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Kodak NOVAJET 500 User's Manual

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1. ERES mm P O LEG HARNESS Figure 5 27 Inside Platen Right Side Assembly Disassembly 5 49 NovaJet 500 630 700 Series Service Manual 11 12 13 14 15 16 17 18 Reinsert the Service Station 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 Reinstall the Power Supply Bracket using four screws and a 2 Phillips screwdriver Perform steps 5 through 14 of the procedures to reconnect the MPCB Reinstall the left Foam Block Reinstall the Left Sideplate Assembly using a 2 Phillips screwdriver Perform steps 1 through 4 of the Install the Ink Delivery System procedures to reinstall the Ink Delivery System 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 5 50 NOTE The sensors for the media Take Up and Feed Assembly are identical but the brackets that they mount to have distinct differences The top bracket has an additional extended arm attached to help in directing the media from blocking the sensor s beam path Ensure that the bracket is being replaced with the correct bracket Remove all media and media rollers from the printer Disconnect the sensor leads from the printers leg assembly by
2. M 215971 00 GRAY recte 215972 00 CAP RESERVIOR 215918 00 TUBE ASSY RESERVIOR BEU E00 215930 00 GRAY 500 215988 00 BLUE 505 630 700 215971 00 GRAY 505 630 700 215972 00 INK DELIVERY SYSTEM 607 212544 02 INK DELIVERY SYSTEM 42 212560 02 INK DELIVERY SYSTEM 36 218116 00 FITTING FEMALE BLUE 214244 00 FITTING FEMALE GRAY 214245 00 C RING iini ite 207789 SIDE PLATE LEFT eene 210850 SIDE PLATE LEFT 736 212763 04 BASE PLATE LEFT 210544 HARDWARE KIT ee 208810 ASSEMBLY EASYPRIME 216072 00 SIMM 32MB 72 PIN me 210610 ASSY HEIGHT GAGE KIT 209996 1 LOOPBACK TEST CABLE 205462 NovaJet 500 630 700 Series Service Manual PARTS LIST 1 Left Side Parts Breakdown Figure 6 6 3 Parts List NovaJet 500 630 700 Series Service Manual FIGURE ITEM 6 2 1 6 2 2 6 2 3 6 2 4 6 2 6 2 6 6 2 7 6 2 8 Parts List PART NAME PART COVER LEF P tetris 214399 00 INK DELIVERY SYSTEM 60 216921 00 INK DELIVERY SYSTEM 42 216923 00 FRAME
3. ion Harnessiconnector to J3 0n on theStepper Motor connector NovaJet 500 630 700 Series Service Manual 13 Connect thelPower Supply 15 the MPCB 14 Reinstalli ny additionalimemory nto J17 performing steps 1 2 the Install Extra Memory SIMM procedure 15 Perform ssteps4 through 10 ofithe Installthe Left Right Covers procedure to nstall the Right and Covers Remove Power Supply Cooling Fan and AC Entry Module NOTE Theifollowingprocedure covers tems whose tion thoseiShown in thetillustrations when refering tothe NovaJet 750 printer 1 Performsteps lthrough9 fitheiRemovetthe Left and Right Covers procedureltoremovelthe Covers 2 Performsteps3through 15 Main Printed Circuiti Board iprocedurelto removeland protectitihe MPCB 3 Reachlbetween thelPower SupplyBracketiand Entry Module carefully the quick idisconnecti ssembly attachingithe Power Supply nputitotthe AC Entry Module Disconnectithe Power Supply from the Entry Module 4 Disconnectthe clip securing the power supply wires top of theisupportibrac
4. 2 Performsteps2 through the Ink Delivery System proceduresito remove the Ink Delivery System 3 Usingla 2 Phillipsiscrewdriver remove theifouriScrews that secures thelLeft Sideplate Assemblyito thePlaten Remove thelLeft SideplatelAssembly 4 Liftt pionthe connector lockitor nlock the TrailingiCableiconnector J1 0onitheiCarriage and remove the TrailingiCable 5 24 Assembly Disassembly NovaJet 500 630 700 Series Service Manual Figure 5 14 Strain Relief Removal Installation Remove the TrailingiCableiand StrainiRelief Carriage Assembly by releasing onithe left lower SidebftheStrain Reliefiand lifting it off back screwdriverito Servo of theiCarriagelAssembly SeelF igure 5 14 ofthe Frame Tensioner and use ofla Motor pulley 1 5 10 Removelthe Compression Spring from Tensioner and Pushithe CarriageiBeltithrough theiFrame Tensioner enough remove thelIdler Pulley Assembly from theniseti sideithe Assembly anditheiFrame Tensioner SeeilFigure 5 15 Assembly Disassembly tio and 5 25 gt 1 m gy lt 1 55 NovaJet 500 630 700 Series Service Manual COMPRESSION SPRING FITS O
5. aA 5 20 Remove the Ink Delivery 2 lt lt lt tenen nett nene na nha nana nnn na 5 21 Install the Ink Delivery System iicet erede tar ren deed d 5 23 Remove the Carriage Assembly Carriage Belt and the Frame Tensioner 5 24 Install the Carriage Assembly Carriage Belt and the Frame Tensioner 5 27 Remove the Carnage PCB o rrr Rue x RR REP HER Bex Pax EE ERE 5 29 Install the beta teer ne y e ada c 5 31 Remove the Paper Sensor or the Encoder Sensor 5 31 Install the Paper Sensor or the Encoder 5 33 Replacing the Carriage Bushings sm 5 34 Remove the Service Staton co seis rere e ne e 5 36 Install the Service Station 5 36 Remove the Trailing Cable 5 37 Install the Trailing Cable 5 37 Remove the Stabilizer Bracket and Encoder Strip 5 38 Install the Stabilizer Bracket and Encoder Strip 2 5 40 Remove the Y Arm Assembly Pinch Rollers Slide Shaft and Auto Load Sensor 5 40 Install the Y Arm Assembly Pinch Rollers Slide Shaft and Auto Load Senso
6. printer Assembly Disassembly 5 5 NovaJet 500 630 700 Series Service Manual Install the Left Top and Right Covers Tolinstall Cover Assembly 1 Position the while depressing the retracting stop assembly the Support Bracket loweritheLeftiCoverintolpositionionto theiLeftiBaseplate i Release theiretracting stop l ssembly Applyingitoomuch torque to theIowerscrews cancause theimounts for the standoffs the cover tolbreak requir ingl lreplacement ofitheicover 2 Usingia 2 Phillips screwdriver secure the Cover with two screws locatedionitheiright side torque to 15an Ibs nditwolocated underthe baseplate torque to 8n lbs 3 Reinstallthe nk reservoirs reservoir door Tolinstallithe Right Cover Assembly 4 Positionlandi oldithe Right Cover Assembly dver the Right Baseplate and reconnectithe Display Power Converter cableito J 10 5 datairibbon cable 0412 the 6 ReconnectthelKeypadiflex cable 1 3 Ensure that the the cable is facing the SIMM slots 7 Whileldepressing theiretracting stop on theSupport Bracket lower the RightiCoverlAssembly nto position Right Baseplate Releaseithemetractin
7. 2 3 46 3 35 Leg Harness Connections Diagram 3 47 3 36 Leg Harness Connections Diagram 750 3 48 Chapter 4 Troubleshooting 4 1 Carriage Board LED D2 Location for NJ 500 Series 4 19 4 2 Carriage Board LED D2 and 05 Location for NJ 630 700 Series 4 21 Chapter 5 Assembly Disassembly 5 1 Right Cover Assembly Removal Installation 5 3 5 2 Left Cover Assembly Removal Installation 2 5 4 5 3 Left Cover Assembly Removal Installation NovaJet 750 5 5 5 4 Keypad and Display Removal Installation 5 8 5 5 Keypad and Display Grounding Connection 5 9 5 6 Extra Memory SIMM 5 10 5 7 MPCB REMOVAl ce mea 5 13 5 8 Power Supply Removal 5 16 XV NovaJet 500 630 700 Series Service Manual List of Illustrations cont Figure Page Chapter 5 Assembly Disassembly cont 5 9 Cooling Fan AC Entry Module 5 17 5 10 Slacken Carriage Belt T 5 19 5 11 Chain Support Bracket 2 5 22 5 12 nicer enitn nnnm nn nenne RE
8. 3 21 3 14 Carrier Head Height 3 22 3 15 Setting Up Tools from Height Gauge 3 22 3 16 Zeroing the Micrometer Gauge 3 23 NovaJet 500 630 700 Series Service Manual List of Illustrations cont Figure Page Chapter 3 Maintenance cont 9 17 TestCartndge Installed thoro oerte rd tocado es 3 23 3 18 Support Bracket 2 3 24 3 19 Color CallDtatioEi teda otn dex cmd 3 26 3 20 Utility LEE 3 27 3 21 Color Callb MON 3 28 3 22 Cyan Vertical Options 3 28 3 23 Slow Deadbarid ede oae T 3 29 o ME educ 3 30 3 25 Calibration Deadband Menu 500 3 31 3 26 Calibration Deadband Menu 630 700 3 31 3 2f Calibration 3 33 3 28 Color DO Menu tica x toux bue BE UD RR X ERE EE 3 34 3 29 Paper AXIS Test eee n ee e EVER NC 3 36 3 90 Diagnostics 3 37 3 31 ACCESSORY eg ua tdv 3 37 3 32 Clear and Clock 3 40 3 33 MPWA Connections 2 eee 3 45 3 34 Carriage PWA Connections
