1 through 9 of the Remove the Left Top and Right Covers procedure to remove the Top and Right Covers KIGINASSV Figure 5 5 Extra Memory SIMM Installation Removal g o gt o lt 2 The SIMM slots are at a 90 angle from the main circuit board Facing the top of the SIMM push the side clips gently to the outside away from the SIMM then push the top of the SIMM module towards the left side of the printer until the SIMM becomes free of the side clips Lift up and pull the SIMM out being careful not to damage the fingers on the top See Figure 5 5 Assembly Disassembly 103 Novajet PROe Series Service Manual Install Extra Memory SIMM NOTE If you are installing two SIMM you must install the one located in J 17 first See Figure 3 4 for location The SIMM slots at 90 angle from the board Place the SIMM at a 45 into the connector as shown in Figure 5 5 2 Slowly push the SIMM up
16. 9 Slide the Carrier Assembly and Drive Belt off the left side of the Slide Shaft 10 Once the Carrier Assembly is removed from the Slide Shaft turn it over so that you can see the Belt Clamp See Figure 5 14 NKIGINASSV gt 2 7 m w lt Figure 5 14 Carrier Belt Clamp Assembly Disassembly 119 Novajet PROe Series Service Manual 11 To disengage the Carrier Belt from the Belt Clamp push the Carrier Belt away from the left post of the Belt Clamp and gently lift up until the bottom edge of the Carrier Belt dears the top of the left post 12 Push the Carrier Belt away from the right post of the Belt Clamp and gently lift up to finish removing the Carrier Belt from the Belt Clamp Failure to use an approved antistatic bag for storage or shipment may cause damage to the MPCB and af fec the Warranty 13 Placethe Carrier Assembly in an ESD antistatic bag in preparation for shipment to ENCAD for replacement or repair or if it is to be stored for repair at your facility Install the Carrier Assembly Carrier Belt and the Frame Tensioner 1 Toinstall the Belt onto the Carrier Assembly the bumps on the belt where the ends of the belt are joined together to make the belt continuous must be positioned between the left and right posts of the Belt Clamp See Figure 5 14 2 Slide the Carrier Belt between the right post and the middle post and guide it down into the Belt Clamp Then slide the
17. Reattach all flex cables on the Carrier PCB 5 Perform the Install the Carrier Assembly Carrier Belt and the Frame Tensioner procedures to reinstall the Carrier Assembly Remove the Paper Sensor or the Encoder Sensor 1 Perform the Remove the Carrier Assembly Carrier Belt and the Frame Tensioner procedures to remove the Carrier Assembly from the Slide Shaft 124 Assembly Disassembly Novajet PROe Series Service Manual Figure 5 16 Paper and Encoder Sensor Removal 2 To remove the Paper Sensor a Unlock the connector at 3 and remove the flex cable b Turn the Carrier Assembly over and hold it while firmly grasping the Paper Sensor between thumb and index finger See Figure 5 16 IN EI EET C Pull straight up on the Paper Sensor and remove it from the Carrier Assembly g o gt 7 o lt 3 To remove the Encoder Sensor a Unlock the connector at J 2 and remove the flex cable b Turn the Carrier Assembly over and lay it with the top side facing down Assembly Disassembly 125 Novajet PROe Series Service Manual c Push down on the plastic clip and at the same time push down on the Encoder until the plastic pieces on each side of the Encoder dear the ridges which hold it in place Then pull it straight out See Figure 5 8 Install the Paper Sensor or the Encoder Sensor Figure 5 17 Paper and Encoder Sensor Installation 1 Toinstall the Paper Sens
18. Right Covers procedure to install the Right and Top Covers Remove the Ink Delivery System 1 Perform steps 1 through 3 and 10 through 13 of the Remove the Left Top and Right Covers procedures to remove the Top and Left Covers NOTE The Foam Chain Shelf being removed in step 2 is only on the PRO 60e printers Remove the Foam Chain Shelf located inside the rear support bracket Move the Carrier to the center of the Slide Shaft 114 Assembly Disassembly Novajet PROe Series Service Manual Figure 5 10 Electronics Cover Removal With a flathead screwdriver press the Electronics Cover p o the Ink Delivery System tab located in the upper slot on the left side of the Carrier Assembly See Figure 5 10 Lift up on the front left side of the Electronics Cover until it comes part way off of the Carrier Assembly Then lift up on the front right side of the Electronics Cover and move the Electronics Cover slightly to the left so that the back of it dears the Back Support Bracket gt 7 m w lt 1419 3557 Assembly Disassembly 115 Novajet PROe Series Service Manual Figure 5 11 Disconnect Ink Delivery System Link NOTE The last link of the Ink Delivery System linkage is a special link and is to remain as part of the Left Sideplate Assembly It is mounted to the Sideplate Assembly and will not be delivered as part of the Ink Delivery System 5 Disconnect the last link of the Ink deliv
19. Carrier Belt between the left post and the middle post and finish placing the Carrier Belt into the Belt Clamp 3 Check the position of the Carrier Belt to make sure it matches Figure 5 14 4 Make sure the left end of the Trailing Cable extends out beyond the left end of the Trailing Cable Support Assembly 120 Assembly Disassembly Novajet PROe Series Service Manual 5 Slide the Carrier Assembly onto the left end of the Slide Shaft making sure that the Encoder Strip fits into the slot in the Slider and the Encoder on the Carrier PCB Guide the belt while sliding the Carrier Assembly from left to right on the Slide Shaft 6 Move the Carrier Assembly to the left end of the Slide Shaft and align the left bushing on the Carrier Assembly with the left end of the Slide Shaft 7 Insert the Strain Relief with Trailing Cable onto the Carrier Assembly by sliding it onto the Strain Relief Support until it snaps firmly into place See Figure 5 13 8 Placethe Trailing Cable into the J 1 connector lock on the Carrier PCB Make sure the silver fingers on the Trailing Cable are fully inserted into the lock and slide both sides of the connector lock shut at the same time 9 Place the right side of the back of the Electronics Cover under the Trailing Cable Support Assembly and gently press down on the ends of the Electronics Cover until the latches snap into the Carrier Assembly 10 Slide the Carrier Assembly to about the middle of the
20. INTERFERENCE FOR CLASS B DEVICE This equipment has been tested and found to comply with the limits for a class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interfer ence to radio communications User Instructions If the equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Consult the dealer or an experienced radio TV technician for help Changes or modifications not expressly approved by ENCAD Inc could void the user s authority to operate the equipment Novajet PROe Series Service Manual VDE Statement Hiermit wird bescheinigt da der NOVAJET PROe in bereinstimmung mit den Bestimmungen der BMPT AmstbIVfg 234 1991 funkentst rt ist Der vorschriftsm Bige Betrieb mancher Ger te z B MeBsender kann allerdings gewissen Einschr nkungen unterliegen Be
21. Micrometer 58 Measurement Positions for Slide Shaft 2 58 Slide Shaft Profile 400000 59 Carrier Head Height Tolerance 60 Setting Up Tools from Height Gauge 61 Zeroing the Micrometer Gauge ssssssssseeeeeeeeeeen nennen 61 13 Novajet PROe Series Service Manual List of Illustrations cont Figure Page Chapter 3 Maintenance cont 3 17 3 18 3 19 3 20 3 21 3 22 3 23 3 24 3 25 3 26 3 27 3 28 3 29 3 30 3 31 3 32 3 33 est Cartridge Installed iR i ea coe eat 62 Color 64 tility 65 Color Calib Men s 000 65 Gyan Vertical Options Menu iioc nates iit etas irte kid tuae aaa 66 Deadband Slow FaSt prenistri ani aeaiee aeaa aiani a 66 MENU E 67 Calibration Deadband 2 0 1000 0000 68 70 gig iH ri 70 Diagnostics up 71 Accessory Menu m 72 NVRAM Clear and Clock Reset Menu semen 74 Tag Connection on 75 MPCB Connections Diagram reno ren tentent annie die 77 Carrier PCB Connections 78 Leg Harness Connections Diagram ssiri naa 79
22. Remove the Trailing Cable Assembly 2 4 2 00 000 0 00 nnne 131 Install the Trailing Cable 132 Remove the Stabilizer Bracket and Encoder 133 Install the Stabilizer Bracket and Encoder 135 Remove the Y Arm Assembly Pinch Rollers Slide Shaft and Auto Load Sensor 135 Install the Y Arm Assembly Pinch Rollers Slide Shaft and Auto Load Sensor 137 Remove the Lower Roller Assembly Stepper Motor and Vacuum Fan 139 Install the Lower Roller Assembly Stepper Motor and Vacuum Fan 142 Remove the Media Take Up and Feed Sensor Brackets and Sensors 145 Install the Media Take Up and Feed Sensor Brackets and Sensors 146 Remove the Media Take Up and Feed 147 Install the Media Take Up and Feed Motors 2 148 Remove the Media Drying eene nennen nnns 149 Install the Media Drying Fans enne 150 Chapter 6 Parts LISU 151 NE DD DONI TIR 161 12 Novajet PROe Series Service Manual List of Illustrations Figure Page Chapter 1 General Description 1 1 Novajet PROe Series Inkjet Printers 17 Chapter 2 Theory of Operation 2 1 General Bloc
23. This additional step requires a special Tag Adapter to be placed between the parallel cable and 16 on the printer s It is a required step that allows some registers and DRAM to be written to allowing a normal firmware reload or upgrade to commence To bring the printer out of a braindead condition 1 Removethe Right Cover completely to connect theJ Tag Adapter see Chapter 5 for removal and installation procedures for the Right Cover See Figure 3 30 for location of J 16 E z m gt Z 9 m n Lr n 45 eee n Oooo a LIE NU e LX a Q 200 OO a 00 00 a d n Figure 3 30 J Tag Connection on MPCB 2 After connecting the Tag Adapter between the parallel port on the computer and J 16 on the MPCB power up the printer Maintenance 75 3 Atthe computer type GO ROMIMAGE from the directory that contains the GO EXE and ROMIMAGE files 4 In about 15 60 seconds a single beep will be heard from the printer to signify a good transfer of data If a beep is not heard cycle the power on the printer and send the file again 5 Turn the printer off disconnect theJ Tag Adapter and reinstall the Right Cover 6 Turn the printer on and continue with a normal firmware reload or upgrade by connecting the computer to the parallel p
24. a misfiring of the cartridge NOTE Care should be used when handling the cartridges Avoid touching the cartridges on the dimple area or on the inkjet holes on the bottom The oils and dirt fingers and hands can contaminate the area and re sult in misfiring of the inkjets Clean the cartridge dimple area by gently dabbing the area with a lint free cloth or cotton swab saturated with isopropyl alcohol Maintenance 47 Novajet PROe Series Service Manual Flex Cable Contact Cleaning Figure 3 3 Flex Cable Contacts Cleaning the flex cable contact area is very important due to the ease of which this area can become dirty This also causes the cartridges to not receive all of the electrical signals for a proper firing of the jets This can be seen as a misfiring of the cartridge NOTE Care should be used when handling the flex cable con tact area Avoid touching the contact area because the oils on your skin can contaminate the area and result in misfiring of the inkjets Clean the flex cable contacts by gently dabbing the area with a cotton swab soaked with isopropyl alcohol Clean and Inspect Stepper Motor Gears The stepper motor gears can become dirty and after time if not deaned up it could cause wide banding in the print This will 48 Maintenance Novajet PROe Series Service Manual reduce the quality of the intended output Clean the motor gears with a stiff brush to knock off any debris A cotton swab s
25. connector to the leg harness plug Push connector in until firmly seated 150 Assembly Disassembly Parts List 6 This chapter lists the items and their associated numbers for the parts and assemblies of the Novajet PROe series printers that are field replaceable The list is in order of part name as identified in the assembly disassembly chapter This list is to be used in conjunction with the assembly disassembl y procedures to aquire the necessary parts and properly install them into the printer The parts and asssemblies may be ordered through your local autho rized dealer ENCAD Inc s Technical Support and Service department FIGURE ITEM PART NAME PART 6 1 1 COVER LEPET ient ter rete 208229 6 1 2 RESERVIOR ASSEMBLY 207616 6 1 3 CAP RESERVIOR iicet eniti 207562 6 1 4 INK DELIVERY SYSTEM 690e 207613 1 INK DELIVERY SYSTEM 42e 207613 2 6 1 5 208231 6 2 1 COVER ASSY TOP 0 207787 1 COVER ASSY TOP 42 207787 2 6 2 2 TRAILING CABLE ASSY 60e 207573 TRAILING CABLE ASSY 42e 207584 6 2 3 STABILIZER ASSY WITH TRAILING CABLE AND ENCODER STRIP 209070 209069 U gt o 151 FIGURE ITEM 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 3 6 3 6 3 6 3 6 3 6 3 6 3 6 4 6 4 6 4
26. for shipment to ENCAD for replacement or repair or if it is to be stored at your facility for repair 106 Assembly Disassembly Novajet PROe Series Service Manual Install the MPCB Integrated circuits may become weakened or damaged by electrical discharge Do not touch or work near integrated circuits without wearing an ESD wrist strap 1 Puton an ESD wrist strap 2 Remove the MPCB from the ESD bag 3 Align the MPCB so that the serial and parallel connections protrude out of the back of the printer and that the screw holes are aligned to the holes on the power supply bracket 4 Using a 2 Phillips Torque Screwdriver fasten the MPCB tothe power supply bracket with 8 in Ib of torque Ensure that the ground straps from the side plate and baseplate are secured to the MPCB by the screw located beside the side plate nearest to the parallel port 5 Connect the Power Supply Cooling Fan connector to J 8 on the MPCB 6 Connect and lock the Trailing Cable connector to J 7 on the MPCB 7 Connect the Vacuum Fan 2 PRO 60e only connector to J 6 on the MPCB g o gt o lt NKIGINASSV 8 Connect the Vacuum Fan 1 connector to J 5 on the MPCB 9 Connect the Load Sensor connector to J 4 on the MPCB 10 Connect the Leg Harness connector to J 3 on the MPCB 11 Connect the Servo Motor connector to 2 on the MPCB 12 Connect the Stepper Motor connector to J 1 on the MPCB Assembly Disassembly 107
27. in the Service Menu as shown in Figure 3 29 Press the lower left button in the Service Menu to bring up the Code Menu The code to be entered to bring up the hidden menu is 16753 Maintenance 73 Figure 3 29 NVRAM Clear and Clock Reset Menu This menu allows the technician to clear the NVRAM and to reset the system clock Clear NVRAM Clearing the NVRAM is required anytime that a MPCB is to be permanently removed from a printer The NVRAM is a section of nonvolatile memory that stores printer size informa tion The MPCB is the identical for both printers but it will have to learn which size printer it is installed in Clearing the NVRAM allows the MPCB to relearn which size printer it is reinstalled into Clock Reset Resets the system clock to 000 This procedure should only be accomplished when refurbishing a MPCB and installing it into another printer Novajet PROe Series Service Manual Firmware Downloading The normal method of downloading new firmware is to send the printer a data file of the new code This requires using an appro priate host utility called go exe This must be done through the parallel port using a IEEE standard 1284 parallel cable This method requires code to be running in the printer to interpret the fileas it is sent If the EEPROM is blank or corrupt so that the printer does not properly initialize braindead there is an additional step to download firmware to the printer