9. Assembly Disassembly laxlefiestsin the V shapedigroove inthe lover the post of plastic s Assembly sin position pinch the belt itolhold NovaJet 500 630 700 Series Service Manual 15 Fit the Compression Spring over the post at the back of the Y Arm Assembly 16 Fit the notch in the front end of the Frame Tensioner over the notch in the front of the Y Arm Assembly 17 Depress the back of the Frame Tensioner and slip the Carriage Belt over the Servo Motor pulley Make sure that the guides in the Carriage Belt are properly fitted over the Servo Motor pulley 18 Gently move the Carriage Assembly from end to end and make sure that the Carriage Belt is not rubbing against any other parts Remove the Carriage PCB Integrated circuits may become weakened or damaged by electrical discharge Do not touch or work near inte grated circuits without wearing an ESD wrist strap 1 Performthe Carriage Assembly Carriage Belt and the Frame Tensioner Removal procedures to remove the Carriage Assembly from the Slide Shaft 2 Putonan ESD wrist strap 3 Unlock the connectors and remove all flex cables on the Carriage PCB 2 gt m lt Assembly Disassembly 5 29 NovaJet 500 630 700 Series Service Manual lt 17 Carriage PCB Removal Installation 4 Unlock the latch on the right end of the Carriage Assembly and lift Figure 5 up the ri
10. Assembly Disassembly 5 7 gt on m 0 lt 1 55 NovaJet 500 630 700 Series Service Manual 5 5 1 Figure 5 4 Keypad and Display Installation Removal 4 Disconnectthegrounding flex cableifrom the Iargeistandoff before removing the KeypadiAssembly See Figure b 5 for location Remove theliKeypadiAssembly 5 8 Assembly Disassembly NovaJet 500 630 700 Series Service Manual Figure 5 5 Keypad and Display Grounding Connections Install the Keypad Display and Display Power Converter 1 Routethe lKeypadflex dataiand ground cablesinto theiRight CoverlAssembly through theiholeprovided Keypad 2 Placeithe Keypad ntoimpositioni ndihold TurnitheRighti Cover Assembly overland position thelDisplaylAssembly onto the threaded studs Keypad Securet sing fourstandoffswithia 1 4 Socket wrench 1 gt o m m lt 3 Attach the Keypadigrounding flex cable tothe cover shown n Figure 8 5 4 SecurethelDisplaylPower Converter ontoithelDisplay standoffs usingfourlkepnuts with 1 4 Socket or wrench Torquelto 6 in Ibs Assembly Disassembly 5 9 NovaJet 500 630 700 Series Service Manual Remove Extra Memory SIMM 1 Integratedicircuitsimay become weakened or electricalidischarge Domot touchioriwork near ntegrated circuits withoutwearinganESD wristi
11. Install the Carriage Assembly Carriage Belt and the Frame Tensioner 1 To nstalltheiBeltiontoithe CarriagelAssembly the bumps the belt wherelthe ends thelbelti re joined together to makeithe belticontinuous must e positioned between the leftiand right posts ofithe Belt Clamp 5 16 2 SlidetheCarriage Belt between theimiddle post and guide it down into theiBeltiClamp i Thenislide theiCarriage Belt between tthe left posti nd theimiddle post and finish placing theiCarriage Belt Clamp PNIS EE gt 2 m 5 lt 3 Checkithe position ofithe Carriage Belt to makelsurelit matches Figure 5 16 4 amp the Trailing Cablelextendsiout beyond theleftiendof the Trailing Cable SupportiAssembly Assembly Disassembly 5 27 NovaJet 500 630 700 Series Service Manual 5 28 10 11 12 13 14 Slideithe CarriagelAssembly ontotthe leftiend of the Slide Shaft thatithe Encoder Strip fits into the 81061 making sure theWarriage MoveltheWarriage Assembly SlideShaft CarriagelPCB Assembly from left toright onitheiSlideiShaft alignithe left and Guide theibelt whileisliding bushing CarriagelAssembly withithe leftie
12. Select the appropriate port that your printer is connected to either Modem or Printer Drag and Drop the XXXX ROM file or the latest version into the Spool Folder Wait approximately 20 to 40 seconds later until you hear a SINGLE beep indicating the download was successful You may encounter a set of double beeps shortly after sending the firmware file but you must wait until you hear the SINGLE beep z m z 2 z 5 After hearing the single beep remove power from printer for 15 20 seconds Apply power to the printer The printer should initialize properly Verify firmware revision by sequencing through Utility Menu Service Menu About menu Verify firmware has been incorporated If the firmware download is not successful you may hear more than 1 beep or complete silence Check port connections and return to step 4 Maintenance 3 43 NovaJet 500 630 700 Series Service Manual Internal Cabling and Signal Flow Diagrams Figures 3 32 through 3 34 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 32 shows all cable connections to the MPWA and the power supply Figure 3 33 shows all cable connections to the carriage PWA an
13. U m 5 Figure 2 9 Quadrature Signal Generation The direction that the Carriage 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 Carriage Assembly moves left and decrements as the Carriage Assembly moves right The hardware counter is only eight bits wide so it cannot store a value large enough to represent an absolute Carriage Assembly position Instead it is read during the servo interrupt and its value compared with that from the previous interrupt This difference is used to update the absolute position value in the software Theory of Operation 2 13 NovaJet 500 630 700 Series Service Manual Interface Circuits Serial amp Parallel SERIAL MICRO GATE PARALLEL CONNECTOR K TRANSCEIVERK processor ARRAY 2 CONNECTOR 2 14 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 primarily to interface to a Macintosh computer 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 Due to the data flow speed limitat
14. 207729 6 10 18 DRYER ASSY THERMAL 60 750 216911 00 DRYER ASSY THERMAL 42 750 216900 00 6 10 19 ENDCAP ASSY RIGHT W PWA 750 217207 00 6 20 Parts List NovaJet 500 630 700 Series Service Manual PARTS LIST Figure 6 10 Power Feed and Take Up Parts Breakdown 6 21 Parts List NovaJet 500 630 700 Series Service Manual This Page Intentionally Left Blank 6 22 Parts List
15. Mot touch or work Near inte gratedicircuits without wearing 1 Performsteps lthrough9 fitheiRemovetthe Left and Covers procedureltoremovelthe Covers 1 55 2 gt m lt 3 Performstep 2 the SIMM procedure remove nyimemory thatiwasladded 4 Disconnectthe PowerSupply connection at theJ15 Tocationiby grasping the Power Supply connector with thumb and forefinger and pulling straight out SeelFigure 3 4 forjack locations Assembly Disassembly 5 11 NovaJet 500 630 700 Series Service Manual 5 12 10 11 12 13 14 Disconnect thelStepper Motor connection atithelJ1 locationiby grasping the Stepper Motor connector withithumb and forefinger andpullingistraightiout Disconnect ServolMotor connection rediand blue 2 by graspingithe ServolMotor connector with thumb and forefingeriand pulling straightiout Disconnect the Harness connection thelJ3 location grasping the Harness connector with thumb andiforefinger and pulling straightiout Disconnectithe Load Sensoriconnection at 74 locationby grasping theilLioad Sensor connector withithumb and forefinger and pulling straightiout Disconnect the Vacuum connect
16. 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 Remove the Media Drying Fans 5 54 1 On the left side of the drying fan assembly is a black wingnut used to adjust the position of the fan assembly Remove the black wingnut Disconnect the drying fan assembly leads from the printers leg assembly by squeezing the sides of the connector to release the quick disconnect latches Lift the entire drying fan assembly off of the printer Assembly Disassembly NovaJet 500 630 700 Series Service Manual 4 Remove the air filter from the fan to be removed by squeezing the tabs on the filter housing to release the housing off the fan 5 Remove the four bolts securing the back bracket the one with the positioning bolts on the bottom to both of the side plates 6 Pullthe back bracket away from the fans to gain access to the faulty fan Carefully pull the fan away from the front bracket until access 1s gained to reach the electrical connector 7 Disconnect the connector to the fan Install the Media Drying Fans 1 Reconnect the electrical connection to the fan Push the connector and
17. 4 Whenthe 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 Cyan Vertical Cancel Next Option selected Prev Option Figure 3 22 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 to accept the selection and return to the Color Calib Menu 3 28 Maintenance NovaJet 500 630 700 Series Service Manual 6 Continue until all six calibrations on the Color Calib Menu have been accomplished Deadband Alignments 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 Deadband Slow Deadband Lines Tests Single Line Test Figure 3 23 Slow Deadband gt z m z 2 z Figure 3 22 shows what the display will look like when printing the slow deadband test if it is out of alignment A correctly aligned printer will appear as if there is only a series of verticallines 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