28. in Ibs and two located under the baseplate torque to 8 in lbs 3 Reinstall the ink reservoirs and reservoir door To install the Right Cover Assembly 4 Position and hold the Right Cover Assembly over the Right Baseplate and reconnect the Display Power Converter cable to J 10 on the MPCB 5 Reconnect the Display data ribbon cable to J 12 on the MPCB 6 Reconnect the Keypad flex cable to J 13 on the MPCB Orient the side of the flex cable labeled 1 to pin 1 the MPCB g o o lt NKIGINASSV 7 While depressing the retracting stop assembly on the Support Bracket lower the Right Cover Assembly into position onto the Right Baseplate Release the retracting stop assembly Assembly Disassembly 99 Novajet PROe Series Service Manual Applying too much torque to the lower screws can cause the mounts for the standoffs on the cover to break requiring a replacement of the cover 8 Using a 2 Phillips screwdriver secure the Right Cover with two screws located on the left side torque to 15 in Ibs and three located under the baseplate torque to 8 in lbs To install the Top Cover 9 Insert the pin located on the right side of the Top Cover into the corresponding hole on the Right Cover Assembly 10 While depressing the retracting stop assembly on the left side of the Top Cover lower the left side of the Top Cover into position and secure it to the Left Cover Assembly by releasi
29. m OO strip Strip Cleaning procedure 5 o damaged replace encoder encoder strip strip bad encoder replace encoder sensor sensor worn carrier replace carrier bushings bushings loosetrailing remove power and cable connections reseat trailing cable connections at the MPCB and the carrier assembly Troubleshooting 83 Novajet PROe Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Internal ERROR cutter assembly replace cutter Carriage Axis malfunction assembly Failure cont damaged carrier 1 check idler drive belt system tension assembly 2 check carrier belt Internal ERROR Encoder Sensor Failure encoder sensor reseat encoder cable unseated sensor cable bad encoder replace encoder sensor sensor Internal ERROR Paper Sensor Failure paper sensor reseat paper cable unseated sensor cable bad paper replace paper sensor sensor Internal ERROR Auto Sensor Failure auto sensor reseat auto cable unseated sensor cable bad auto replace auto sensor sensor 84 Troubleshooting Novajet PROe Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Internal ERROR Trailing Cable Failure Internal ERROR MPCB Failure Does Not Print Ink Cartridge Misfiring trailing cable cable unseated bad paper sensor bad MPCB bad connection between computer and printer firmware is corrupted ba
30. necessary to correctly accomplish this adjustment Color Calibration This procedure describes how to check that the cartridges are properly aligned for color plotting and should be followed each time the ink cartridges installed Figure 3 18 is a representation of how a color calibration looks when printed Maintenance 63 1 wd Mo Wo Wo Wo Wd d d d M Figure 3 18 Color Calibration The Current Heads Y M C view represents the alignment of the heads as they are currently entered This is just an overview of all heads and how they are aligned Do not attempt to align the heads using this view The Color Horizontal H ead to H ead Calibration checks the align ment of the nozzles horizontally and allows corrections when re quired J ust enter the value below the set of lines that are correctly aligned Be careful that you are aligning the correct color by observ ing the C cyan M magenta and Y yellow on the right side of the plot The Color Vertical H ead to H ead Calibration checks the alignment of the nozzles vertically and allows corrections when required J ust enter the value below the set of lines that are correctly aligned Be careful that you are aligning the correct color by observing the C cyan M mage
31. of Operation 27 Novajet PROe Series Service Manual The Carrier Axis Drive 28 ENCODER STRIP T P TENSIONING BELT SERVO 7 ASSY MOTOR Figure 2 3 Carrier Axis Drive The Carrier Axis Drive moves the printer s carrier assembly along the length of the printer The drive consists of a servo motor linear encoder strip drive belt and tensioning assembly These items are illustrated in figure 2 3 The servo motor drive belt and tensioning assembly are the compo nents that actually drive the carrier assembly The servo motor drives the belt back and forth allowing the attached carrier assembly to be repositioned as required The tensioning assembly is spring controlled and allows the proper amount of tension on the belt linear optical encoder strip is used to obtain the printers accu racy along the axis of the printer It is made with 150 parallel lines per inch etched into it By utilizing two optical encoder sensors that are slightly off set from each other and reading the leading and trailing edges of the lines a resolution of 600 dpi can be obtained The stepper and servo motors are controlled from the main printed circuit assembly by the microprocessor Theory of Operation Novajet PROe Series Service
32. personnel of specific details to improve quality to give reminders of interrelated parts and to provide other helpful information They are indicated by NOTE Followed by a paragraph describing the concern General Description Printer Specifications The specifications and performance characteristics of the Novajet PROe Color Inkjet Printers are as follows Max Printing Area PRO 42e PRO 60e Norm 40 8 58 8 104 1 49m Extend 41 61 59 61 1 06m 1 51m Language Emulation HP RTL ENCAD RTL Buffer 8 MB installed upgradeable to 16 32 and 64 MB Power Requirements Input Voltage 90 246 VAC 47 63 Hz Output Power 20 W idle 140 W typical 215 W maximum Baud Rates 9600 19200 38400 115200 Resolution Mono 300x300 dpi Color 300x300 dpi Novajet PROe Series Service Manual WHANAD Accuracy 0 2 line length with ROLL mode off m D U m z Interface Centronics parallel IEEE 1284 RS 422 serial Network Option via 10BaseT 10Base2 Print Server Environment Operating 59 to 95 F 15 to 35 C 10 to 70 RH non condensing Storage 5 to 140 F 21 to 60 C 5 to 80 RH non condensing Dimensions Height 44 1 12m Width 77 1 96m PRO 42e 95 2 41m PRO 60e Depth 28 0 71m General Description 21 Novajet PROe Series Service Manual Contents of this Service Manual 22 Figures are used in this manual to clarify pro
33. rotating the servo motor monitor the readings on the meter The acceptable range is 25 40 ohms Typically the readingis 29 36 ohms 5 If the measurement is found to be unsatisfactory replace the motor 6 Performthe same procedure on the remaining motor Maintenance 55 Novajet PROe Series Service Manual Banding Hardware vs Software 56 The technician must be able to identify whether the banding that is being observed is related to either a hardware or a software problem The two examples in Figure 3 10 represent classic types of hardware and software banding errors HARDWARE SOFTWARE Figure 3 10 Examples of Banding Hardware banding is usually characterized by consistent banding strips as shown It signifies a slippage in the media s normal move ment that is possibly due to the stepper motor lower drive shaft assembly or the rollguides on the back of the printer All these possible faulty areas deal with a rotational movement that if faulty will generate a consistent banding pattern The MPCB and Carrier PCB can also causethis type of error toincur Software banding is characterized by inconsistent banding lines These banding lines are generated by the software when incorrectly interpreting the paper advancing ink firing sequence of the expected print file Because it is not directly tied to a mechanical movement the bands become inconsistent in both frequency and duration The possible causes are the printer d
34. test Figure 3 24 Calibration Deadband Menu 5 When the plot is complete select Deadband at the Calibration Menu This brings up the options menu for the fast deadband adjustment This menu is similiar to the menu depicted in Figure 3 21 NO TE The values for thefast deadband adjustment is equivalent to 300 sections per inch For every incremented value the print will move 1 300 of an inch Positive values movethe middle seg ment to the right while more negative values move the middle segment to the left 6 Observe the plot and using either Prev Option or Next Option rotate through the selections until one that seems doser to the correct valueis selected Press Ok to accept the selection and return to the Service Menu 7 8 10 11 Paper Axis Calibration The paper axis calibration procedure ensures that the processing Novajet PROe Series Service Manual Continue performing steps 4 through 6 until the fast deadband adjustment is correct At the Calibration Menu select Slow Db Test to run the slow deadband test When the plot is complete select Slow Deadband at the Service Menu This brings up the options menu for the slow deadband adjustment This menu is similiar to the menu depicted in Figure 3 21 Observe the plot and using either Prev Option or Next Option rotate through the selections until one that seems closer to the correct value is selected Press Ok to accept the sel
35. the bottom of the Platen that holds the Vacuum Fan in place using a 32 Phillips screwdriver Do not allow the screws to come out at an angle Figure 5 24 Inner Platen Assembly Disassembly 140 Assembly Disassembly Novajet PROe Series Service Manual 9 Using a 1 Phillips screwdriver remove the black flat head screws from the top of the Platen that holds the left and right Drive Shaft Supports in place It may be necessary to loosen do not remove the screws that secure the Y Arm Assembly to the Platen so that the Lower Drive Roller Assembly clears the ends of the screws that protrude inside of the Platen when removing the Lower Drive Roller Assembly It may be necessary to loosen do not remove the screws that securetheleft L eg Assembly to the Platen so that the Lower Drive Roller Assembly clears the ends of the screws that protrude inside of the Platen when removing the Lower Drive Roller Assembly TheFan Assemblies will be removed at the same time that the Lower Drive Roller Assembly is removed Exercise extreme care that the fan assemblies do not drop out of the Platen when removing the Lower Drive Roller Assembly g o gt o lt KIGINASSV 10 Carefully slide the Lower Drive Roller Assembly and the Fan Assemblies out of the left side of the Platen Assembly Disassembly 141 Novajet PROe Series Service Manual 11 Remove the Stepper Motor Extension Spring
36. the PWM Pulse Width Modulation waveforms for the servo controller The gate array is a Xilinx device It is a static RAM based field programmable gate array This means that the logicthat it imple ments is determined by configuration information in internal RAM storage Each time power is turned on this information must be downloaded from the system ROM This type of gate array allows for the flexibility of upgrading the logic by simply downloading the new system software Memory Circuits Memory is used to retain large amounts of information This infor mation is stored in the device memory in the form of binary bits Printer memory consists of Flash EEPROM DRAM and EEPROM Maximum installable memory is as follows DRAM 132 Flash EEPROM 1 Serial EEPROM Flash EEPROM Flash EEPROM is Electrically Erasable Programmable Read Only M emory used to store instructions and data constants which the microprocessor can access and interpret with noloss of information when power is off The system firmware is stored in Flash EEPROM The Flash EEPROM allows the firmware to be upgraded by simply downloading a file containing the new firmware It can be erased and repro grammed more than 10 000 times The term Flash means that bytes cannot be individually erased A block or the whole device is erased at the same time and the block or whole device is then repro grammed Theory of Operation Novajet PROe Series Ser
37. the Slide Shaft Release the spring and verify that the spring enters the hole in the Slide Shaft and that no kinks are present in the spring Perform steps 4 and 5 for all pinch rollers Using a 2 Phillips screwdriver secure the Y Arm Assembly to the Platen using seven screws Torque to 15 in lbs Perform the Install the Stabilizer Bracket and Encoder Strip procedures to install the Stabilizer Bracket and Encoder Strip Perform the Install the Carrier Assembly Carrier Belt and the Frame Tensioner Procedures to install the Carrier Assembly Carrier Belt and the Frame Tensioner Perform the Install the Trailing Cable Assembly procedures to install the Trailing Cable Assembly Perform the Install the Ink Delivery System procedures to install the Ink Delivery System Perform the Install the Left Top and Right Covers procedures to install the Left Top and Right Covers Perform the Head Height Adjustment procedures found in Chapter 3 of this service manual Assembly Disassembly Novajet PROe Series Service Manual Remove the Lower Roller Assembly Stepper Motor and Vacuum Fan The Inner Platen contains the Lower Drive Roller Assembly the Vacuum Fan Assembly the Stepper Motor Assembly Drive Shaft Supports and the Foam Block These parts are collectively referred to as the Inner Platen Parts NOTE The removal of the Lower Drive Roller Assembly and Vacuum Fan s is easier if extracted out of the left side of the Plat
38. the Stabilizer Bracket g o gt o lt 5 Remove the ferrite and the tape securing it to the Trailing Cable Assembly Disassembly 131 Novajet PROe Series Service Manual Install the Trailing Cable Assembly 1 Apply two new pieces of double sided tape to the Stabilizer Bracket Ensure that the tape is in the same location as the original tape was Theright side of theTrailing Cable the side connected to the MPCB must extend beyond the Stabilizer Bracket by 5 4 7 8 5 1 8 or 128mm 125mm 131mm 2 Slip the ferrite around the Trailing Cable and insert the right side of the Trailing Cable Assembly through the access hole provided in the Right Side plate 3 Slide the Carrier Assembly if installed to the far left side of the Slide Shaft While ensuring a 5 125mm overhang on the right side position the Trailing Cable over the Stabilizer Bracket and slowly lower it onto the bracket Ensure that the Trailing Cable goes on straight and that there are no buckles in the cable Firmly press the Trailing Cable Assembly onto the tape to secure it into position 4 Connect the right end to the MPCB at theJ 6 location 5 Tape the ferrite to the Trailing Cable approximately 1 4 6mm from the left side of the side plate 6 If the Carrier Assembly is not installed perform steps 5 through 18 of the Install the Carrier Assembly Carrier Belt and the Frame Tensioner procedures 132 Assembly Di
39. to a 90 angle until the two side clips snap into place Make sure the SIMM is fully seated 3 Perform steps 4 through 10 of the Install the Left Top and Right Covers procedure to install the Right and Top Covers Remove the MPCB Main Printed Circuit Board Integrated circuits may become weakened or damaged by electrical discharge Do not touch or work near integrated circuits without wearing an ESD wrist strap l Perform steps 1 through 9 of the Remove the Left Top and Right Covers procedure to remove the Top and Right Covers 2 Puton an ESD wrist strap 3 Perform step 2 of the Remove Extra Memory SIMM procedure to remove any memory that was added 4 Disconnect the Power Supply connection at the J 15 location by grasping the Power Supply connector with thumb and forefinger and pulling straight out See Figure 3 4 for jack locations 104 Assembly Disassembly Novajet PROe Series Service Manual 5 Disconnect the Stepper Motor connection at the J 1 location by grasping the Stepper Motor connector with thumb and forefinger and pulling straight out 6 Disconnect the Servo Motor connection red and blue wires at the J 2 location by grasping the Servo Motor connector with thumb and forefinger and pulling straight out 7 Disconnect the Leg Harness connection at the J location by grasping the Leg Harness connector with thumb and forefinger and pulling straight out 8 Disconnect the Load Sensor connection at th
40. 1 Disconnect the servo motor connection from the MPCB 2 Usinga standard ohmmeter or multimeter connect the meter leads to the two wires going to the motor 3 While manually rotating the servo motor monitor the readings on the meter The acceptable range is 6 30 ohms Typically the reading is 7 11 ohms 5 If the measurement is found to be unsatisfactory replace the servo motor Maintenance 53 Novajet PROe Series Service Manual Stepper Motor Winding Resistance Check Figure 3 8 Stepper Motor 1 Disconnect the stepper motor connection from the MPCB 2 Usinga standard ohmmeter or multi meter measure between pins 1 red wire and 3 3 Thereading should indicate 7 2 8 0 ohms 4 Continue by measuring between pins 4 and 6 5 Reading should also indicate 7 2 8 0 ohms 6 Ifeither measurement is out of tolerance replace the stepper motor 54 Maintenance Novajet PROe Series Service Manual Power Feed and Take Up Motor Winding Resistance Check hit Figure 3 9 Power Feed and Take Up Motor 1 Removethe feed and or take up roll from the printer E z m z gt Z 9 m 2 Using Phillips screwdriver remove the four screws that secure the cradle idler from the right leg 3 Easethe cradle idler off of the leg enough to disconnect the motor wires from the leg harness 4 Usinga standard ohmmeter or multimeter measure between the connections on the motor While manually
41. 6 4 4 m e ON m N m UJ amp N ON DOU RA PART NAME PART SLIDE SHAFT 606 207492 SLIDE SHAFT 426 207493 60 eere hit etit 207475 BELT 426 iiir testas 207476 FRAME TENSIONER 203870 1 SPRING COMPRESSION 203999 IDLER ASSEMBLY tnn 203405 1 AUTOFEED SENSOR ASSY 207629 PINCH ROLLER nennt nnn 207497 SERVICE STATION ASSY 207611 PLATEN ASSY 60e enitn 207496 PLATEN ASSY 42 207509 KNIFE DAMPER ASSY 202000 COVER RIGHT iiis nenne 208230 KEYPAD 55 207619 DISPLAY ASSN seeded 207803 PWA DISPLAY PWR CONVERTER 207775 POWER ENTRY MODULE 207508 FAN COOLING POWER SUPPLY 207593 MAIN PRINTED CIRCUIT BOARD 207624 POWER SUPPLY ASSEMBLY 207618 MOTOR ASSY SERVO mne 207517 STEPPER MOTOR ASSY 209071 FAN ASSEMBLY VACUUM 203443 EXHAUST GRILL nn 204976 LOWER ROLLER ASSY 60e 207023 LOWER ROLLER ASSY 42e 207506 Novajet PROe Series Service Manual FIGURE ITEM PART NAME PART 6 5 1 DELIVERY SYSTEM 60e 207613 1 INK DELIVERY SYSTEM 42 207613 2 6 5 2 CARTRIDGE TUBE ASSY BLUE 207614 CARTRIDGE TUBE ASSY GRAY
42. E 17 OVGIVIGW 19 Related 5 nenne 19 Electrostatic Discharge ESD Sensitivity 4 aa 19 Warnings Cautions and 20 Printer Specificato NS reais arae ies caede au a 21 Contents of this Service nnns 22 Technical Support ee Ce INED 24 Chapter 2 Theory of Operation 25 2 25 Novajet PROe Printer General Block Diagram 25 AXIS DIVO siais esii ete Le E tend tee Ree EE e Pd 27 The Carrier Axis 0244 1010 0000 enne nnne nennt 28 Media Feed and Take Up System essent 29 Main Printed Circuit Board 30 MIGKOPIOCOSSON etc 31 Gate Array lt C ER 31 Memory CCU NS ieietu 32 Stepper Motor Controller sssssessseeeeneeeenennenen nennen 34 Servo Motor Controller cicer deo t ae Ret oed 36 Interface Circuits Serial amp Parallel 38 Carrier Assembly CIICUlls i e Fe gia 39 IOV e E EET 40 Power SU pply thv uc Leve 41
43. ER SENSOR CONTROL MICRO PANEL PROCESSOR pcc e TUNE CARRIER en ASSEMBLY POWER GATE FEED SUPPLY gt i ARRAY SENSOR FED PS MOTOR i MEDIA MEMORY a AUTO LOAD CIRCUITS 2 SENSOR TAKE UP MPCB SENSOR LOWER STEPPER __PAPER AXIS DRIVE DRIVE MOTOR ASSEMBLY LEGEND ELECTRICAL CONNECTION MECHANICAL CONNECTION MAIN DATA BUS gt Figure 2 1 General Block Diagram 26 Theory of Operation Novajet PROe Series Service Manual Paper Media Axis Drive STEPPER PINCH ROLLERS _ MOTOR 23 E 29 LOWER DRIVE SHAFT ASSY REDUCTION GEARS Figure 2 2 Paper Media Axis Drive The Paper Media Axis Drive moves the plotting media in a direc tion perpendicular to the length of the printer This friction drive utilizes a micro step drive technology and consists of a stepper motor reduction gears lower drive shaft assembly and pinch wheels This can be seen in figure 2 2 The micro step technology associated with the stepper motor gives the capability of a resolution up to 9600 dpi The reduction gear meshes the stepper motor to the lower drive shaft assembly which allows the media to advance or retract The purpose of the pinch wheels is to apply pressure to the media onto the drive shaft assembly to reduce the chance of slipping Misaligned pinch wheels is the main cause of skewing of the media Theory
44. Frame Tensioner 1 Perform steps 1 through 13 of the Remove the Left Top and Right Covers procedures to remove the Left Top and Right Covers NKIGINASSV 2 Perform steps 2 through 7 of the Remove the Ink Delivery System procedures to remove the Ink Delivery System gt n z lt 3 Using a 2 Phillips screwdriver remove the four screws that secures the Left Sideplate Assembly to the Platen Remove the Left Sideplate Assembly 4 Lift up on the connector lock to unlock the Trailing Cable connector J 1 on the Carrier PCB and remove the end of the Trailing Cable Assembly WDisassembly 117 Novajet PROe Series Service Manual 118 Figure 5 12 Strain Relief Removal Installation Remove the Trailing Cable and Strain Relief from the Carrier Assembly by releasing the latch on the left lower side of the Strain Relief and lifting it off of the Carrier Assembly See Figure 5 12 Compress the back of the Frame Tensioner and use the end of a screwdriver to remove the Carrier Belt from the Servo Motor pulley See Figure 5 9 Remove the Compression Spring from the Frame Tensioner and set it aside Push the Carrier Belt through the Frame Tensioner enough to remove the Idler Pulley Assembly from the Frame Tensioner and then se aside the Idler Pulley Assembly and the Frame Tensioner See Figure 5 13 Assembly Disassembly Novajet PROe Series Service Manual Figure 5 13 Frame Tensioner
45. Manual Media Feed and Take Up System Ie 4 EF JO AYOSHL Figure 2 4 Power Feed and Take Up System The media feed and take up system comprises of two optical sensors and two dc motors SeeFigure 2 4 The motors are used to advance the media feed roll and the media take up roll dependant upon the signals they receive from the MPCB The MPCB generates the control signals for the motors from the information it receives from the media feed and take up sensors The optical sensors are designed to inform the MPCB when there is not a proper amount of slack in the media by sensing the curl of the media at the bottom of its loop This method is used so that all approved forms of media including transparent backlit media is able to take advantage of the power feed and take up system Theory of Operation 29 Novajet PROe Series Service Manual Main Printed Circuit Board MPCB CRYSTAL X1 STEPPER CARRIER CONTROLLER PCB EEPROM CONTROL PANEL SERVO CONTROLLER INTERFACE CIRCUITS Figure 2 5 Main Printed Circuit Board The Main Printed Circuit Board MPCB consists of six functional areas 1 Microprocessor CPU 2 Gate Array 3 Memory Circuits 4 Stepper Motor Controller 5 Servo Motor Controller 6 Interface Circuits Serial amp Parallel 30 Theory of Operation Novajet PROe Series Service Manual Microprocessor Th
46. Novajet PROe Series Service Manual Reseat Connectors on MPCB and Carrier Board Integrated circuits may become weakened or damaged by electrical discharge Do not touch or work near in tegrated circuits without wearing an ESD wrist strap Ribbon connectors can be easily damaged if incorrectly handled Observe extreme caution when handling the ribbon connectors to avoid damage Many problems can be corrected simply by removing and reseating connections found in circuit assemblies This process helps to clean the contacts and can dissipate any static electrical charges that might have developed 50 Maintenance Novajet PROe Series Service Manual Ej 1 e mE 000 00 n Bm a a CC us Spoons E z m gt z 9 m Locations
47. OMETER a DIAL GAUGE TIGHTEN SET SCREWS TEST CARTRIDGE MEASURING L TIP EXTENDER ENSURE TIP EXTENDS BELOW CARTRIDGE 1 4 6mm Figure 3 15 Setting Up Tools from Height Gauge Kit 3 Placethetest cartridge upright on a flat surface and Zero the gauge by loosening the knob near the top and turning the dial until the needle is at the 0 position on the dial Tighten the knob See Figure 3 16 E z m gt z 9 m Figure 3 16 Zeroing the Micrometer Gauge 4 Remove the Cyan ink cartridge Snap the test cartridge with the micrometer gauge into the position vacated by the Cyan ink cartridge See Figure 3 17 Ensurethat the micrometer can be read from the BACK of the printer Maintenance 61 Novajet PROe Series Service Manual Q Figure 3 17 Test Cartridge Installed 5 Slightly loosen the screws located on the back of the Y arm that secures the stabilizer to the Y arm Damage may occur to the micrometer gauge if the Carrier is moved without lifting up on the measuring tip This action could also take the micrometer out of alignment and foul the results of the alignment 6 While lifting up the measuring tip of the micrometer slide the Carrier to the left side of the stabilizer Position it as cl
48. Remove the Power Supply Bracket 8 Using a 1 Phillips screwdriver and a 1 4 wrench or socket remove the Fan from the Right Baseplate See Figure 5 8 g o gt o lt IN EI EET Assembly WDisassembly 109 Novajet PROe Series Service Manual Figure 5 8 Cooling Fan AC Entry Module Removal Using 1 4 wrench or socket disconnect the AC Entry Module ground from the ground stud on the Right Baseplate Remove the AC Entry Module by pressing in on the securing tabs until the module is released Install the Power Supply Cooling Fan and AC Entry Module To install the Cooling Fan and AC Entry Module 1 Insert the AC Entry Module into the AC Entry Module hole on the Right Baseplate from the back of the printer Press in until it snaps securely into place Attach the AC Entry Module ground connection to the grounding stud on the Right Baseplate Hold the Cooling Fan into place while inserting the four bolts into the assembly Attach the four 1 4 nuts to the bolts to secure Fan assembly Torque to 4 in Ibs Reinstall the Power Supply Bracket using four screws Insert and hold the Power Supply into place while securing it with four screws Torque to 15 in lbs 110 Assembly Disassembly Novajet PROe Series Service Manual 6 Reconnec the Power Supply to the AC Entry Module by reattaching the quick disconnect connection Push the quick disconnect assembly behind the Power Supply Bracket
49. S WO2 AVI WOO He 1222 Hc l am Ht ONITIV3IL Figure 3 32 Carrier PCB Connections Diagram Novajet PROe Series Service Manual MOLOW MOSN3S dN FJVL NOSN3S 9333 YOLOW dfi ivL MAINTENANCE 2 NVJ 9 5 ONIN ONIAMCI E 0 9 u oNOOC qavos unos NIVIN Figure 3 33 Leg Harness Connections Diagram 79 Maintenance This Page Intentionally Left Blank Troubleshooting 4 Introduction Chapter 4 Troubleshooting consists of a table that is intended to aide the technician in troubleshooting the Novajet PROe printers This table addresses symptoms with their possible causes and solutions Basic troubleshooting skills will be required to perform the symptom identification troubleshooting fault isolation and repair of the printer when using this table Ensure that all applicable software diagnostic tests have been properly executed all visual indications including LED status have been observed and all applicable pushbuttons have been depressed to obtain a complete list of symptoms to be applied to the table below Usethe table in conjunction with Chapter 3 Maintenance whenever the table prompts you for additional information This information may be in the form of an illustration additional dat
50. Slide Shaft and stretch out the Carrier Belt 11 Insert the Carrier Belt into the Frame Tensioner so that the belt extends about an inch past the Frame Tensioner 12 Holding the Carrier Belt and Frame Tensioner insert the Idler Pulley Assembly into the loop of the belt Make sure that the side of the Idler Pulley Assembly with the thicker outer ring of plastic is facing up See Figure 5 13 IN II EET 13 Once the Idler Pulley Assembly is in position pinch the belt to hold the Idler Pulley Assembly in place and pull it into the Frame Tensioner so that the axle rests in the V shaped groove in the Frame Tensioner g o gt T o E lt 14 Insert the Compression Spring into the opening in the back of the Frame Tensioner so that the end of the spring fits over the post inside the opening Assembly Disassembly 121 Novajet PROe Series Service Manual 15 16 17 18 Fit the Compression Spring over the post at the back of the Y Arm Assembly Fit the notch in the front end of the Frame Tensioner over the notch in the front of the Y Arm Assembly Depress the back of the Frame Tensioner and slip the Carrier Belt over the Servo Motor pulley Make sure that the guides in the Carrier Belt are properly fitted over the Servo Motor pulley Gently move the Carrier Assembly from end to end and make sure that the Carrier Belt is not rubbing against any other parts Remove the Carrier PCB Integrated c
51. a or a procedure that needs to be performed a OO Table 4 1 Troubleshooting Table w z m Symptoms di No Power printer not ON depress power switch faulty power replace power cord cord AC input not replace AC entry present at power module supply 81 Novajet PROe Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms No Power cont all DC output replace power voltages not supply present see Figure 3 30 for voltages all DC voltages replace MPCB present at MPCB Media Does Not Move perform Stepper replace stepper Motor Winding motor if out of Resistance check tolerance rough motion bad bearings while spinning replace stepper stepper motor motor paper sensor replace paper not responding Sensor media control driver corrupted switches are reload printer operating correctly driver firmware reload firmware corrupted bad MPCB replace MPCB 82 Troubleshooting Novajet PROe Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Internal ERROR Carriage Axis Failure dirty or perform Slide Shaft lubricated slide Cleaning procedure shaft perform Servo replace servo motor Motor Winding Resistance check check servo bad bearings motor for smooth replace servo motor movement obstruction in remove obstruction path of carrier may or may not be visible 4 dirty encoder perform Encoder I
52. achten Sie deshalb die Hinweise in der Bedienungsanleitung Dem Zentralamt f r Zulassungen im Fernmeldewesen w rde dan Inverkehrbringen dieses Ger tes angezeigt und die Berechtigung zur berpr fung der Serie auf die Einhaltung der Bestimmungen eingeraumt ENCAD Inc U S A Novajet PROe Series Service Manual Material Safety Data Sheet NOVAJET PRO eQIS Quality Image Supplies ink is nonhazardous requiring no special disposal handling It can be harmful if swallowed and should be kept away from children To obtain a Material Safety Data Sheet contact Inc at 6059 Cornerstone Court West San Diego CA 92121 3734 619 452 4350 International users should contact their local dealer or distributor Novajet PROe Series Service Manual WARRANTY OR DAMAGE CLAIMS United States ENCADS Inc warrants its printers to be free from defects in workmanship and materials for a period of one year from the date of purchase In order to submit a Warranty claim please contact the ENCAD Help Desk at 619 452 4350 ENCAD reserves the right to make changes or improvements to Products without incurring any obligation to similarly alter Products previously purchased Buyer s sole and exclusive rights pursuant to this Warranty shall be for the repair or replacement of defective Product ENCAD specifically disclaims any and all other warran ties expressed or implied including but not limited to implied warra