18. 6 Perform steps 4 and 5 for all pinch rollers 7 Using 2 Phillips screwdriver secure the Y Arm Assembly to the Platen using seven screws Torque to 15in lbs 8 Perform Install the Stabilizer Bracket and Encoder Strip procedures to install the Stabilizer Bracket and Encoder Strip 9 Perform the Install the Carriage Assembly Carriage Belt and the Frame Tensioner Procedures to install the Carriage Assembly Carriage Belt and the Frame Tensioner 1 gt o m lt 10 Perform the Install the Trailing Cable Assembly procedures to install the Trailing Cable Assembly 11 Perform the Install the Ink Delivery System procedures to install the Ink Delivery System Assembly Disassembly 5 43 NovaJet 500 630 700 Series Service Manual 12 Perform the Install the Left Top and Right Covers procedures to install the Left Top and Right Covers 13 Perform the Head Height Adjustment procedures found in Chapter 3 of this 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 two Foam Blocks 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 Platen 1 Perform steps 1 through 13 of the R
19. Delivery System SupportiBracket it sleasierito Carriage Cover portion af theisSystem theiCarriage for reins Reattachithe Chain SupportiBracket to Positionthe Carriage tallation thel Rear Support Bracket CarriagelAssembly Depress 1 ontotthe Carriage ntil tisnaps into place Move theiCarriagelAssembly SupportiBracket and attacheditothelCarriage l over Figure5 13 Perform SupportiBracket thisiprocedure ofthe Chain of theiCoveri nd lower thelAssembly theiChain SupportiBracketiand adjust ithe Position of Support Bracket tol nsure that there is 0 104inch clearancelbetween the top the bottom of thelchainiassembly thatis on the Carriage Assembly screws Assembly Disassembly 5 23 gt on m 0 lt NovaJet 500 630 700 Series Service Manual 0 10 inch Figure 5 13 Chain Support Bracket Adjustment 6 Performisteps lthroughi3i nd 9 0 of the Install the Left and RightiCoversiprocedure toinstall theil eft Covers Remove the Carriage Assembly Carriage Belt and the Frame Tensioner 1 Performsteps lithrough13 ofthe Remove the Left Top and Right Covers procedures to removelthe Left TopiandiRight Covers
20. iif iit isito be stored your facility for repair Assembly Disassembly 5 13 NovaJet 500 630 700 Series Service Manual Install the MPCB 5 14 Integrated circuitsmay become weak electricalidischarge Domot touchioriwork near ntegrated circuits withoutwearinganESD wrististrap 1 Putioni nlESD wrist strap 2 RemovethelMPCB from thelESD bag enedioridamagediby 3 AligntheMPCBsisotthatitheiseriali ndparalleliconnectionsiprotrude outldfithe back thelholes 4 Usingia 2 Phillips Torque powersupply bracket withi8 n Ibiofitorque ofthe printeri ndithatithe screw holesiare aligned to theipowerisupply bracket Screwdriver fastenithe MPCB to the Ensurethat the groundistraps from thelside 1 5 Connect MPCB 6 Connect 7 Connect MPCB 8 Connect 9 Connect 10 Connect 11 Connect 12 Connect the the the the the the TrailingiCable LoadiSensoriconnector to 4 ServolMotor connector toJ2 Assembly Disassembly screw located beside theiside plate nearest to the the Power Supply tolJ8 onithe connector 7 the MPCB 2 60 connector 16 01 5
21. NovaJet 500 630 700 Series Service Manual 2 10 Serial EEPROM Serial EEPROM 1 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 nonvolatile EEPROM stores calibration and configura tion information It retains data while the unit is off Stepper Motor Controller DATA BUS GENERATOR WAVEFORM gt CURRENT STEPPER COMPARATOR L DRIVER SENSE m MOTOR 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 com mands which the Stepper Motor receives from the microprocessor 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 generator 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 ou
22. Parts List NovaJet 500 630 700 Series Service Manual FIGURE ITEM PART NAME PART 6 9 I WIBER iste eter teo 2092776 6 9 SERVICE STATION ASSEMBLY 207611 03 6 18 Parts List NovaJet 500 630 700 Series Service Manual PARTS LIST Figure 6 9 Service Station Parts Breakdown 6 19 Parts List NovaJet 500 630 700 Series Service Manual FIGURE ITEM PART NAME PART 610 1 SHAFTW FIXED RIGHT ROLLER teens 207657 1 o E 207657 2 610 2 GUIDE PAPER ADJUSTABLE 207644 610 3 CLAMP GUIDE PAPER 207659 610 4 SENSORASSEMBLY 207727 610 5 BRACKET ASSY SENSOR TOP 207656 1 610 6 BRACKET ASSY SENSOR 207752 1 6 10 LEGDRIVE WIRING ASSEMBLY 500 505 630 700 209522 217192 00 610 8 MOUNTING BRACKET DRYER RIGHT 750 217056 00 610 9 MOUNTING BRACKET DRYER 217057 00 610 10 207767 610 11 GEAR DRIVE 207666 630 19 CRADLE DRIVE 207671 6 10 13 STRIKE PLATE ESD BRUSH ASSY 211170 610 214 CRADLE IDLER 207667 610 15 HARNESS RYER WINDER 209043 610 16 FANASSEMBLY DRYER 500 505 630 700 210853 610 17 FILTER DRYER FAN 500 505 630 700
23. gt o m lt 2 AttachthelACIEntry Module ground connection to theigrounding studion Baseplate 3 HolditheiCoolingiF an ntoiplacewhile nserting four boltsinto theldssembly Attach four 1 4 inuts bolts toisecure Fan assembly Torquelto4iin lbs Assembly Disassembly 5 17 NovaJet 500 630 700 Series Service Manual 4 ReinstalltheiPowerlSupply Bracket using four screws 5 Inserti ndhold theiPowerlSupply into place whileisecuring t with fouriScrews l orqueito 15 n lbs 6 Reconnectithe Power Supply tothe Entry Moduleiby reattaching theiquick disconnect connection assembly behindithe Power Supply Bracketiandidut ofisight Push theiquick disconnect 7 Performsteps lithrough 14 0fithe Install procedure to installitheMPCB 8 Performsteps4through l0 ofthe Install the Left andiRight Covers procedure Covers Remove Servo Motor 5 18 1 Performisteps l through Covers procedureltoremovelthe Covers 2 Performiteps33through 13 Circuit Board procedure to MPCB Top And Right Main Printed idisconnect alliconnectors 3 Reachbetweenithe PowerSupply Bracketlandithe Entry Module andicarefully pull outithheiquickidisconnectl ssembly
24. 4 2 Table 4 1 Troubleshooting Table cont Symptoms No Power cont Initialization Failure Media Does Not Move Troubleshooting DCoutput voltage not present see Figure 3 32 for pin out DC voltage present at MPCB SIMM unseated defective or missing faulty take up or feed motor if installed faulty leg harness cable power supply defective trailing cable defective perform Stepper Motor Winding Resistance check rough motion while spinning stepper motor replace power supply replace MPCB reseat or replace SIMM replace motor disconnect at J3 on MPCB to test replace as necessary replace power supply replace trailing cable replace stepper motor if out of tolerance bad bearings replace stepper motor NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Media Does Not paper sensor replace paper Move cont not responding sensor media control driver corrupted switches are reload printer operating correctly driver firmware reload firmware corrupted bad MPCB replace MPCB ESD discharge ensure that all ESD components are properly installed then replace MPCB Internal ERROR Carriage Axis Failure dirty or perform Slide Shaft IZ lubricated slide Cleaning procedure shaft w perform Servo replace servo motor Motor Winding Resistance check check serv
25. Axis Drive U m 5 AYOSHL The Paper Media Axis Drive moves the plotting media in a direction 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 rollers 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 rollers is to apply pressure to the media onto the drive shaft assembly to reduce the chance of slipping Misaligned pinch wheels is a main cause of skewing of the media For that reason the NovaJet 500 630 700 Series was designed with self aligning pinch rollers As the media is fed forward the rollers are aligned correctly However these pinch rollers will not stay aligned while the media is being fed backwards Theory of Operation 2 3 NovaJet 500 630 700 Series Service Manual The Carriage Axis Drive ENCODER STRIP TENSIONING ASSY MOTOR Figure 2 3 Carriage Axis Drive The Carriage Axis Drive moves the printer s carriage 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 m
26. Option rotate through the selections until the value you want is selected Press to accept the selection and return to the Calibration Menu 7 Continue performing steps 4 through 6 until the slow deadband adjustment is correct Maintenance NovaJet 500 630 700 Series Service Manual Color Deadband Alignment for 630 700 Series The color deadband alignments are necessary to ensure that the output images are being produced with the highest quality standards available while using the ENCAD printer in a bidirectional mode These adjustments help to compensate for any deviations that may have become apparent due to the carriage speed and or the type of media loaded Precise calculations are being performed to time the release of the ink drop so that they land on the media at the correct location Differences in media thickness make the distance that the ink has to fall vary and this variable needs to be compensated for in the calcula tions perform the Color Deadband Alignments for the 630 700 Series 1 Select Utility Menu from the Main Menu This brings up the Utility Menu as shown in Figure 3 19 gt z m z 2 z 2 Select the Calibration Menu from the Utility Menu This brings up the Calibration Menu as shown in Figure 3 26 Use Calib XY Open Jet Menu Paper Axis Test Paper Axis Color Db Menu Figure 3 27 Calibration Menu 3 Selectthe Color Db Menv from the Calibrati
27. aeree 207493 SLIDE SHAFT 867 2 2 209265 6 3 bete 207475 BELT 42 decentia re terre 207476 BELT 86 205678 6 8 8 SPRING COMPRESSION IDLER 203999 6 3 9 FRAME TENSIONER 203870 1 6 8 10 IDLER ASSEMBLY 203405 1 6 8 11 AUTOLOAD SENSOR ASSY 207715 6 3 12 PINCH ROLLER ASSEMBLY 207486 6 3 13 SPRING COMP PINCH ROLLER 212542 00 6 3 14 RETAINING E TYPE 200507 6 3 15 PLATEN ASSY 60 207496 8 PLATEN ASSY 42 207509 6 PLATEN ASSY 36 215137 01 6 3 16 KNIFE DAMPER ASSY 202000 6 6 Parts List NovaJet 500 630 700 Series Service Manual Rs gt o o Figure 6 3 Platen and Above Parts Breakdown Parts List 6 7 NovaJet 500 630 700 Series Service Manual FIGURE ITEM PART NAME PART 6 4 1 COVER ASSEMBLY WITH KEYPAD AND DISPLAY RIGHT 210051 AND DISPLAY RIGHT 7396 215045 00 6 4 2 KEYPAD ASSEMBLY 209096 3 KEYPAD ASSEMBLY 736 215046 00 6 4 3 DISPLAY ASSY teet tette tee 210068 04 6 4 4 POWER ENTRY MODULE 207508 6 4 5 FAN COOLING POWER SUPPLY 207593 6 4 6 MAIN PRINTED WIRING
28. check all quick release fittings and connections for possible leaks and ensure that the cartridge 18 primed properly 6 Improper priming The lower secondary chamber within the cartridge may de prime and then temporarily recover after entering the service station causing a momentary color drop out in the print if the cartridge is improperly primed Please reference Technical Bulletin 97 for a more detailed explaination and the corrective priming procedures Maintenance NovaJet 500 630 700 Series Service Manual 7 A flow restriction in the ink delivery system or ink starvation in the cartridge Ink starvation in the cartridge can be caused by a broken valve in a quick release fitting or pinched tube in the ink supply lines of the tubing chain assembly Check the ink delivery system for any flow restrictions by disconnecting the ink cartridge needle from the cartridge in question raise the tip of the needle and observe the rate that the ink flows back into the reservoir The ink should take approximately 1 inch per second to clear the 3 5 inch cartridge tubing between the cartridge and the first quick release fitting flowing back toward the reservoir if it takes longer than this you may need to replace a defective quick release fitting near the cartridge or the reservoir or tubing chain assembly 8 Wiping during a print can sometimes cause a band of lighter density color in the image Auto wipe may need to be temporarily turned off
29. 2 5 2 5 Main Printed Wiring 2 6 2 0 Gato itae aera Re n 2 7 2 7 Stepper Motor 22 2 2 10 2 8 Servo MHO 2 12 2 9 Quadrature Signal Generation 2 13 2 10 Interface CIEGUIES uctor trece eder ru nde c tradet 2 14 2 11 Carriage Assembly 2 15 2 12 Malin MGA 2 E 2 16 Chapter 3 Maintenance 3 1 Cleanirig e tote i taux exui bte RR xe RUEDA Ea Mes 3 5 9 2 Cartridge Dimple Regloh tci oct ort c ste dee eo ra ex edd 3 5 3 9 Flex Cable Contacts cite Ex ud bue 3 6 3 4 MPWA Connection Locaflorns ore cere dd ext d cad 3 9 3 5 Carriage PWA Connection Locations 3 10 3 6 Ribbon Connector Locking Mechanism 3 11 S EE 3 12 3 8 Stepper 3 13 3 9 Power Feed Take Up Motor 3 14 3 10 Examples of Baridingi 2 irre xia dae ota e a 3 15 3 11 Dial Gauge Micrometer 3 19 3 12 Measurement Positions for Slide 3 20 3 13 Slide Shaft Profile
30. 700 Series Service Manual 3 32 Deadband Alignment for 500 Series The deadband alignment is necessary to ensure that the output images are being produced with the highest quality standards available while using the ENCAD printer in a bidirectional mode This adjustment helps to compensate for any deviations that may have become apparent due to the carriage speed and or the type of media loaded Precise calculations are being performed to time the release of the ink drop so that they land on the media at the correct location Differences in media thickness make the distance that the ink has to fall vary and this variable needs to be compensated for in the calcula tions perform the Deadband Alignment for the 500 Series printers 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 3 Select the Calibration Menu from the Service Menu 4 The Calibration Menu is shown in Figure 3 24 and is where the deadband test is performed for the 500 series printers Select Deadband Test to run the deadband test 5 When the plot is complete select Deadband at the Calibration Menu This brings up the options menu for the deadband adjustment This menu is similiar to the menu depicted in Figure 3 21 6 Observe the plot and using either Prev Option or Next
31. Fan Assem blies are oriented in the correct position before inserting into the Platen 3 Slidetheright side of the Lower Drive Roller Assembly inside of the left side of the Platen until the first roller 18 inserted 4 Position and hold one of the Fan Assemblies under the Lower Drive Roller Assembly and between the first and second rollers Continue toinsert the Lower Drive Roller Assembly into the Platen 5 Position and hold the other Fan Assembly for 60 inch model 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 5 48 Assembly Disassembly NovaJet 500 630 700 Series Service Manual 6 Reaching inside the Fan Exhaust hole under the Platen position and secure the Fan Assembly ies using a 2 Phillips screwdriver 7 Reinstall the Fan Exhaust Assembly ies using a 2 Phillips screwdriver 8 Install the Lower Drive Roller Assembly support brackets using a 2 Phillips screwdriver 9 Install the Center Support Bracket Insert the Platen Plug 10 Reinsert the right 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 27 The Foam Block is positioned between the Stepper Motor and the Servo Motor Make sure it is not tilted at an angle SERVICE STEPPER STATION MOTOR
32. LEFT eee 217221 02 TUBE ASSY RESERVIOR BLUE 215930 00 TUBE ASSY RESERVIOR GRAY 215933 00 CAP RESERVIOR ASSY 215918 PACK 215987 00 RESERVIOR ASSEMBLY WITH CAP AND TUBE ASSEMBLY BEBE 215971 00 eee ede 216000 00 GBAY eoi oed 215972 00 PACK eene 216001 00 FITTING FEMALE BLUE 214244 00 FITTING FEMALE GRAY 214245 00 dc 207789 NovaJet 500 630 700 Series Service Manual 2 o Figure 6 2 Left Side Parts Breakdown NovaJet 750 Parts List 6 5 NovaJet 500 630 700 Series Service Manual FIGURE ITEM PART NAME PART 6 3 COVER ASSY 60 216953 00 COVER ASSY 42 216954 00 COVER ASSY 36 215065 00 6 3 2 SPRING COMPESSION 209052 6 3 3 STOP ASSEMBLY 208838 01 6 3 4 TRAILING CABLE ASSY 607 211194 TRAILING CABLE ASSY 42 211195 TRAILING CABLE ASSY 36 209269 01 6 3 5 STABILIZER ASSY WITH ENCODER STRIP 60 209070 ENCODER STRIP 42 209069 ENCODER STRIP 36 215590 00 6 3 6 SLIDESHATT 60 207492 SLIDE SHAFT 42