53. and out of sight 7 Perform steps 1 through 14 of the Install the MPCB procedure to install the MPCB 8 Perform steps 4 through 10 of the Install the Left Top and Right Covers procedure to install the Right and Top Covers Remove Servo Motor 1 Perform steps 1 through 9 of the Remove the Left Top and Right Covers procedure to remove the Top and Right Covers 2 Perform steps 3 through 13 of the Remove the MPCB Main Printed Circuit Board procedure to disconnect all connectors from the MPCB 3 Reach between the Power Supply Bracket and the AC Entry Module and carefully pull out the quick disconnect assembly attaching the Power Supply input to the AC Entry Module Disconnect the Power Supply input from the AC Entry Module NOTE The following procedure will leave the MPCB and Power Supply still attached to the Power Supply Bracket For this procedure there is no reason to re move these assemblies from the Power Supply Bracket NKIGINASSV 4 Using a 2 Phillips screwdriver remove the screw securing the ground strap from the MPCB to the side plate g o gt o lt 5 Using a 2 Phillips screwdriver remove the four screws securing the Power Supply Bracket to the Right Baseplate Remove the Power Supply Bracket Assembly Disassembly 111 Novajet PROe Series Service Manual Figure 5 9 Slacken Carrier Belt 6 Remove the Right Sideplate to gain access to the Servo Motor by unscrewin
54. arrier Assembly Carrier Belt and the Frame Tensioner Removal procedures to remove the Carrier Assembly from the Slide Shaft g o gt o lt NKIGINASSV Assembly Disassembly 127 Novajet PROe Series Service Manual Figure 5 18 Carrier Bushing Removal 2 Usea flat tip screwdriver to push up on the latch which holds the Carrier Bushing in place See Figure 5 18 3 Pull the Carrier Bushing out of the Carrier Assembly 4 Repeat Steps 2 and 3 for the other Carrier Bushing Figure 5 19 Carrier Bushing Installation 5 Orient the new Bushing as shown in Figure 5 19 so that the metal tab on top of the Bushing goes into the Carrier Assembly first 6 Push the Bushings in until they snap into place 7 Perform the Reinstall the Carrier Assembly Carrier Belt and the Frame Tensioner procedures to reinstall the Carrier Assembly if Carrier was removed 128 Assembly Disassembly Novajet PROe Series Service Manual Remove the Service Station Seals and Wipers Figure 5 20 Service Station Exploded View IN EI EET g o gt o lt 1 Place the Top Cover in the open position 2 Move the Carrier Assembly to the left side of the Slide Shaft 3 Reach into the Right Cover and pull back on the Service Station release tab located on the far side of the Service Station See Figure 5 20 Assembly Disassembly 129 Novajet PROe Series Service Manual 4 Rais
55. cedures They are for illustrative purposes only and may not necessarily be drawn to scale Material in this manual may be repeated in various chapters so that each chapter can stand alone This allows information to be located without having to refer back and forth between chapters Figures and tables are easily located and cross referenced and are listed in the front of the manual under List of Illustrations and List of Tables This manual is divided into six chapters as Chapter 1 GENERAL DESCRIPTION Contains a general description of the ENCAD Novajet PROe printer This indudes printer specifications and related materials Also included is a description of the use of Warnings Cautions and Notes as used in this manual and chapter contents Chapter 2 THEORY OF OPERATION Functional descriptions of the overall printer and major assemblies are contained in this chapter Chapter 3 MAINTENANCE This chapter covers the scheduled maintenance cleaning procedures and alignment adjustments recommended to perform on the printers Diagnostics and a signal flow diagram are also listed Chapter 4 TROUBLESHOOTING A table containing problems that could occur and possible causes and repairs is found in this chapter This table is not intended to be a complete listing of troubleshooting procedures It will isolate the problem down to the lowest replacable assembly If the problem happens to be the wiring between assemblies standard tr
56. d MPCB cartridge low on ink firing rate set too fast power down and reseat trailing cable replace paper sensor replace MPCB reseat cable connections on computer and printer refresh EEPROM firmware with new download replace MPCB refill or replace cartridge adjust firing rate lower optimum is 5 Troubleshooting 85 o I 2 10 318n OH Novajet PROe Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Ink Cartridge Misfiring cont Troubleshooting flex contacts dirty or damaged cartridge dimple area dirty or damaged cartridge not seated correctly bad cartridge service station dirty or not properly sealing cartridge jet area bad carrier assembly bad MPCB 1 perform Flex Cable Contact Cleaning procedures 2 replace carrier assembly 1 perform Cartridge Dimple Cleaning procedure 2 replace cartridge reseat cartridge replace cartridge 1 perform Service Station Cleaning procedures 2 replace seal on service station replace carrier assembly replace MPCB Novajet PROe Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Paper Skewing e paper guides install paper installed guides Stepper motor perform Clean and gearing dirty or Inspect Stepper damaged Motor Gears procedure Printer Output is Banding if banding is 1 inspect and or consisten
57. dband Slow F ast Novajet PROe Series Service Manual Figure 3 22 shows what the display will look like when printing either the fast or slow test if it is out of alignment A correctly aligned printer will appear as if thereis only a series of vertical lines printed No difference between the top and bottom set of lines to the center set of lines would be appearant The SLOW DEADBAND calibration is a precision test that checks the firing time of the jets as related to the forward and reverse direction Allowable values for the Slow Deadband is from 2 to 2 and from 0 to 120 for the Fast Deadband The Single Line Test and Line Test are variations of the Slow and Fast Tests except they print longer lines sothat long time integration of the deadband calibration can be observed The Single Line Test prints only one lineat a time while the Line Test prints all lines at the same time To perform the Deadband Alignments E z m gt z 9 m 1 Select Utility Menu from the Main Menu This brings up the Utility Menu as shown in Figure 3 19 2 Select the Service Menu from the Utility Menu This brings up the Service Menu as shown in Figure 3 23 Figure 3 23 Service Menu Maintenance 67 3 Select the Calibration M enu from the Service Menu 4 TheCalibration Menu is shown in Figure 3 24 and is where all the deadband tests are performed Select Deadband Test to perform the fast deadband
58. e and be careful not to strip the head of the screw or to cause damage to the Encoder Strip 5 Insert the back screw into the Servo Motor and tighten it 6 Tighten both screws on the Servo Motor to 15 in Ib of torque 7 Depress the back of the Frame Tensioner and wrap the Carrier Belt over the Servo Motor pulley Make sure that the guides on the inside of the belt are inserted in the pulley grooves and that the belt is not twisted g o o lt NKIGINASSV 8 Move the Carrier Assembly back and forth to check the Carrier Belt tension 9 Reinstall the Right Sideplate with four screws and a 2 Phillips screwdriver Press the side plate down and towards the back of the printer before tightening Torque to 15 in Ib Assembly Disassembly 113 Novajet PROe Series Service Manual 10 11 12 13 14 15 Ensure that all cable endings are protruding through the cable access hole in the Right Sideplate Reinstall the Power Supply Bracket with assemblies using four screws Reconnect the grounding strap from the MPCB to the side plate Reconnect the Power Supply to the AC Entry Module by reattaching the quick disconnect connection Push the quick disconnect assembly behind the Power Supply Bracket and out of sight Perform steps 5 through 13 of the Install the MPCB procedure to reinsert the removed connections from the MPCB Perform steps 4 through 10 of the Install the Left Top and
59. e 103 Install Extra Memory 5 104 Remove the MPCB Main Printed Circuit 104 mstallthe MPOB 107 Remove Power Supply Cooling Fan and AC Entry Module 108 Install the Power Supply Cooling Fan and AC Entry Module 110 REMOVE Servo MOIOF 111 Install Servo hate Pha na A e da din andan idis aud 113 Remove the Ink Delivery System 114 Install the Ink Delivery System ssssssssseeeenemenneneen nenne 117 Remove the Carrier Assembly Carrier Belt and the Frame Tensioner 117 Install the Carrier Assembly Carrier Belt and the Frame Tensioner 120 Remove the 122 11 Novajet PROe Series Service Manual Table of Contents cont Chapter 5 Assembly Disassembly cont Install the Carrier tercii eth acte cea ra De v EE C antes 124 Remove the Paper Sensor or the Encoder Sensor 124 Install the Paper Sensor or the Encoder Sensor 126 Replacing the Carrier 0 127 Remove the Service Station Seals and 129 Install the Service Station Seals and Wipers 2 130
60. e J 4 location by grasping the Load Sensor connector with thumb and forefinger and pulling straight out 9 Disconnect the Vacuum Fan 1 connection at the J 5 location by grasping the Vacuum Fan 1 connector with thumb and forefinger and pulling straight out 10 Disconnect the Vacuum Fan 2 connection at the J 6 location Pro 60e version only by grasping the Vacuum Fan 2 connector with thumb and forefinger and pulling straight out 11 Disconnect the Trailing cable connection at the J 7 location Use the thumb and forefinger to pull up on the connector lock and remove the Trailing Cable from the connector 12 Disconnect the Power Supply Cooling Fan connection at the 8location by grasping the Power Supply Cooling Fan connector with the thumb and forefinger and pulling straight out 13 With a 2 Phillips screwdriver disconnect the ground straps going to the side plate and baseplate by removing the screw located near the parallel port on the MPCB NKIGINASSV g o gt o lt 14 Using care remove the MPCB by unscrewing the remaining screws securing the MPCB to the bracket using a 2 Phillips screwdriver See Figure 5 6 Assembly Disassembly 105 Novajet PROe Series Service Manual Figure 5 6 MPCB Removal Failure to use an approved antistatic bag for storage or shipment may cause damage to the MPCB and af fec the Warranty 15 Place the MPCB in an ESD bag antistatic bag in preparation
61. e drive belt Novajet PROe Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Line Quality Degraded cont Fan Does Not Power Up Media Take Up Motor Not Operating Sensor Works drive belt slipping on idler vacuum fan not operating MPCB has 24 VDC atJ 3 pins 1 2 power not being applied to fan printer not in Take U p Mode bad connection to the motor bad Take Up motor faulty wiring leg harness bad MPCB Troubleshooting replace frame tensioner spring or idler replace fan assembly 1 reseat connection at MPCB tofan 2 replace fan 1 reload firmware 2 replace MPCB put in Take Up Mode under Supply Type from Paper Option Menu reconnect Take Up motor Replace Take Up motor reseat or replace leg harness replace MPCB 91 o I jo 2 0 Novajet PROe Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Media F eed Motor Not Operating Sensor Works bad connection reconnect F eed to the motor motor bad Feed motor Replace F eed motor faulty wiring leg reseat or replace harness leg harness bad MPCB replace MPCB Media Feed and Take Up Motors Not Operating Both Sensors Working printer is in put in Take Up Sheet Mode Mode to activate both or Roll Mode to activate feed motor only under Supply Type from Paper Option Menu 92 T
62. e microprocessor PowerPC is the central processor unit which supervises system functions executes the printer firmware manipulates data and controls input output data busses It has two built in serial ports a two channel DMA Direct Memory Access controller a timer module dock generator and an on board chip select generator One serial port connects to the Mini DIN connector which can be used to communicate with the host computer the other serial port interfaces to the Control Panel One DMA channel supplies data to the gate array for jet firing the other DMA channel is used to receive data through the parallel port via the gate array or the serial port when using a high speed serial mode One timer generates a servo interrupt every millisec ond the other is used for timing the Stepper Motor E E 29 divide by two circuit generates the 33MHz system clock from a 66MHz crystal reference X1 The chip select generator is programmed to generate chip selects at the appropriate addresses with the appropriate data size byte word and with the appropriate number of wait states Gate Array PARALL PORT TO CARRIER PCB Figure 2 6 Gate Array Theory of Operation 31 Novajet PROe Series Service Manual 32 The gate array contains the hardware logic for dot firing monitoring changes in the Carrier Assembly position controlling DMA through the parallel port and generating
63. e the right side of the Service Station out of the Platen 5 Lift out the left side of the Service Station from the Platen and remove the Service Station Moving the Service Station farther to the right might be required to release the left side of the Service Station 6 To remove a Service Station Wiper lift the Wiper up and off of the Wiper support 7 To remove a Service Station Seal a Disconnect the Sled spring from the post on the bottom of the Service Station Sled See Figure 5 20 b Slidethe Service Station Sled to the right and up until it is removed from the Service Station Base c While pushing the Service Station Seal in remove the retaining ring from the other side This releases the Seal Post with the Seal attached and the Seal spring d Remove the Seal from the Seal Post by sliding the rubber Seal until it is released Install the Service Station Seals and Wipers 1 Toinstall a Service Station Seal a Slide the new Seal over the Seal Post b Insert the Seal Post through the Seal spring c Align the Seal Post and spring into the hole on the Service Station Sled it is keyed to only go in one way d Press the Seal Post in to give enough dearance on the other side to attach the retaining ring e Insert the Service Station Sled into the Service Station Base by sliding the Service Station Sled down and to the left into the Base To seat the Sled completely into the Base it will be necessary to pres
64. ection and return to the Service Menu Continue performing steps 8 through 10 until the slow deadband adjustment is correct E z m z gt Z 9 m that drives the stepper motor is correct to minimize line length accuracy errors To perform the paper axis procedure 1 Select Utility Menu from the Main Menu This brings up the Utility Menu as shown in Figure 3 19 From the Utility Menu select Calibration Menu This brings up the Calibration Menu as shown in Figure 3 25 Maintenance 69 Figure 3 25 Calibration Menu 3 Fromthe Calibration Menu select Paper Axis Test This runs the paper axis test which prints out two T figures that are mirrored from each other and about 33 apart See Figure 3 26 Figure 3 26 Paper Axis Test Novajet PROe Series Service Manual 4 With a precision drafters measuring stick measure the exact distance from each of the T intersections 5 Select Paper Axis at the Calibration Menu This brings up the options menu for the paper axis adjustment This menu is similiar to the menu depicted in Figure 3 21 6 Using either Prev Option or Next Option rotate through the selections until the exact value of the measurement found in step 4 is selected Press Ok to accept the selection and return to the Calibration Menu Diagnostics Menu The Diagnostics Menu is located in the Service Menu shown in Figure 3 23 and is seen in Figure 3 27
65. ee Chapter 6 for installa tion procedures Care must be taken when choosing a SIMM module for the printer Not all SIMM s on the market today will work on the printer It has to do with the presence detect signals on pins 67 and 68 of the SIMM s Not all SIMM manufactures use these signals so they disable them Recommended SIMM s to be used are listed in the User Guide Theory of Operation 33 Novajet PROe Series Service Manual Serial EEPROM Serial EEPROM is an Electrically Erasable Programmable Read Only Memory which provides storage for calibration constants and user configuration data entered from the host computer An 8K bit serial non volatile EEPROM stores calibration and con figuration information It retains data while the unit is off Stepper Motor Controller DAIA BUS gt WAVEFORM CURRENT STEPPER GENERATOR PR DRIVER SENSE MOTOR 34 Figure 2 7 Stepper Motor Controller The media is driven by a Stepper Motor which drives the media in a direction perpendicular to the width of the printer The media in the printer can advance forward and backward depending upon the commands which the Stepper M otor receives from the microproces Sor The Stepper Motor Controller contains two identical circuits one for each winding of the stepper motor The circuit is a combination of two simpler types of circuits and can be thought of as a variation of either one A waveform genera
66. en 1 Perform steps 1 through 13 of the Remove the Left Top and Right Covers procedures to remove the Left Top and Right Covers 2 Perform steps 2 through 4 of the Remove Servo Motor procedures to remove the Right Sideplate Assembly 3 Perform steps 2 through 5 of the Remove Service Station procedures to remove the Service Station Be careful when removing the F oam Block so that it does not tear It is very important to have an intact Foam Block to produce sufficient vacuum inside the Platen to properly hold down the media 1419 3557 o o w lt 4 Using the accesses gained by removing the Right Sideplate and the Service Station remove the foam block from between the Lower Drive Roller Assembly and the Servo Motor 5 Perform steps 2 through 6 of the Remove the Ink Delivery Assembly Disassembly 139 Novajet PROe Series Service Manual System procedures to remove the Ink Delivery System 6 Using a 2 Phillips screwdriver remove the two screws that secure the Left Sideplate Assembly to the Platen SeeFigure 5 24 NOTE The Novajet PRO 42e printer has one Vacuum Fan and Exhaust assembly while the 60e has two sets of Vacuum Fans and Exhausts 7 Using a 1 Phillips screwdriver remove the four screws on the bottom of the Platen which holds the Fan Exhaust s in place 8 While holding the Vacuum Fan through the hole left when the Exhaust assembly was removed remove the 3 screws on
67. er obstruction in path of carrier carrier bushings worn debris or obstruction in fan drive belt slipping on idler hardware or assemblies loose carrier height too low lower drive shaft gears are dirty or misaligned noisy servo motor noisy stepper motor dean printer remove obstruction dean printer replace carrier bushings clean fan assembly replace frame tensioner spring or idler tighten hardware or assemblies perform Carrier Head Height Adjustment dean and or realign lower drive shaft gears replace servo motor replace stepper motor Troubleshooting 89 o I jo 2 10 318n OH Novajet PROe Series Service Manual 90 Table 4 1 Troubleshooting Table cont Line Quality De graded Troubleshooting ink cartridges dirty or clogged cartridge dimple region dirty or damaged color calibration needed deadband calibration needed in bidirectional printing mode debris or lubrication on slide shaft eaks or bubbles in ink delivery lines dirty encoder strip carrier bushings worn drive belt worn Symptoms dean and prime ink cartridges clean or replace cartridge perform Color Calibration perform Deadband Calibration clean slide shaft 1 reseal prime ink delivery lines on both sides 2 replace ink delivery lines clean encoder strip replace carrier bushings replac
68. er 3 Maintenance Chapter 4 Troubleshooting 4 1 Troubleshooting Table eerte nette erre er return rts 81 Chapter 5 Assembly Disassembly Chapter 6 Parts List 6 1 LIE 151 16 General Description 1 NOILdIH9S3G ED Figure 1 1 Novajet PROe Series Inkjet Printers Introduction This manual provides service information for the ENCAD Inc Novajete PROe Series Color Inkjet Printer There are two ver sions of the Novajet PROe printer Novajet PRO 42e and Novajet PRO 60e It is written for service personnel who possess analog and digital circuitry experience Chapter 2 Theory of Operation should be read and thoroughly understood before troubl eshooting calibrating the printers 17 Novajet PROe Series Service Manual 18 The printers support pre cut and roll media Media size is auto matically determined and harddip limits are set accordingly Pre cut media uses different maximum plotting areas than roll media See the Printer Specifications for more details Both RS 422 serial and Centronics parallel connections are provided to interface with the host computer Commands sent from the host computer be in several forms including HP RTL Encad RTL formats Drivers are supplied to support Windows based PC s 3 XX 95 and NT as well as Macintosh and Power PC computers These printers expand upon ENCAD s tradition of delivering fast h
69. ery System from the rest of the link assembly by pressing in on the two small posts from the next to last link that are located in the holes of the last link See Figure 5 11 Releasing one post at a time may be easier to accomplish than trying both at once 6 Disconnect the Ink Delivery System Bracket from the Left Sideplate using a 2 Phillips screwdriver 7 Carefully slide the Ink Delivery System out of the printer 116 Assembly Disassembly Novajet PROe Series Service Manual Install the Ink Delivery System 1 Secure the Ink Delivery System Bracket to the Left Sideplate using two screws 2 Reattach the rest of the Ink Delivery System linkage train to the last link located on the Left Sideplate 3 Position the Ink Delivery System into the Support Bracket so that it is easier to orient the Electronics Cover portion of the system over the Carrier for reinstallation 4 Position the Electronics Cover over the Carrier with the back of the Electronics Cover under the Support Bracket Depress the two tabs on each side of the Cover and lower the Assembly onto the Carrier until it snaps into place 5 Place the Foam Chain Shelf in the Support Bracket PRO 60e only Align the left side of the Shelf to the center of the leftmost pinch roller 6 Perform steps 1 through 3 and 9 and 10 of the Install the Left Top and Right Covers procedure to install the Left and Top Covers Remove the Carrier Assembly Carrier Belt and the
70. from the Stepper Motor and the post on the Left Lower Drive Shaft Bracket See Figure 5 25 Figure 5 25 Stepper Motor Removal Installation 12 Remove the hardware securing the Stepper Motor to the Left Lower Drive Shaft Bracket and remove the Stepper Motor Install the Lower Roller Assembly Stepper Motor and Vacuum Fan 1 Loosely attach the Stepper Motor to the Lower Roller bracket using Stepper Motor hardware as shown in Figure 5 19 2 Attach the Stepper Motor tension spring to the Stepper Motor and the Lower Roller Bracket Tighten the Stepper Motor hardware to 8 in Ib of torque It may be necessary to loosen do not remove the screws that secure the Y Arm Assembly to the Platen so that the Lower Drive Roller Assembly clears the ends of the screws that protrude inside of the Platen while installing the Lower Drive Roller Assembly 142 Assembly Disassembly Novajet PROe Series Service Manual It may be necessary to loosen do not remove the screws that securetheleft Leg Assembly to the Platen so that the Lower Drive Roller Assembly clears the ends of the screws that protrude inside of the Platen when removing the Lower Drive Roller Assembly NO TE Ensure that the Lower Drive Supports and Fan As semblies are oriented in the correct position before inserting into the Platen See Figure 5 24 for visual indication of correct orientation Slide the right side of the Lower Drive Roller Assembly inside of the
71. g a 72 Phillips screwdriver remove the two screws securing the bracket to the leg assembly Assembly Disassembly 145 Novajet PROe Series Service Manual Figure 5 27 Media Take Up and Feed Sensor Removal Install the Media Take Up and Feed Sensor Brackets and Sensors 1 Using a 2 Phillips screwdriver install the two screws securing the bracket to the leg assembly 2 Insert the sensor into the hole on the sensor bracket secure by screwing on the plastic nut onto the front of the sensor 3 Route the sensor wires to the back of the bracket and secure the wires using two wire tie wraps 4 Bringing the wire from under the bracket attach the wire connector to the leg harness plug Push connector in until firmly seated 146 Assembly Disassembly Novajet PROe Series Service Manual Remove the Media Take Up and Feed Motors 1 Remove all media and media rollers from the printer 2 Remove the four screws holding the Cradle Idler to the leg assembly See Figure 5 28 3 Carefully slide the Cradle Idler assembly out of the leg assembly until the wires going to the motor can be removed 4 Remove the wires from the motor 5 From the back of the Cradle Idler disconnect the tension spring from the post located on the Cradle Idler 6 Using a 2 Phillips screwdriver remove the screw and washer holding the motor mount to the Cradle Idler Carefully remove the motor motor mount and motor gear subassembly fr
72. g materials are also required IN ESI EET g o gt o lt Isopropyl Alcohol Cotton Swabs Lint Free Cloth or Tissue Double Sided Tape 1 16 thick 3 4 wide Loctite Blackmax P N 200172 A Hardware Kit is available for the printers See Chapter 6 of this manual for the part number 95 Novajet PROe Series Service Manual Always turn the printer OFF remove the power cord and the interface cable before beginning any disas sembly procedures An electrical shock hazard may be present if these precautions are not followed Remove the Left Top and Right Covers 96 Removing the Left Cover allows access to the left side of the Platen for removal of the Carrier Assembly Carrier Drive Belt Tension Assembly and the Cutter Activator Also located on this side is the ink reservoirs and the Ink Delivery System portion that is con nected to the reservoirs Removal of the Left Cover is a require ment to remove the Lower Roller Assembly and the Vacuum Fan s from inside the Platen Removing the Right Cover provides access to the Main Printed Circuit Board MPCB Display and Keypad circuits Servo Motor AC Entry Module and the Power Supply Cooling Fan The Top Cover needs to be removed before any of the other covers can be removed It also gives access to the Carrier Assembly and the Service Station when in the open up position and the Carrier is at the Carrier Access position To
73. g the four screws securing it to the Platen 7 Depress the back of the Frame Tensioner see Figure 5 9 to create slack in the Carrier Belt and slip it off of the Servo Motor pulley 8 Movethe Carrier Belt to the left so it is out of the way of the Servo Motor pulley 9 Move the Carrier Assembly to the left end of the Slide Shaft 10 Lift up gently and hold the right end of the Trailing Cable 11 Using a 32 Phillips screwdriver remove the back screw on the Servo Motor The screwdriver will be at a slight angle Be careful not to strip the head of the screw or to cause damage to the Encoder Strip 12 Lower the Trailing Cable back into place 13 While holding the Servo Motor remove the front screw on the Servo Motor 112 Assembly Disassembly Novajet PROe Series Service Manual 14 Lower the motor to dear the pulley assembly from the platen and carefully bring the motor out of the printer Install Servo Motor 1 Reinsert the Servo Motor under the Platen with the connector facing the FRONT side of the Platen Guide the pulley up through the opening in the Platen 2 Oncethe Servo Motor pulley is through the Platen push up on the Servo Motor and align the screw holes with the screw hole openings 3 Insert the front screw into the Servo Motor and tighten it almost all the way 4 Lift up gently and hold the right end of the Trailing Cable Make sure the screw does not go into the motor at an angl
74. ice Manual HILFLELFLFLFLFLFL T 23 29 inco Nu Figure 2 9 Quadrature Signal Generation The direction that the Carrier Assembly is moving is known based upon the state of one detector s output and the direction of the transition of the other detector s output A hardware counter in the gate array increments as the Carrier Assembly moves left and decrements as the Carrier Assembly moves right The hardware counter is only eight bits wide so it cannot store a value large enough to represent an absolute Carrier Assembly position Instead it is read during the servo interrupt and its value compared with that from the previous interrupt This differenceis used to update the absolute position value in the software Theory of Operation 37 Novajet PROe Series Service Manual Interface Circuits Serial amp Parallel SERIAL MICRO GATE PARALLEL CONNECTOR TRANSCEIVER PROCESSOR ARRAY CONNECTOR 38 Figure 2 10 Interface Circuits Data from the host computer is received either through the Centronics parallel port or the serial port The gate array provides the control signals for DMA transfers from the parallel port to DRAM The serial port is designed primaril
75. ies Service Manual 9 Disconnect the Display Power Converter connector at the J 10 location on the MPCB To disconnect grasp the Display Power Converter connector between thumb and forefinger and pull straight out To remove the Left Cover Assembly 10 Open the reservoir access Door Disconnect and remove all ink reservoirs Figure 5 2 Left Cover Assembly Removal Installation 11 With a 2 Phillips screwdriver remove the two screws securing the Left Cover Assembly to the Left Baseplate and the two screws securing it to the Left Sideplate See Figure 5 2 12 Reach under the Support Bracket and depress and hold the retracting stop assembly that secures the Left Cover Assembly to the Support Bracket 13 Carefully lift the Left Cover Assembly up and off the printer 98 Assembly Disassembly Novajet PROe Series Service Manual Install the Left Top and Right Covers To install the Left Cover Assembly 1 Position the Left Cover Assembly over the Left Baseplate and while depressing the retracting stop assembly on the Support Bracket lower the Left Cover into position onto the Left Baseplate Release the retracting stop assembly Applying too much torque to the lower screws can cause the mounts for the standoffs on the cover to break requiring a replacement of the cover 2 Using Phillips screwdriver secure the Left Cover with two screws located on the right side torque to 15
76. igh quality color or monochrome graphics for a variety of applica tions ENCAD has made significant advances in designing these printers to respond to and anticipate our customers needs Princi pal features are summarized below Locally or Remotely Configured via Host Computer Powered Media Take Up and Feed System Media Drying System Quick Ink Changeover Self Aligning Pinch Rollers PowerPC 33 MHz Microprocessor 8 User Configurable Settings 104 J et Ink Cartridges Ink Priming System 500ml Ink Reservoirs Smart Cartridges General Description Novajet PROe Series Service Manual Overview Printers draw according to instructions issued from a host com puter Every printer is engineered to understand a specific set of instructions and to execute each instruction in a precise manner In addition most printers are designed to execute predetermined characters automatically without a specific line by line instruction from the program These characters are part of the printer s permanent memory ED m D U m z Related Publications The following publication contains additional information which may be useful in servicing the ENCAD Inc Novajet PROe Color Inkjet Printers ENCAD Inc Novajet PROe User Guide P N 208713 1 Copies of this and other ENCAD Inc publications may be obtained by contacting your nearest authorized ENCAD Inc dealer or by contacting ENCAD s Technical Support and Se