33. Manual If the LED does not go out setup the printer and download new firmware as discussed in Chapter 3 Repeat these procedures TROUBLE SHOOTING LED D2 If the LED still does not go out possible areas to suspect is the MPCB carriage board or the trailing cable Figure 4 1 Carriage Board LED D2 Location for NJ 500 Series 4 19 Troubleshooting NovaJet 500 630 700 Series Service Manual Initialization Troubleshooting 630 700 Series 4 20 sequence that the printer follows during initialization power up is as follows 1 Power supply turns on LED D2 on carriage turns on then 05 turns on 2 Readsthe Flash ROM information 3 Performs memory test with installed SIMMs 4 Writes the Flash ROM data into RAM for quicker execution of the code Starts executing instructions from RAM 5 Loads MPCB gate array with boot code data 6 Checks for a valid ROM If the ROM is not valid waits for a ROM image to be downloaded 7 Steps 2 4 performed again 8 Loads MPCB gate array with ROM code data 9 Loads gate array on the carriage board LED D2 goes out as soon asthe carriage board gate array 18 programmed 10 Turns on power supply cooling fan 11 Moves carriage 12 Checks and measures media size if loaded 13 Turn on display To troubleshoot using the D2 and D5 LEDs With the power off move the carriage away from the service station and snap the carriage cover off just enough
34. Removing thelLeftiCover allows access tothe left Sidelofithe Platentifor Assembly Carriage Drive Belt Tension Assem bly i nditheiCutter Activator Also located on thisisideisthe nk reservoirs and thelInk Delivery System portionithatis connected reservoirs Removal ofithe Left Cover isla requirement Lower Rollerl Assembly anditheVacuumFan s ifrom inside the Platen Removing tthe Right Cover provides ito fhe Main Printed Circuit Board MPCB Display circuits Servo Motor AC Entry Modulelandtthe Power Supply Cooling Fan The Cover needs to be removed beforelany ofithe other be removed Itidlsolgivesiaccess tottheCarriage Assembly land thelService Station when up positioni ndithe Carriagelislatithe CarriagelAccess position Cover 1 position by lifting the position 2 Depressandholdtheretracting stopl ssembly located on the left side ofthe Cover to disengagelit from Cover 3 itidlears the whileistillidepressing thelretracting stopldssembly then slide the coverito the left disengage it from the Right Cover 5
35. The Color Horizontal Head to Head Calibration checks the alignment of the nozzles horizontally and allows corrections when required Just 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 magenta and Y yellow on the right side of the plot The Color Vertical Head to Head Calibration checks the alignment of the nozzles vertically and allows corrections when required Just 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 magenta and Y yellow on the right side of the plot perform the Color Calibration 1 Select Utility Menu from the Main Menu This brings up the Utility Menu as shown in Figure 3 19 gt z m z 2 z Display Settings Access Cartridge Print Settings Color Calib Menu Service Menu Calibration Menu Exit Figure 3 20 Utility Menu Maintenance 3 27 NovaJet 500 630 700 Series Service Manual 2 From the Utility Menu select Color Calib Menu This brings up the color calibration menu and it looks like Figure 3 20 Cyan Vertical Cyan Horizontal Magenta Vertical Magenta Horizontal Yellow Vertical Yellow Horizontal Calib Print Test Exit Figure 3 21 Color Calib Menu 3 Select Calib Print Test to print the color calibration plot as shown in Figure 3 18
36. 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 Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Connect equipment into an outlet on a circuit different from that to which the receiver is connected Consult the dealer 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 500 630 700 Series Service Manual for NovaJet 736 and 750 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 736 or 750 printers FEDERAL COMMUNICATIONS COMMISION RADIO AND TELEVISION INTERFERENCE FOR CLASS A DEVICE This equipme
37. and the tape securing it to the Trailing Cable Install the Trailing Cable Assembly 1 Apply two new pieces of double sided tape to the Stabilizer Bracket Ensure that the tape 1s in the same location as the original tape was The right side of the Trailing Cable the side connected to the MPCB must extend beyond the Stabilizer Bracket by 5 4 7 8 5 1 87 or 128mm 125mm 181mm 1 gt o m lt 1 55 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 Assembly Disassembly 5 37 NovaJet 500 630 700 Series Service Manual 3 Slidethe Carriage 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 Connect the right end to the MPCB at the J6 location Tape the ferrite to the Trailing Cable approximately 1 4 6mm from the left side of the side plate If the Carriage Assembly is not installed perform steps 5 through 18 ofthe Install the Carriage Assembly Carriage Belt and the Frame Tensioner procedures If the Carriage Assembly is installed inse
38. attachingithe Power Supply input Entry Module Disconnect the Power Supply nput from Entry Module NOTE The following procedure will leavetherMPCB and Power Supply still attachedtoitheiPowerlSupply Bracket ilor thisiprocedure thereismo reasonito removel these assem blies fromthe Bracket 4 Usinga 2Phillips Screwdriver remove theiscrew securingithe ground the plate 5 UsingaZ2Phillips theiPowerlSupply Bracketitoithe Screwdriver removelthe fouriScrews securing Power Supply Bracket Assembly Disassembly Right the NovaJet 500 630 700 Series Service Manual PUSH IN HERE TO SLACKEN CARRIAGE BELT Figure 5 10 Slacken Carriage Belt 6 RemovetheiRight Sideplate toigain access to the ServolMotor by unscrewing the fouriscrews securing t tothe Platen 7 DepressthebackifthelFrame Tensioner seelF igure 5 10 to createislack n theiServolMotor pulley 8 Movetthe Carriage Belt toitheleftiso t1s outiof Servo Motor pulley 9 Movelthe Carriage Assembly tothe leftiendiof theiSlide Shaft 10 Liftup gentlyl nd hold themightiend of the Trailing Cable 11 Using 2 Phillhipsiscrewdriver removeithe back screw on the Servo Motor The screwdriver will be at
39. cause erroneous prints or even damage to the MPWA electrical circuits should be free of foreign material especially those materials with conductive properties Clean the MPWA by blowing the objects away or gently brush them aside with a soft brush 1f required Inspect the MPWA 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 MPWA Maintenance 3 7 NovaJet 500 630 700 Series Service Manual Clean and Inspect Carriage Assembly Foreign material on the carriage assembly could short out signals being developed on the carriage assembly and cause erroneous prints or even damage to the carriage assembly A very common problem is where ink has been spilled onto the carriage assembly electrical circuits should be free of foreign material especially those with conductive properties Clean the carriage 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 carriage assembly for any damage to the boards connec tions or any of the components on the assembly Reseat Connectors on MPWA and Carriage Board Integrated circuits may become weakened or damaged by electrical discharge Do not touch or work near integrated circuits without wearing an ESD
40. dampen a cotton swab with isopropyl alcohol and wipe along the length of the encoder strip on both sides This is necessary to remove any possible residue that may have been left from the NovaKlean solution Reconnect the power cord and interface cable 34 Maintenance NovaJet 500 630 700 Series Service Manual Figure 3 1 Encoder Strip Cleaning Cartridge Jet Area amp Dimples Cleaning gt z m z 2 z CARTRIDGE DIMPLE AREA gt gt CIC DOGG ACA IIT LP Figure 3 2 Cartridge Dimple Region Maintenance 3 5 NovaJet 500 630 700 Series Service Manual 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 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 on fingers and hands can contaminate the area and result 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 NovaKlean Be sure to clean the yellow cartridge because it is not readily apparent that it is dirty The yellow ink is hard to see and could be overlook
41. is damaged 1 55 D gt m lt Assembly Disassembly 5 39 NovaJet 500 630 700 Series Service Manual Install the Stabilizer Bracket and Encoder Strip 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 Install the Support Bracket onto the Stabilizer Bracket Assembly by placing the Support Bracket onto the Stabilizer Bracket with a slight forward tilt Perform the Install the Carriage Assembly Carriage Belt and the Frame Tensioner Procedures to install the Carriage Assembly Carriage Belt and the Frame Tensioner Perform steps 2 through 7 of the Install the Trailing Cable Assembly procedures to finish installing 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 Remove the Y Arm Assembly Pinch Rollers Slide Shaft and Auto Load Sensor 5 40 1 3 Perform steps 1 through 13 of the Remove the Left Top and Right Covers procedures to remove the Left Top and Right Covers Perform steps 2 through 6 of the Remove the Ink Delivery System procedures to remove the Ink Delivery System Perform the R