77. igned to the corresponding command that is dis played closest to the physical location of the button Power Supply An internal UL recognized switching power module supplies power for the Novajet PROe printer It provides a constant 24VDC output from input voltage in the range of 90 246 VAC A power switch turns the power and off The 24VDC is applied to the MPCB where it is further regulated and seperated into 24VDC 13VDC and 5VDC The 24V supply is used for the stepper controller which advances the paper the servo controller which moves the Carrier and power to fire the inkjets The 5V supply powers the logic circuits T 39 29 The power supply is fused using 2A 250V fast blow type fuse The outputs share a common ground which is isolated from earth ground with in the supply itself Earth ground and DC ground are connected external of the power supply The power supply will shut down under overload short circuit conditions on any output over the full range of input voltage Overvoltage protection is 2096 3096 above nominal for the 24V output Beeper and Fans The beeper contains built in driver circuitry sothat it beeps under firmware control The beeper alerts the user to error conditions There exists three types of fans on the Novajet PROe series print ers A single fan located behind the power supply is used for cooling the power supply Air blows over the power supply and the heated air i
78. in either polarity to drive the current to the desired value Theory of Operation 35 Novajet PROe Series Service Manual Servo Motor Controller ENCODER CARRIER GATE ARRAY Figure 2 8 Servo Motor Controller The Carrier Assembly is driven by the Servo Motor The speed of the Carrier Assembly is controlled by varying the duty cycle of the power applied to the controller The microprocessor checks the position of the Carrier Assembly approximately 1 000 times per second during the servo interrupt It then updates the PWM pulse width modula tor register the gate array which sets the duty cycle to make adjustments to the Carrier Assembly speed A linear optical encoder is used to monitor the Carrier Assembly position The optical encoder strip runs the length of the Stabilizer Bracket and contains 150 lines and spaces per inch Thus there are 300 edges per inch The detector circuit actually consists of two optical edge detectors They are separated from each other by one half the width of one of the optical lines on the encoder strip This allows 4 evenly spaced pulses to be developed for each line on the encoder strip This is known as quadrature signals It gives an effective resolution of 600 lines per inch See figure 2 9 for a graphical repre sentation of quadrature signals For 300 dpi resolution one of the detectors is not used 36 Theory of Operation Novajet PROe Series Serv
79. ircuits may become weakened or damaged by electrical discharge Do not touch or work near integrated circuits without wearing an ESD wrist strap Perform the Carrier Assembly Carrier Belt and the Frame Tensioner Removal procedures to remove the Carrier Assembly from the Slide Shaft Put on an ESD wrist strap Unlock the connectors and remove all flex cables on the Carrier PCB 122 Assembly Disassembly Novajet PROe Series Service Manual Figure 5 15 Carrier PCB Removal Installation 4 Unlock the latch on the right end of the Carrier Assembly and ASSEMBLY DISASSEMBLY lift up the right end of the Carrier PCB See Figure 5 15 left end of the Carrier PCB from the slot in the Carrier 5 Slide the Carrier PCB to the right to remove the tab on the Assembly 123 Assembly Disassembly Novajet PROe Series Service Manual Failure to use an approved antistatic bag for storage or shipment may cause damage to the Carrier PCB and affect the Warranty 6 Placethe Carrier PCB in an ESD bag antistatic bag in preparation for shipment to ENCAD for replacement or repair or if it is to be stored at your facility for repair Install the Carrier PCB 1 Put the tab on the left end of the Carrier PCB into the slot in the left side of the Carrier Assembly See Figure 5 15 2 Ensure that no flex cables are underneath the Carrier PCB 3 Push down the right end of the Carrier PCB until the latch snaps into place 4
80. k Diagram isis niki keke eed qui 26 2 2 Paper Media Axis Drive rnnt nennen 27 2 9 Carrier AXIS bei ber ied gel coire 28 2 4 Power Feed and Take Up 29 2 5 Main Printed Circult Board 30 2 6 Gate iecur reete ot o Race eue iets fecutus 31 2 7 Stepper Motor Controller oiii eec 34 2 8 Servo Motor Controller essen 36 2 9 Quadrature Signal Generation 37 2 10 Interface CCHS 38 2 11 Carrier Assembly 4204 60 41 nnne nnn nnn 39 Py NI CIE 40 Chapter 3 Maintenance 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 3 16 Encoder Strip 0 46 Cartridge Dimple Region 4024 47 Flex Cable Contacts 48 Connection Locations cete 51 Carrier Connection Locations 1 2 51 Ribbon Connector Locking 52 CTS 53 ied C 54 Power Feed Take Up 55 Exaimpl s of Bandin cuente tod a certc rr Re rud 56 Dial Gauge
81. left side of the Platen until the first roller is inserted Position and hold one of the Fan Assemblies under the Lower Drive Roller Assembly and between the first and second rollers Continue to insert the Lower Drive Roller Assembly into the Platen Position and hold the other Fan Assembly for PRO 60e only under the Lower Drive Roller Assembly and between the seventh and last rollers Continue to insert the Lower Drive Roller Assembly completely into the Platen NKIGINASSV Reaching inside the Fan Exhaust hole under the Platen position and secure the Fan Assembly ies using a 2 Phillips screwdriver n gt 27 on m w lt Reinstall the Fan Exhaust Assembly ies using a 2 Phillips screwdriver Assembly Disassembly 143 Novajet PROe Series Service Manual 8 Install the Lower Drive Roller Assembly support brackets using a 2 Phillips screwdriver 9 Reinsert the Foam Block Make sure that the Stepper Motor and Fan s cables are exiting out of the back corner of the Foam Block See Figure 5 26 The Foam Block is positioned between the Stepper Motor and the Servo Motor Make sure it is not tilted at an angle Figure 5 26 Inside Platen Right Side 11 Reinsert the Service Station 12 Reinstall the Right Sideplate using a 2 Phillips screwdriver Ensure that all cables from inside the Platen are exiting out of the large hole in the Sideplate 13 Reinstall the Power Supply Bracket
82. ly Remove the black wingnut 2 Disconnect the drying fan assembly leads from the printers leg assembly by squeezing the sides of the connector to release the quick disconnect latches NKIGINASSV g o gt o lt 3 Lift the entire drying fan assembly off of the printer 4 Remove the air filter from the fan to be removed by squeezing Assembly Disassembly 149 Novajet PROe Series Service Manual 7 the tabs on the filter housing to release the housing off the fan Remove the four bolts securing the back bracket the one with the positioning bolts on the bottom to both of the side plates Pull the back bracket away from the fans to gain access to the faulty fan Carefully pull the fan away from the front bracket until access is gained to reach the electrical connector Disconnect the connector to the fan Install the Media Drying Fans 1 Reconnect the electrical connection to the fan Push the connector and wires into the bracket so the fan can be seated correctly on the bracket Carefully orient all the fans so that the back bracket can be installed correctly Secure the back bracket to the side plates Install the air filter and air filter housing Lay the entire assembly onto the support brackets on the printer Ensure that the cable connector is on the right side of the printer as it is installed Reattach the positioning wingnut on the left side of the assembly Attach the wire
83. n the shaft s profile z gt 2 9 m You will need the following Height Gauge Kit Assembly 1 4 open and box end wrench 110 thick Height Gauge Alignment Kit Contents are Dial Gauge Micrometer Measuring Tip Extension Modified Novajet 4 Pro Pro 50 Cartridge Platen Carrier Shaft Mounting Block Extension Not used Calibration J o Block 1 434 Not used Plastic Gauge Card 0 011 Not used Modified Cadjet Black Cartridge Not used Modified Novajet 1 2 3 Cartridge Not used Maintenance 57 Novajet PROe Series Service Manual There aretwo basic measurements that are to be made using this kit ensure power is off prior to performing these procedures 1 Slide Shaft Profile Adjustment 2 Carrier Cartridge Head Height Setting 1 Connectthe dial gauge micrometer to the Shaft mounting block as shown in Figure 3 11 d 7 AZN e Figure 3 11 Dial Gauge Micrometer Assembly 2 Place gauge against left side of shaft assembly allowing micrometer tip to rest directly on top of shaft Figure 3 12 Zerothe gauge this is to become the reference point Figure 3 12 Measurement Positions for Slide Shaft 3 Measuretheright side next to media alignment mark and note the difference Divide this amount by two 58 Maintenance Novajet PROe Series Service Manual 4 Measure just
84. ng the retracting stop assembly Remove the Keypad Display and Display Power Converter 1 Perform steps 1 through 9 of the Remove the Left Top Right Covers procedure to remove the Top and Right Covers 100 Assembly Disassembly Novajet PROe Series Service Manual Figure 5 3 Keypad and Display Installation Removal Turn the Right Cover Assembly over and disconnect the Display power cable located at J 13 from the Display Power Converter With a 1 4 socket or wrench remove the four kepnuts securing the Display Power Converter See Figure 5 3 Remove the Display Power Converter With a 1 4 socket or wrench remove the four standoffs that secures the LCD Display Assembly to the Keypad Remove the Display Assembly Disconnect the grounding flex cable from the large standoff before removing the Keypad Assembly See Figure 5 4 for location Remove the K eypad Assembly Assembly Disassembly 101 g o gt o lt IN ESI EET Novajet PROe Series Service Manual Figure 5 4 Keypad Grounding Connection Install the Keypad Display and Display Power Converter 1 Route the K eypad flex data and ground cables into the Right Cover Assembly through the hole provided for the Keypad 2 Place the K eypad into position and hold Turn the Right Cover Assembly over and position the Display Assembly onto the threaded studs of the Keypad Secure using four standoffs with a 1 4 socket or wrench
85. not a field removable item The entire Stabilizer Bracket Assembly with the Encoder Strip and Trailing Cable installed is to be replaced if the Encoder Strip is damaged 134 Assembly Disassembly Novajet PROe Series Service Manual Install the Stabilizer Bracket and Encoder Strip l Install the Stabilizer Bracket Assembly with Encoder Strip and Trailing Cable onto the Y Arm Assembly using the four alignment Allen screws and washers Hand tighten only 2 Install the Support Bracket onto the Stabilizer Bracket Assembly by placing the Support Bracket onto the Stabilizer Bracket with a slight forward tilt 3 Perform the Install the Carrier Assembly Carrier Belt and the Frame Tensioner Procedures to install the Carrier Assembly Carrier Belt and the Frame Tensioner 4 Perform steps 2 through 7 of the Install the Trailing Cable Assembly procedures to finish installing the Trailing Cable Assembly 5 Perform the Install the Ink Delivery System procedures to install the Ink Delivery System 6 Perform the Install the Left Top and Right Covers procedures to install the Left Top and Right Covers 7 Perform the Head Height Adjustment procedures found in Chapter 3 of this service manual Remove the Y Arm Assembly Pinch Rollers Slide Shaft and Auto Load Sensor 1 Perform steps 1 through 13 of the Remove the Left Top and Right Covers procedures to remove the Left Top and Right Covers KIGINASSV o gt o
86. nta and Y yellow on the right side of the plot Novajet PROe Series Service Manual To perform the Color Calibration 1 Selec Utility Menu from the Main Menu This brings up the Utility Menu as shown in Figure 3 19 Figure 3 19 Utility Menu 2 Fromthe Utility Menu select Color Calib Menu This brings up the color calibration menu and it looks like Figure 3 20 E z m gt z 9 m Figure 3 20 Color Calib Menu 3 Select Calib Print Test to print the color calibration plot as shown in Figure 3 18 Maintenance 65 4 When the plot is complete select Cyan Vertical at the Color Calib Menu This brings up the options menu for the cyan vertical adjustment as shown in Figure 3 21 Figure 3 21 Cyan Vertical Options Menu 5 Observe the plot and using either Prev Option or Next Option rotate through the selections until the one that best aligns the cyan color on the plot is selected Press Ok to accept the selection and return to the Color Calib Menu 6 Continue until all six calibrations on the Color Calib Menu have been accomplished Deadband Alignment Deadband calibration compensates for minute differences created when bidirectional printing is used Unidirectional printing is not affected by deadband There are four types of deadband tests slow deadband fast deadband fast deadband vertical lines all fast deadband vertical lines one Figure 3 22 Dea
87. nties of merchantability and fitness for a particular purpose In no event shall ENCAD be liable for any loss of profit or other commercial damages special incidental or consequential damages or any other damages or claims whatsoever This Warranty gives Buyer specific legal rights and Buyer may also have other rights that vary from state to state This Warranty applies only to printers purchased from ENCAD or authorized ENCAD distributors or dealers The intent of this Warranty is to repair or replace defective Prod ucts subjected to normal wear and tear when operated according to ENCAD instructions This Warranty does not cover damage to the Product resulting from the following Accident or negligence Unauthorized modification of the Product Adverse environmental conditions Service of the Product by other than an ENCAD authorized service provider Unauthorized or improper use including but not limited to Use in applications for which the Product was not designed Using cartridges or ink other than those supplied by ENCAD or authorized ENCAD resellers Using media other than that supplied by ENCAD or authorized ENCAD resellers Lubricating any part of the printer Internationally Contact your dealer or distributor for warranty information Novajet PROe Series Service Manual Table of Contents Chapter 1 General Description 17 2 E
88. oaked isopropyl alcohol can be used to remove any ink that may have accumulated on the gears Clean and Inspect MPCB Foreign material on the MPCB could short out electrical signals being developed on the MPCB and cause erroneous prints or even damage tothe MPCB AII electrical circuits should be free of foreign material especially those with conductive properties Clean the MPCB by blowing the objects away or gently brush them aside with a soft brush if required Inspect the MPCB for any damage to the board connections or any of the components on the board Replace board if inspection reveals any damage or flaws that could effect the function of the MPCB Clean and Inspect Carrier Assembly E z m z gt Z 9 m Foreign material on the carrier assembly could short out signals being developed on the carrier assembly and cause erroneous prints or even damage to the carrier assembly A very common problem is where ink has been spilled onto the carrier assembly All electrical circuits should be free of foreign material especially those with conductive properties Clean the carrier assembly by blowing the objects away or gently brush them aside with a soft brush if required Be careful not to let anything to fall into the printer as you clean or it could cause a new problem later Inspect the carrier assembly for any damage to the boards connec tions or any of the components on the assembly Maintenance 49
89. off the center of the slide shaft and adjust the center turnbuckle with an open ended wrench if required for the average value the value found in step 3 SeeFigure 3 13 NO TE The Novajet PRO 60e has two turnbuckles so these need to be adjusted together for the center position m gt z 9 m Figure 3 13 Slide Shaft Profile Adjustment Maintenance 59 Novajet PROe Series Service Manual For example If the Left 0 Right 40 004 then the Center should be adjusted to 0 002 This will ensure a smooth plane of travel for the carriage assembly There are no adjustments on either end of the shaft in all models Head Height Alignment Procedure Perform this procedure only when the encoder strip stabilizer has been removed from the Y Arm or whenever the alignment is in question The head height alignment procedure is to ensure that a 0 065 0 003 0 065 0 003 difference exists between the cartridge jet plate and the Platen See Figure 3 14 Figure 3 14 Carrier Head Height Tolerance 1 Removethe and the right cover of the printer See Chapter 5 for procedures 2 Obtain the3 tools Micrometer Dial Gauge Test Cartridge and Measuring Tip Extender from the Height Gauge Kit Assemblethe tools as shown in Figure 3 15 60 Maintenance Novajet PROe Series Service Manual SPIN HEAD ON MICROMETER GAUGE TO FACE BACKWARDS MICR
90. om the Cradle Idler 7 Remove the C that is securing the motor gear to the motor 8 Using a 1 Phillips screwdriver remove the three screws washers and lock washers from the motor mount to remove the motor o o w lt 1419 3557 Assembly Disassembly 147 Novajet PROe Series Service Manual Install the Media Take Up and Feed Motors 148 Using a 1 Phillips screwdriver install the three screws washers and lock washers that secures the motor to the motor mount Install the motor gear to the motor Secure with a C damp Insert the motor motor mount and motor gear subassembly into the back of the Cradle Idler Tilt the subassembly slightly while installing to align the motor gear with the opening on the top of the Cradle Idler Screw in the screw and washer that secures the motor mount to the Cradle Idler Attach the tension spring to the post on the Cradle Idler Position the Cradle Idler assembly in front of the hole in the leg assembly Attach the wire connectors to the motor red to the positive terminal black to the negative terminal Insert the Cradle Idler Assembly into the leg and secure with four screws Assembly Disassembly Novajet PROe Series Service Manual Figure 5 28 Media Take Up and Feed Motor Removal Remove the Media Drying Fans 1 Ontheleft side of the drying fan assembly is a black wingnut used to adjust the position of the fan assemb
91. or a Turn the Carrier Assembly so that the bottom side of it is facing up b Route the flex on the Paper Sensor through the slot in the Carrier Assembly Make sure the flex cable goes all the way through and does not curl under the Carrier PCB C Grasp the Paper Sensor between thumb and index finger and guide the sides of the board into the grooves on each side of the opening See Figure 5 17 d Push the Paper Sensor board down into the Carrier Assembly until it snaps firmly into place e Turn the Carrier Assembly over and insert the Paper Sensor flex cable into the connector at 3 126 Assembly Disassembly Novajet PROe Series Service Manual f Push both sides of the connector lock shut at the same time 2 To install the Encoder Sensor a Turn the Carrier Assembly so that the bottom side of it is facing up b Push down on the plastic clip and slide the back of the Encoder Sensor over it c Push the Encoder Sensor in past the ridges until the Encoder Sensor snaps into place d Turn the Carrier Assembly over and insert the Encoder flex cable into the connector at J 2 e Push both sides of the connector lock shut at the same time 3 Perform the Carrier Assembly Carrier Belt and the Frame Tensioner Reinstallation procedures to reinstall the Carrier Assembly Replacing the Carrier Bushings If there is not enough space on both sides of the Slide Shaft to remove the Carrier bushings perform the C
92. ort and send the firmware file using the GO EXE type GO NJ PROExx ROM where xx is the version of the firmware NO TE The actual name of the firmware file may change and be different than what is stated above Internal Cabling and Signal Flow Diagrams Figures 3 31 through 3 33 are schematics of the major components and the cabling associated between them The diagrams depicts component boards or assemblies jack connections cables and signal flow It is to be used by the technician as an additional aid in troubleshooting and improve understanding of the printers theory of operation Figure 3 31 shows all cable connections to the MPCB and the power supply Figure 3 32 shows all cable connections to the carrier PCB and Figure 3 33 shows all connections of the leg harness assembly Novajet PROe Series Service Manual MAINTENANCE NM gt ING 8OSN3S AS avoi Alddfis SNIHOIMS T ONS M3MOd z L qavog Loa CBINId NIVW 0193 3nn HOLMS INdNI DV Figure 3 31 MPCB Connections Diagram 77 Maintenance d Ll agavo ayos UNON CaINRId NIVW 6 8 4 HZ 9 Ag
93. ose to the screw as possible and drop the measuring tip onto the platen Dothis a couple of times to ensure an accurate reading 7 Movetheleft end of the stabilizer bracket until a reading of 0 075 0 003 is observed Read only the RED numbers on the micrometer gauge 62 Maintenance Novajet PROe Series Service Manual NOTE The measurement of 0 075 instead of 0 065 as stated earlier is used due to the fact that the test cartridge does not contain a jet plate assembly A 0 010 differ ence had to be added to compensate for the lack of a jet plate assembly on the test cartridge 8 Tighten the screw on the left side of the stabilizer 9 While lifting up the measuring tip of the micrometer slide the Carrier tothe right until the next stabilizer screw is lined up Position it as close to the screw as possible and drop the measuring tip onto the platen Do this a couple of times to ensure an accurate reading 10 Movethe left end of the stabilizer bracket until a reading of 0 075 0 003 is observed Read only the RED numbers on the micrometer gauge E z z gt Z 9 m 11 Tighten the screw on the stabilizer that is next tothe Carrier 12 Continue performing steps 10 through 12 until all four of the stabilizer screws have been adjusted 13 Reposition the Carrier to all of the adjustment positions and verify that the measurements are correct 14 Perform steps 6 through 14 as many times as
94. oubleshooting techniques will have to be implemented to correct the problem General Description Novajet PROe Series Service Manual Chapter 5 ASSEMBLY DISASSEMBLY Contains detailed procedures to remove and replace printer parts and assemblies Chapter 6 PARTS LIST Contains a complete listing of all field replacable parts and assemblies for the Novajet PROe Color Inkjet Printer Illustrated parts breakdown drawings are included to help clarify and identify parts for ordering Special kits and adjustment jigs may also be required WHANAD m D 7 z ORIENTATION Instructions in this manual are based on the assumption that the service person is facing the front of the printer References to top view back view and so forth are consistent with this engineering standard References to the X Axis and Y Axis Paper Axis and Carrier Axis respectively follow the standard of AutoCAD absolute coordinates up and down for X left to right for Y General Description 23 Novajet PROe Series Service Manual Technical Support 24 ENCAD offers full technical support and service for its various products If you are unable to find the answer to your question in either the User s Guide Service Manual or other related publica tions check out ENCAD s Technical Bulletins located on ENCAD s bulletin board or the Internet ENCAD BBS 619 452 2653 or 619 452 3768 ENCAD Website http www encad com Addi
95. remove the Top Cover 1 Putthe Top Cover in the open position by lifting the front of the Cover to the full upward position 2 Depress and hold the retracting stop assembly located on the left side of the Top Cover to disengage it from the Left Cover Assembly Disassembly Novajet PROe Series Service Manual 3 Lift up on the left side of the Top Cover until it dears the Left Cover while still depressing the retracting stop assembly then slide the cover to the left to disengage it from the Right Cover To remove the Right Cover Assembly Figure 5 1 Right Cover Assembly Removal i nstallation 4 With a 2 Phillips screwdriver remove the three screws securing the Right Cover Assembly to the Right Baseplate and the two screws securing it to the Right Sideplate SeeFigure 5 1 5 Reach under the Support Bracket and depress and hold the retracting stop assembly that secures the Right Cover Assembly to the Support Bracket 6 Carefully lift up on the Right Cover Assembly until it clears the printer enough to gain access to the Keypad Display and Backlight connections going to the Main Printed Circuit Board MPCB g o o 00 lt NKIGINASSV 7 Disconnect the Keypad flex cable connection at the J 13 location on the MPCB See Figure 3 4 for jack locations on the MPCB 8 Disconnect the Display data ribbon cable connector at the J 12 location on the MPCB Assembly Disassembly 97 Novajet PROe Ser
96. river the original software package or the RIP if used To eliminate the chance that it is the printer driver 1 Remove RIP or network systems and connect the printer directly to the computer 2 Print atest file approved by ENCAD that uses only the printer driver software and the ENCAD printer Maintenance Novajet PROe Series Service Manual If thetest file prints correctly the problem lies in either the soft ware package that generated the print or the RIP if used Alignments Adjustments The ENCAD Novajet PROe Series printers are designed with a minimum of maintenance requirements in mind Calibrations include color calibration deadband alignment and X axis calibra tion The mechanical adjustment requirements indude the slide shaft profile and cartridge head height adjustments They do not require any electrical alignments Slide Shaft Profile Adjustment The Novajet PROe series printers Slide Shaft height is factory set to 1 418 36mm from the top of the Slide Shaft to the Platen surface The normal operating range for the height of the Slide Shaft is between 1 390 35 3mm to 1 440 36 6mm The Slide Shaft is firmly mounted on the outer sides and only has adjust ments in the middle portion of the shaft to remove any bowing of the shaft s profile The following procedure is to ensure that the Slide Shaft is relatively perpendicular to the surface of the Platen and to remove any bowing that may be present i
97. roubleshooting Novajet PROe Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Media Feed or Take Up Sensor s Not Operating reflective decal dean decal and or is dirty or blocked dear obstruction reflective decal replace reflective missing decal sensor not replace or reshape aligned correctly sensor bracket sensor bracket bent or misaligned o I jo 2 10 318n OH Troubleshooting 93 Novajet PROe Series Service Manual This Page Intentionally Left Blank 94 Troubleshooting Assembly Disassembly 5 Introduction Chapter 5 contains the procedures for removal and replacement of the NOVAJ ET PROe series printer assemblies and mechanisms Illustrations are provided for clarity Steps for each replaceable part may depend on parts already removed in previous disassembly directions It is recommended that you read through each proce dure before beginning the removal and replacement of any assem blies or mechanisms The following is a list of tools which are recommended to disas semble and reassemble the printer 1 Phillips Torque Screwdriver 2 Phillips Torque Screwdriver 1 Slotted Torque Screwdriver 2 Slotted Torque Screwdriver 1 Phillips Screwdriver 2 Phillips Screwdriver 1 Slotted Screwdriver 2 Slotted Screwdriver Wrench 1 4 Screwdriver Socket Head 1 4 Wire Cutters Needle Nose Pliers X ACTO Knife ESD Wrist Strap The followin
98. rvice Department Electrostatic Discharge ESD Sensitivity PCBs Printed Circuit Boards associated with the Novajet PROe printers have components sensitive to ESD electrostatic discharge Care must be taken to avoid damage to any of the components by following current ESD handling procedures and practices Always use an approved ESD grounding strap when handling or working with PCBs General Description 19 Novajet PROe Series Service Manual Warnings Cautions and Notes 20 Warnings cautions and notes are used when additional informa tion instructions or care should be observed In this manual warnings cautions and notes precede the text to which each ap plies The definition of each is provided below WARNINGS Warnings are used to stress that the following steps or procedure has the potential to cause serious harm or death to service personnel Extreme care should be observed when following the procedures and to exercise standard safety procedures They are indicated by Followed by a paragraph describing the concern CAUTION Cautions depict that the following steps or procedures can cause damage to the equipment if not properly followed Ex treme care should be observed when following the procedures and to exercise standard safety procedures They are indicated by Followed by a paragraph describing the concern NOTE Notes are placed before a procedure to inform the service
99. s down on the tab on the Actuator 130 Assembly Disassembly Novajet PROe Series Service Manual f Reattach the spring onto the post on the bottom of the Service Station Sled 2 To install a Service Station Wiper press the new Wiper onto the wiper support 3 Position the Service Station inside the Right Cover and place the left side of the Service Station into the Platen 4 Push down on the right side of the Service Station until the Service Station snaps into place 5 Slide the Carrier Assembly to the right and back into the home position 6 Lower the Top Cover Remove the Trailing Cable Assembly 1 Perform steps 1 through 13 of the Remove the Left Top and Right Covers procedures to remove the Left Top and Right Covers 2 If you have not already removed the Carrier Assembly from the Slide Shaft you will need to perform Steps 3 through 7 of the Removing the Carrier Assembly Carrier Belt and the Frame Tensioner procedures in order to remove the Electronics Cover and release the left end of the Trailing Cable from the Carrier PCB 3 Disconnect the Trailing Cable Assembly connector at the J 6 location on the MPCB Use the thumb and forefinger to pull forward on the connector lock and remove the Trailing Cable from the connector See Figure 3 6 if necessary IN ESI EET 4 The Trailing Cable Assembly is secured to the Stabilizer Bracket by two pieces of double sided tape Remove the Trailing Cable Assembly from
100. s forced out the back of the printer Theory of Operation 41 Novajet PROe Series Service Manual 42 A fan is located inside the platen with its fan vent seen from under the platen on the right side of the printer This fan provides suction on the platen bed and holds the paper media flat during the print ing process The PRO 60e version has an additional suction fan located near the center of the printer inside the platen A fan assembly is attached to the lower part of the printer legs that is used to speeed up the drying time of the ink that is deposited onto the media This is to ensurethat the ink is completely dry before the media is rolled onto the take up reel The PRO 42e has five drying fans while the PRO 60e version has seven The drying fan assembly has been designed to keep power consump tion down to a minimum by only activating the amount of fans that are required to dry the size of media that is loaded on the printer The drying asssembly can also be disabled thru the printers firm ware via the keypad Theory of Operation Maintenance 3 Introduction This chapter contains general maintenance and deaning instruc tions for the Novajet PROe series printers Scheduled Maintenance Scheduled maintenance consists of a list of checks that are planned to be performed on a regular basis or when conditions warrant it Scheduled maintenance can be thought of as preventive mainte nance since its purpose is