42. may be useful in servicing the ENCAD Inc NovaJet 500 630 700 Series Color Inkjet Printers ENCAD NovaJet 500 630 700 Quick Start Guide P N 212528 04 ENCAD NovaJet System CD ROM P N 212532 02 Copies of these and other ENCAD Inc publications may be ob tained by contacting your nearest authorized ENCAD Inc dealer or by contacting ENCAD s Technical Support and Service Department Electrostatic Discharge ESD Sensitivity PWAs Printed Wiring Assemblies associated with the NovaJet 500 630 700 series 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 PWAs General Description 1 3 NovaJet 500 630 700 Series Service Manual Warnings Cautions and Notes 14 Warnings cautions and notes are used when additional information instructions or care should be observed In this manual warnings cautions and notes precede the text to which each applies The defini tion of each is provided below WARNINGS Warnings are used to stress that the following steps or procedures has the potential to cause serious harm or death to service personnel Extreme care should be observed when following the proce dures and to exercise standard safety procedures are indicated WARNING Followed by a paragraph d
43. nee AR RR ARR unn 5 22 5 13 Chain Support Bracket Adjustment 5 24 5 14 Strain Relief Removal Installation 2 22 2 224 5 25 5 15 Frame Tensioner RE ter deae 5 26 5 16 Carriage Belt Clamp rtr nite 5 26 5 17 Carriage Removal Installation 5 30 5 18 Paper and Encoder Sensor Removal ns 5 32 5 19 Paper and Encoder Sensor Installation 5 33 5 20 Carriage Bushing eene nennen 5 35 5 21 Carriage Bushing 5 35 5 22 Service Station 5 36 5 23 Stabilizer Bracket Installation Removal sse 5 39 5 24 Y Arm 5 41 5 29 Pinch ERE 5 42 5 26 Stepper Motor Removal Installation 5 47 5 27 Inside Platen rtt exe en take dre 5 49 5 28 Media Take Up and Feed Sensor Removal 5 51 5 29 Media Take Up and Feed Motor Removal 5 53 5 30 Inner Platen Assembly Disassembly 5 57 Chapter 6 Parts List xvi 6 1 6 2 6 3 6 4 6 5 6 6 6
44. observed Read only the RED numbers on the micrometer gauge Tighten the screw on the stabilizer that is next to the Carriage Continue performing steps 10 through 12 until all four of the stabilizer screws have been adjusted Maintenance 3 25 NovaJet 500 630 700 Series Service Manual 14 Reposition the Carriage to all of the adjustment positions and verify that the measurements are correct 15 Perform steps 6 through 14 as many times as necessary to correctly accomplish this adjustment 16 Install the ink delivery system support bracket following the procedures located in Chapter 5 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 areinstalled Figure 3 18 1s a representation of how a color calibration looks when printed SS SS SS SS SS A M SS SS SS SS SS SS c COLOR VERTICAL HEAD TO HEAD CALIBRATION M M I ft ft et d W Wm he Current Heads Y M Figure 3 19 Color Calibration 3 26 Maintenance NovaJet 500 630 700 Series Service Manual The Current Heads Y M 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
45. of applications ENCAD has made significant advances in designing these printers to respond to and anticipate our customers needs Principal features are summarized below Locally or Remotely Configured via Host Computer Powered Media Take Up and Feed System 700 series only Powered Feed Roll and Take Up Basket 500 amp 630 series Optional Powered Take Up Roll System 500 amp 630 series Media Drying System optional on the 500 amp 630 series Thermal Media Drying System NovaJet 750 Quick Ink Changeover Self Aligning Pinch Rollers PowerPC 33 MHz Microprocessor 8 User Configurable Settings 104 Jet Ink Cartridges 500 series 208 Jet Ink Cartridges 630 amp 700 series Ink Priming System 4 500ml Ink Reservoirs 8 for the NovaJet 750 Smart Cartridges Odometer Function Improved Septum Connector Design General Description NovaJet 500 630 700 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 perma nent memory m o Q 2 U z Related Publications The following publication contains additional information which
46. onboard commands that require printing to complete that function The fans will automatically shutdown approximately 20 minutes after the print 1s complete The drying assembly can also be disabled through the printers firmware via the control panel This drying fan assembly is part of the mechanical take up system that 1s optional on the NovaJet 500 and 630 series printers On the NovaJet 750 printers a thermal media drying assembly is used instead of the fan assembly as on the other models It accepts control commands from the MPWA that turns the heating elements on and off It also has two fans located underneath the plenum to push the heated unheated air out of the holes facing the platen to dry the media The drying assembly can be operated with or without the heating elements being turned on Theory of Operation Maintenance 9 Introduction This chapter contains general maintenance and cleaning instructions for the NovaJet 500 630 700 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 maintenance since its purpose is to prolong the life of the printer Itis not intended to repair or isolate an existing problem though it can sometimes be gt helpful in detecting a condition due to weakened component that has not yet completely failed
47. plane of travelfor the carriage assembly There are no adjustments on either end of the shaft in all models Maintenance 3 21 NovaJet 500 630 700 Series Service Manual 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 1s to ensure that the correct amount of distance exists between the cartridge jet plate and the Platen See Figure 3 14 CARTRIDGE JET PLATE M lest PLATEN HEAD HEIGHT pot o Figure 3 14 Carriage Head Height Tolerance 1 Removethe lid and the right cover of the printer See Chapter 5 for procedures 2 Obtainthe 3 tools Micrometer Dial Gauge Test Cartridge and Measuring Tip Extender from the Height Gauge Kit Assemble the tools as shown in Figure 3 15 SPIN HEAD ON MICROMETER GAUGE MICROMETER TO FACE BACKWARDS m di DIAL GAUGE TIGHTEN SET SCREWS TEST CARTRIDGE MEASURING ME TIP EXTENDER ENSURE EXTENDS _ 50 BELOW CARTRIDGE 1 4 6mm Figure 3 15 Setting Up Tools from Height Gauge Kit 3 22 Maintenance NovaJet 500 630 700 Series Service Manual 3 Place the test 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 ZERO ENSU
48. 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 in the shaft s profile Maintenance NovaJet 500 630 700 Series Service Manual The Slide Shaft is set to 1 418 36cm from the top of the Slide Shaft to the Platen surface for the NovaJet 500 630 and 700 series printers The normal operating range for the height of the Slide Shaft is between 1 390 35 3cm to 1 440 36 6cm The NovaJet 505 Slide Shaft is set to 1 478 87 5cm from the top of the Slide Shaft to the Platen surface The normal operating range for this height of the Slide Shaft is between 1 471 87 4cm to 1 483 37 4cm 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 gt Modified Novajet Cartridge for newer products Modified Novajet 4 Pro Pro 50 Cartridge Not Used m Platen Carriage Shaft Mounting Block gt Calibration Jo Block 1 434 Not used Plastic Gauge Card 0 011 Not used m There are two 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 Carriage Cartridge Head Height Setting 1 Connectthe dial gauge micrometer to the Shaft mounting block as shown in Figure 3 11 ZERO Lee GAUGE SH
49. reverse direction Allowable values for the Slow Deadband calibration is 2 1 0 1 and 2 The Single Line Test and Line Test are variations of the deadband test except they print longer lines so that long time integration of the deadband calibration can be observed The Single Line Test prints only one line at a time while the Line Test prints all lines at the same time These tests were designed primarily to be used in manufactoring only The deadband test on NovaJet 500 series printer will look like the display in Figure 3 22 and the procedures to adjust the values are in following section Maintenance 3 29 NovaJet 500 630 700 Series Service Manual Allowable values for the Deadband calibration on the 500 series printers 18 from 0 to 120 The deadband test on a NovaJet 630 or 700 series printer will print a display similiar to Figure 3 22 but will print the pattern for each of the four colors This is just a visual check of the color deadband alignment No adjustments can be made for this test make adjustments if needed see the Color Deadband Calibration section Allowable values for the Color Deadband calibrations on the 630 700 series printers 18 from 0 to 120 but the actual value used by the printer will only accept certain numbers The real value used by the printer will be the closest of 12 20 28 36 44 52 60 68 76 84 92 or 100 To perform the Slow Deadband Alignment 1 Select Utilit
50. the Platen 13 Remove the Stepper Motor Extension Spring from the Stepper Motor and the post on the Left Lower Drive Shaft Bracket See Figure 5 26 5 46 Assembly Disassembly NovaJet 500 630 700 Series Service Manual ATIACH SPRING TO POST ON BRACKET Figure 5 26 Stepper Motor Removal Installation 14 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 26 2 Attach the Stepper Motor tension spring to the Stepper Motor and the Lower Roller Bracket Tighten the Stepper Motor hardware to 8in lb of torque gt 1 m lt Assembly Disassembly 5 47 NovaJet 500 630 700 Series Service Manual 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 ofthe screws that protrude inside of the Platen while installing the Lower Drive Roller Assembly It may be necessary to loosen do not remove the screws that secure the left 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 NOTE Ensure that the Lower Drive Supports and
51. to communicate with the MPWA The optical sensors receive their inputs from the optical encoder strip and sends this data to the MPWA The MPWA uses this information to determine the horizontal position of the carriage assembly so that accurate printing can be established Theory of Operation 2 15 U m 5 2 30 AYOSHL NovaJet 500 630 700 Series Service Manual 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 MPWA which immediately begins an out of paper subroutine This subroutine stops the printer from printing until more media is loaded sensor also checks for the size of the media loaded so it can deter mine the proper printing parameters Control Panel The Control Panel 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 to different functions and are dependant upon the selections that were previously selected 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 Load Media Feed Media Menu Cut Setup Menu Pause Utility Menu Reset Figure 2 12 Main Men
52. to prevent banding 9 Operator intervention If someone lifts up the media on the take up side of the printer while it is printing it can cause momentary banding in the print Lifting up the media while printing changes the inkjet head to media distance and will effect the printed dot size and placement of the ink droplets z m z gt z 10 Cartridge failures cause banding electrical cartridge failures and partial clogging of the inkjets can produce banding With Inkjet Detection and Compensation technology electrical cartridge failures and clogging can be corrected for up to 20 failures per cartridge with minimal degradation of the output 11 Media width variations causing the media to drag on the media guides can cause banding Check the edges of the media for evidence of media drag and edge anomalies 12 Lower quality dithering Select the highest quality dithering pattern in the printer driver i e stochastic dithering 13 Deadband and cartridge calibrations If the deadband calibration is off or the cartridge calibration is off it can effect banding Also if one color seems to be causing the banding shifting the color calibration of that color 1 unit may help Maintenance 3 17 NovaJet 500 630 700 Series Service Manual 14 Inkjet sputter If the cartridge heater is set too high inkjet sputter may occur causing intermittent white spots throughout the print 15 Improper gr
53. to view the LEDs located in Figure 4 2 Turn the unit After a short delay the LED D2 will light This will be followed by D5 turning on D5 will illuminate dimly After about 3 4 seconds LED D2 will extinguish Ensure that the LED extinguishes after about 3 4 seconds Approximately 4 seconds later LED D5 will illuminate brightly momentarily and then return to the dimly lit status The fan will turn on and the carriage assembly will begin to move Troubleshooting NovaJet 500 630 700 Series Service Manual Turn the unit off immediately after the LED D5 returns to the dimly lit status to ensure no damage occurs to the carriage or carriage cover due to the carriage movement as stated in step 11 Snap the cover back onto the carriage LED D5 signifies that bias voltage is available on the carriage board If LED D2 does not go out setup the printer and download new firmware as discussed in Chapter 3 Repeat these procedures If LED D2 still does not go out possible areas to suspect is the MPCB carriage board or the trailing cable I J 5 Figure 4 2 Carriage Board LED D2 and D5 Locations Troubleshooting 4 21 NovaJet 500 630 700 Series Service Manual This Page Intentionally Left Blank 4 22 Troubleshooting Assembly Disassembly 5 Introduction Chapter 5 containsithe procedures for NovaJet 500 630 700 printerlassembliesla
54. wires going to the motor can be removed Remove the wires from the motor From the back of the Cradle Idler disconnect the tension spring from the post located on the Cradle Idler 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 from the Cradle Idler Remove the C clamp that is securing the motor gear to the motor Using a 1 Phillips screwdriver remove the three screws washers and lock washers from the motor mount to remove the motor Assembly Disassembly NovaJet 500 630 700 Series Service Manual MOUNT e GEAR Sole 257 x N EL EN 7 we IU 0 dt C CLAMP CRADLE IDLER AK 1 55 D gt m lt Figure 5 29 Media Take Up and Feed Motor Removal Assembly Disassembly 5 53 NovaJet 500 630 700 Series Service Manual Install the Media Take Up and Feed Motors 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 clamp 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
55. wires into the bracket so the fan can be seated correctly on the bracket 2 Carefully orient all the fans so that the back bracket can be installed correctly Secure the back bracket to the side plates 3 Install the air filter and air filter housing 4 Laythe entire assembly onto the support brackets on the printer Ensure that the cable connector 18 on the right side of the printer as it is installed 5 Reattach the positioning wingnut on the left side of the assembly 6 Attach the wire connector to the leg harness plug Push connector in until firmly seated IXIGINASSV 2 gt o m lt Assembly Disassembly 5 55 NovaJet 500 630 700 Series Service Manual Remove the Thermal Dryer Assembly NovaJet 750 Once the dryer is plugged in there is continuous power being applied to the dryer even when the printer is turned off DISCONNECT POWER CORD BEFORE SERVICING This assembly emits heat by radiation 1 Disconnect the Thermal Dryer Assembly power cord from the back of the printer 2 Disconnect the data cable from the right side of the Thermal Dryer Assembly 3 Locate and remove the four screws securing the Thermal Dryer Assembly to the support brackets Gently lift the Dryer Assembly off the support brackets See Figure 5 30 5 56 Assembly Disassembly NovaJet 500 630 700 Series Service Manual Figure 5 30 Thermal Dryer Assembly Removal 4 Liftthe entire drying fa
56. 0 105535 Adds SS3N3l VH N3lV ld ST LO 00 O 00 O9 55 GaLNiud NIVIN iagram 750 ions D Leg Harness Connecti 3 36 Figure Maintenance 3 48 Troubleshooting 4 Introduction Chapter 4 Troubleshooting consists of a table that is intended to aide the technician in troubleshooting the Novajet 500 630 700 Series 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 Use the 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 data or a procedure that needs to be performed o A 2 Table 4 1 Troubleshooting Table 0 2 m Symptoms printer not ON depress power switch faulty power replace power cord cord AC input not replace AC entry present at power module supply 4 1 NovaJet 500 630 700 Series Service Manual