101. sassembly Novajet PROe Series Service Manual 7 fthe Carrier Assembly is installed insert the Trailing Cable Assembly into the Strain Relief Assembly Insert the Strain Relief with Trailing Cable onto the Carrier Assembly by sliding it onto the Strain Relief Support until it snaps firmly into place See Figure 5 4 Remove the Stabilizer Bracket and Encoder Strip 1 Perform steps 1 through 13 of the Remove the L eft Top and Right Covers procedures to remove the Left Top and Right Covers 2 Perform steps 2 through 6 of the Remove the Ink Delivery System procedures to remove the Ink Delivery System 3 Perform the Remove the Carrier Assembly Carrier Belt and the Frame Tensioner procedures to remove the Carrier Assembly from the Slide Shaft 4 Perform steps 3 and 4 of the Remove the Trailing Cable Assembly procedures to remove the Trailing Cable Assembly 5 Remove the Support Bracket by slightly tilting the top of the Support Bracket towards the front of the printer and lifting it straight up See Figure 5 21 1419 3557 o o w lt Assembly Disassembly 133 Novajet PROe Series Service Manual Figure 5 21 Stabilizer Bracket Installation Removal 6 Remove the Stabilizer Bracket from the Y Arm Assembly by removing the four alignment Allen screws and washers located on the back of the Y Arm Assembly The Encoder Strip is
102. t replace stepper motor perform Stepper Motor Winding Resistance Check 2 inspect and or replace stepper motor gears and or o z lower roller oc 0 assembly sr at 3 replace MPCB check amount replace or refill of ink in cartridges cartridges e cartridges need perform Prime to be primed color calibration perform Color required Calibration X axis perform X axis calibration Calibration required Troubleshooting 87 Novajet PROe Series Service Manual 88 Table 4 1 Troubleshooting Table cont Symptoms Printer Output is Banding cont Keypad Locked Up or Not Func tioning Properly Troubleshooting cartridge dimple area dirty or damaged flex cable contacts dirty or damaged carrier belt is loose too tight worn or damaged carrier bushings worn or damaged firmware problem keypad assembly damaged faulty connection between MPCB and keypad bad MPCB 1 perform Cartridge Dimple Cleaning procedure 2 replace cartridge 1 perform Flex Cable Contact Cleaning 2 replace carrier assembly reinstall check tension assembly and or replace belt replace bushings 1 reset printer 2 refresh or up grade firmware replace keypad assembly reseat or replace connector replace MPCB Novajet PROe Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Noisy Operation ink or paper debris in print
103. t will perform a series of tests continuously Powering down and restarting the printer is the only way of exiting this test loop Novajet PROe Series Service Manual The Continuous Test will first prime the cartridges followed by a serial port test parallel port test and a fast deadband display The daedband display is used only as a visual inspection of the operating condition of the printer No adjustments can be performed while in the Continuous Test mode A loopback Test Cable is required to correctly accomplish the serial and parallel port tests Install both ends of the Loopback Cable before running this test The Loopback Test Cable is listed in Chapter 6 After completing the deadband display the test will begin again with the prime and continue until power is removed Fan 1 and Fan 2 Tests Tests the operation of the fans on the printer Fan 1 Test while depressed turns on the power supply cooling fan and the suction fan inside the platen on the right side of the printer Fan 2 Test while depressed turns on the suction fan inside the platen near the center of the printer The PRO 42e printer does not have this second suction fan therefore the Fan 2 Test is disabled m 2 gt 2 9 m Legs Test Tests the condition of the leg harness connections and the components of the power feed and take up system Limited Access Menu A menu that is not accessable to the operators can be activated
104. ter dust cover 3 Carefully movethe carrier toward the center of the printer Maintenance 45 Novajet PROe Series Service Manual Using a cotton swab dampened with distilled water wipethe seals and the rubber wiper in the service station until no more ink residue or dust can be removed With a dry swab wipe all moisture from the seals and wipers Close the lid and reconnect the power cord and interface cable Linear Encoder Strip Cleaning Clean the linear encoder strip monthly or as necessary to remove any buildup of debris Distilled water or isopropyl alcohol may be used You may notice that it tends to fog the encoder strip however no detrimental effect has been observed in the field To clean the Encoder Strip 1 2 Disconnect the power cord and interface cable Slightly dampen a cotton swab with distilled water or isopropyl alcohol and wipe along the length of the encoder strip on both sides Reconnect the power cord and interface cable Figure 3 1 Encoder Strip Cleaning 46 Maintenance Novajet PROe Series Service Manual Cartridge Dimples Cleaning T Cartridge Dimples E z m gt z 9 m Figure 3 2 Cartridge Dimple Region The cartridge dimple area can easily be contaminated by oils and dirt on fingers and hands or ink spilled onto them This causes the cartridges to not receive some of the electrical signals for a proper firing of the jets This can be seen as
105. the Slide Shaft Carefully remove the spring that is going into the Slide Shaft from the top of the pinch roller 11 Remove the pinch roller 12 From the bottom of the Y Arm Assembly remove the four screws that secure the Slide Shaft and its two supports from the Y Arm Assembly 13 Using a 1 Phillips screwdriver remove the two screws that secure the Auto Load Sensor to the Y Arm Remove the Auto Load Sensor wires from the four wire clamps on the back part of the Y Arm Bracket Install the Y Arm Assembly Pinch Rollers Slide Shaft and Auto Load Sensor NKIGINASSV o gt o w lt 1 Install the Auto Load Sensor Assembly into the back part of the Y Arm Bracket using 1 Phillips screwdriver Torque to 6 in Ibs Assembly Disassembly 137 Novajet PROe Series Service Manual 138 10 11 12 13 Route the Load Sensor wires through the four wire clamps the back part of the Y Arm Bracket Install the Slide Shaft and two supports to the Y Arm Assembly using four screws Torque to 8 in Ibs Insert the back compression spring onto the shaft of the pinch roller and push the back of the shaft through the back of the Y Arm Assembly Install the C clamp around the shaft of the pinch roller While compressing the forward pinch roller spring with a screwdriver or other flat object position the pinch roller onto the Y Arm Assembly until the forward spring is located under the hole in
106. tional information is available though our Technical Support and Service Department s Help Desk ENCAD Inc Technical Support amp Service Dept 6059 Cornerstone Court West San Diego CA 92121 Help Desk Telephone 619 452 4350 Help Desk FAX 619 546 0659 International Users contact your local ENCAD service provider see details on your ENCAD registration card General Description Theory of Operation Introduction This chapter explains the mechanical and electrical theory of opera tion of the ENCAD Novajet PROe Series Color Inkjet printer The Novajet PROe is a PowerPC 33M Hz microprocessor based digital printer that receives plotting instructions from a host com puter through either the RS 422 serial interface or the Centronics parallel interface Novajet PROe Printer General Block Diagram Figure 2 1 illustrates the major functional areas of the printer The Novajet PROe printer consists of three mechanical assemblies 1 2 3 Paper Media Axis Drive Carrier Axis Drive Media Feed and Take U p System and four main electrical assemblies 1 2 MPCB Main Printed Circuit Board Carrier Assembly Keypad Power Supply 25 0 m gt 2 I m lt Novajet PROe Series Service Manual SERVO avi novE MOTOR CARRIER AXIS DRIVE 4 SENSOR ENCOD
107. to prolong the life of the printer It is not E intended to repair or isolate an existing problem though it can z sometimes be helpful in detecting a condition due to a weakened E component that has not yet completely failed 2 Below is a list of scheduled maintenance checks and their periodic e ity Clean external areas weekly or as required Clean slide shaft monthly Clean service station biweekly Clean encoder strip monthly Clean cartridge dimples if prime fails Clean flex cable contacts if prime fails or cartridge is replaced Clean and inspect motor gears annually Clean and inspect MPCB annually Clean and inspect carrier assembly annually Reseat connectors on MPCB annually Reseat connectors on carrier board annually Replace carrier bushings biannually 43 Novajet PROe Series Service Manual Cleaning Procedures Always turn the printer OFF remove the power cord and the interface cable before cleaning the printer An electrical shock hazard may be present if these proce dures are not followed External Cleaning Do not use abrasive deansers of any sort on the sur faces of the printer Damage to the surface may result The exterior surfaces of the printer may be cleaned with a soft cloth which has been dampened For more persistent stains a small amount of liquid detergent may be used Cleaning intervals are determined by the environment in which the printer is used Slide Shaft Cleaning
108. tor receives digital data from the CPU and generates a sine wave output This signal is fed into a comparator circuit that is measuring the current through the winding of the stepper motor If the current is too low a pulse of 24V is generated When the current goes above the output of the waveform generator the pulse turns off Every time the output of the waveform genera tor is changed by the microprocessor the motor moves 1 micro step Theory of Operation Novajet PROe Series Service Manual Each circuit contains four main blocks see Figure 2 7 1 Reference waveform generator The microprocessor uses a D A digital to analog converter to set the desired level for the current in the stepper motor winding The output of the D A converter varies in time to create a refer ence waveform This reference waveform is centered around 10V 2 Motor current sense The voltage across a series current sense resistor is measured and level shifted so that it is centered around 5V 23 E 29 3 Comparator This portion divides the output of the reference waveform gen erator by two and compares it to the output of the motor current sensor Logic inside the gate array generates the control signals for the power driver that applies voltage across the motor wind ing in order to make the actual current match the reference waveform 4 Power driver An H bridge allows the supply voltage to be applied across the winding
109. using four screws and a 2 Phillips screwdriver 144 Assembly Disassembly Novajet PROe Series Service Manual 14 Perform steps 5 through 14 of the procedures to reconnect the MPCB 15 Reinstall the Left Baseplate using a 2 Phillips screwdriver 16 Reinstall the Left Sideplate using a 2 Phillips screwdriver 17 Perform steps 1 through 4 of the Install the Ink Delivery System procedures to reinstall the Ink Delivery System 18 Perform the Install Left Top and Right Covers procedures to install the Left Top and Right Covers Remove the Media Take Up and Feed Sensor Brackets and Sensors NO TE The sensors for the media Take Up and F eed As sembly are identical but the brackets that they mount to have distinct differences The top bracket has an additional extended arm attached to help in direct ing the media from blocking the sensor s beam path Ensure that the bracket is being replaced with the correct bracket 1 Remove all media and media rollers from the printer 2 Disconnect the sensor leads from the printers leg assembly by squeezing the sides of the connector to release the quick disconnect latches 3 With a pair of wire cutters cut the wire tie wraps see Figure 5 27 that is securing the sensor leads to the sensor bracket KIGINASSV o o w lt 4 Remove the sensor by unscrewing the plastic nut off of the front of the sensor Pull the sensor out of the bracket 5 Usin
110. vice Manual The normal method of downloading new firmware is to send the printer a file of the new code This requires using an appropriate host utility This can be done through either the serial or parallel port This method requires code to be running in the printer to interpret the file If for some reason the EEPROM is blank or corrupt there is an additional step to download firmware to the printer This additional step requires a special Tag Adapter to be placed between the parallel cable and J 16 on the printer s MPCB It is a required step that allows some registers and DRAM to be written to based upon commands sent through the port See Firmware Downloading in Chapter 3 for more information DRAM 23 E 29 DRAM is Dynamic Random Access Memory which provides tempo rary storage of the microprocessor calculation and input output data It is also a faster type of memory then the Flash EEPROM Thats why the printer control program is also copied from the Flash EEPROM to RAM where it can be executed faster The printer also has two 72 pin 32 bit SIMM sockets for DRAM The printer is supplied with a SIMM of 8 Megabytes installed on the MPCB The following SIMM sizes are supported 4MB 1M x32 8MB 2M x32 16M B 4M x32 and 32MB 8M x32 The SIMMs must have a minimum operating speed of 70ns and conform Standard 21 D release 4 or later Remove the Right Cover to install additional memory s
111. y so that accurate printing can be established Theory of Operation 39 Novajet PROe Series Service Manual The paper sensor circuitry senses for the presence of loaded media It does this automatically during the start up and load sequences It also constantly monitors the media during printing to determine if the media has run out If no paper is sensed the paper sensor sends this information to the MPCB which immediately begins an out of paper subroutine This subroutine starts the LEDs on the printer to blink green blinks slow while yellow blinks faster It also informs the host computer of the situation and stops the printer from printing until more media is loaded The sensor also checks for the size of the media loaded so it can determine the proper printing parameters Keypad The K eypad is located on the right side of the printer and consists of 8 variable action control buttons and an LCD graphics display The control buttons are assigned different functions and are dependant upon the selections that are presently shown on the graphics display There are four buttons on the left of the display and four buttons on the right with the display showing up to eight possible selections Figure 2 12 Main Menu 40 Theory of Operation Novajet PROe Series Service Manual Figure 2 12 shows the keypad after the printer has been turned on and finished the start up process As seen in the figure the control buttons are ass
112. y to interface to a Macintosh printer port It has an eight pin Mini DIN connector The data TXD RXD signals meet RS 422 electrical specifications and the control signal DTRCLK meets the RS 423 electrical specifications The control signal can be configured as a 1MHz clock for high speed serial communications with a Macintosh The serial port is compatible with RS 422 devices when an appropri ate adapter cableis used This cableis available from ENCAD Theory of Operation Novajet PROe Series Service Manual Carrier Assembly Circuits OPTICAL ENCODER OPTICAL SENSOR TRAILING CABLE PAPER SENSOR T 23 29 TRAILING CARRIER CABLE PCB CONNECTION FROM MPCB CARTRIDGE 1 CARTRIDGE2 CARTRIDGE3 CARTRIDGE 4 INKJET DRIVERS o CARRIER ASSEMBLY Figure 2 11 Carrier Assembly Circuits The Carrier Assembly contains 1 Carrier PCB 2 Optical Sensors 3 Paper Sensor 4 Inkjet Cartridges The Carrier PCB contains the logic and drive circuitry for the firing of the inkjet cartridges It also establishes an interface path for the optical sensor and paper sensor to communicate with the MPCB The optical sensors receive their inputs from the optical encoder strip and sends this data tothe MPCB The MPCB uses this information to determine the horizontal position of the carrier assembl

SERVICE MANUAL 60e 42e

Contents

Download Pdf Manuals

Related Search

Related Contents