57. 06 NovaJet 500 630 700 Series Service Manual Figure 6 5 Right Side Parts Breakdown NovaJet 750 Parts List 6 11 18511 1 NovaJet 500 630 700 Series Service Manual FIGURE ITEM PART NAME PART 6 6 1 MOTOR ASSY SERVO W FERRITE AND CAPACITOR 213674 04 6 6 2 BLOCK RIGHT FOAM 207559 BLOCK RIGHT FOAM 736 215526 00 6 6 3 STEPPER MOTOR ASSY 210848 1 6 6 4 BRACKET LOWER ROLLER ASSY 208987 1 6 6 5 BLOCK LEFT FOAM 209177 6 6 6 LOWER ROLLER ASSY 60 207023 207506 c sista 210836 COMPLETE WITH STEPPER MOTOR AND BRACKETS Hed d 217453 00 AD thongs 217454 00 M 217455 00 6 6 GROUND STRAP STEPPER 210837 6 6 8 FANASSEMBLY VACUUM 210139 6 6 9 EXHAUST GRILL 204976 6 6 10 FAN ASSY VACUUM 60 ONLY 210140 6 6 11 SUPPORT CENTER 750 213496 02 SHAFT SUPPORT 750 215252 00 BEARING BALL 750 207503 6 6 12 PLUG PLATEN 750 215189 00 6 12 Parts List NovaJet 500 630 700 Series Service Manual Figure 6 6 Inner Platen Parts Breakdown Parts List 6 13 1511 1
58. 1 1 RE 1 1 e c 1 3 Related Publications 1 3 Electrostatic Discharge ESD Sensitivity 1 3 Warnings Cautions and Notes 1 4 Printer Specifications otio Hk ea EAE ay beds 1 5 Contents of this Service 2 1 6 Technical Support 1 8 Chapter 2 Theory of Operation 4 44 112 1 1 12221 2 1 Een 2 1 NovaJet 500 630 700 Printers General Block Diagram 2 1 Paper Media AXIS DIVE irte ferte Rt RH un ua 2 3 The DEVO e e a teda tes noe dei ee d 2 4 Media Feed and Take Up 1 2 5 Main Printed Wiring Assembly 2 6 se 2 7 Errare 2 7 Ausente 2 8 Flash EEPROM 2 8 DRAM 2 9 Serial EEPROM 4 teret lad dre d a re td du ed a rcd 2 10 Stepper Motor Controller 2 10 Servo Motor CR iia ce 2 12 Interface Circuits Serial amp Parallel 2 14 Carriage Assembly Circuit
59. 2 Assembly Disassembly NovaJet 500 630 700 Series Service Manual theiRBightiCover Assembly Figure 5 1 Right Cover Assembly Removal Installation 4 Withazi2iPhillipsiscrewdriver remove the three screws securing theiRightiCover Assembly RightiBaseplatei nd the two screws securing iit to the RightiSideplate iSeel Figure 5 1 5 Reachunderithe Support Bracketiandidepress and holdithe retractingstop ssemblyithatiSsecures thelRight Cover Assembly to the SupportiBracket gt o m lt 1 55 6 Right Cover Assemblytuntiliticlearsithe printer enough ccessito Display and Backlighticonnections the Main PrintediCircuit Board MPCB 7 Disconnectithe Keypad flexicableiconnection thetJ13 location theiMPCB See Figure 3 4ifor jack locationsion the MPCB Assembly Disassembly 5 3 NovaJet 500 630 700 Series Service Manual 8 DisconnectthelDisplayidatairibbonicableiconnector 12 location MPCB 9 Disconnectithe Display Power Converter connector 10 location the MPCB Toidisconnect grasp Display Power Converter Connector between thumb andfforefingerland pull straight out Toemovelthe Cover Assembly non NovaJet 750 version 10 Door Disconnecti nd r
60. 7 6 8 6 9 6 10 Left Side Parts tte te e estt 6 3 Left Side Parts Breakdown NovaJet 750 6 5 Platen and Above Parts Breakdown 2 6 7 Right Side Parts Breakdown eene 6 9 Right Side Parts Breakdown NovaJet 750 6 11 Inner Platen Parts Breakdown 6 13 Carriage Assembly Parts Breakdown 6 15 Carriage Cover Parts Breakdown sse 6 17 Service Station Parts Breakdown 6 19 Power Feed and Take Up Parts Breakdown 6 21 List of Table Chapter 1 General Description Chapter 2 Theory of Operation Chapter 3 Maintenance 3 1 MPWA Connections Table 3 2 Carriage PWA Connections Table Chapter 4 Troubleshooting 4 1 Troubleshooting Table Chapter 5 Assembly Disassembly Chapter 6 Parts List NovaJet 500 630 700 Series Service Manual Tables Page xvii NovaJet 500 630 700 Series Service Manual This Page Intentionally Left Blank xviii General Description 1 Figure 1 1 NovaJet 500 630 700 Series Inkjet Printers Introduction This manual provides service information for the ENCAD Inc NovaJete 500 NovaJet 630 and the NovaJet 700 Series of Col
61. A is the identical for both printers but it will have to learn which size printer it is installed in Clearing the allows the MPWA to relearn which size printer it 1s reinstalled into Clearing the NVRAM also resets all values to their default settings including the clock After clearing the NVRAM all user settings and electrical calibrations will be lost and needs to be performed again Clock Reset Resets the system clock to 000 This procedure should only be accomplished when refurbishing a MPWA and installing it into another printer Firmware Download Upgrading for the PC gt z m z 2 z normal method of downloading new firmware is to send the file as ifit was a standard print job perform the firmware download follow the steps listed below 1 Power OFF printer wait 15 seconds 2 Connect parallel printer cable between the printer and PC 3 Turnthe printer ON 4 Obtain the latest firmware for your NovaJet 500 505 630 700 736 or 750 printer Save both of the files to the same directory on the hard drive Double click on XXXX EXE file to inflate the compressed files The file name might be different then listed above 5 Gotoa DOS environment and from within that same directory type GO XXXX ROM and press Enter The firmware is sent to the printer as an ordinary print job Maintenance 3 41 NovaJet 500 630 700 Series Service Manual NOTE For NT3 5x or NT4 0
62. AFT MOUNTING TIGHTEN SET 7 BLOCK SCREW NOT SHOWN Figure 3 11 Dial Gauge Micrometer Assembly Maintenance 3 19 NovaJet 500 630 700 Series Service Manual 2 Placegauge against left side of shaft assembly allowing micrometer tip to rest directly on top of shaft See Figure 3 12 Zero the gauge this is to become the reference point MEASURE MEASURE MEASURE FIRST LAST SECOND L A ADJUST IF NECESSARY Figure 3 12 Measurement Positions for Slide Shaft 3 Measure the right side next to media alignment mark and note the difference Divide this amount by two 4 Measure just 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 See Figure 3 13 NOTE The NovaJet 500 630 700 60 inch models have two turn buckles so both of these need to be adjusted together for the center position 3 20 Maintenance NovaJet 500 630 700 Series Service Manual THESE ARE THE TURNBUCKLE SCREWS POSITION GAUGE IN BETWEEN THE SCREWS AND AS CLOSE TO CENTER AS POSSIBLE THIS IS THE INNER SCREW lt gt POSITION GAUGE DIRECTLY 7 IN FRONT OF IT Figure 3 13 Slide Shaft Profile Adjustment gt z m z 2 z For example If the Left 0 Right 0 004 then the center should be adjusted to 0 002 This will ensure a smooth
63. ASSEMBLY MPWA 500 505 213731 00 ASSEMBLY MPWA 630 213782 00 ASSEMBLY MPWA 700 213733 00 ASSEMBLY MPWA 736 218351 00 6 4 POWERSUPPLY ASSEMBLY 209156 07 6 4 8 SIDE PLATE RIGHT 210543 SIDE PLATE RIGHT 736 212761 02 6 4 9 BASE PLATE ASSY RIGHT 210542 6 8 Parts List NovaJet 500 630 700 Series Service Manual PARTS LIST Figure 6 4 Right Side Parts Breakdown 6 9 Parts List NovaJet 500 630 700 Series Service Manual 6 10 FIGURE ITEM 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 Parts List 1 1 0 55 COVER ASSEMBLY WITH KEYPAD AND DISPLAY RIGHT 215350 00 KEYPAD ASSEMBLY 209096 3 REFLECTIVE DISPLAY ASSY 210068 04 MAIN PRINTED WIRING ASSEMBLY 215042 00 POWER ENTRY MODULE 215349 00 FAN COOLING POWER SUPPLY 207593 POWER SUPPLY ASSEMBLY 209156 07 GROUND STRAP 2 5 209160 BASE PLATE 214385 01 SIDE PLATE RIGHT ene 212761 02 GROUND STRAP 10 209159 GROUND STRAP 2 INSIDE COVER ASSEMBLY 2096
64. Below is a list of scheduled maintenance checks and their recom m mended periodicity Clean external areas as required Clean service station 20 30 plot hours Clean cartridge jet area amp dimples 50 60 plot hours Clean slide shaft 75 100 plot hours Clean encoder strip 75 100 plot hours Clean flex cable contacts 75 100 plot hours Clean Y Arm surface 75 100 plot hours Clean cutter groove 75 100 plot hours Clean pinch lower roller 75 100 plot hours Clean platen vacuum holes 100 125 plot hours Clean dryer plenum body NJ 750 only 100 125 plot hours Clean paper sensor as required Clean and inspect motor gears annually Clean and inspect MPWA annually Clean and inspect carriage assembly annually Reseat connectors on MPWA annually Reseat connectors on carriage board annually Replace carriage bushings 3000 plot hours NovaJet 500 630 700 Series Service Manual 32 Cleaning Procedures Always turn the printer OFF remove the power cord and the interface cable before cleaning the printer An electri cal shock hazard may be present if these procedures are not followed External Cleaning Do not use abrasive cleansers of any sort on the surfaces 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 or NovaKlean may be used Cleaning intervals are det
65. CB to fan 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 NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Media Feed Motor Not Operating Sensor Works bad connection reconnect Feed to motor motor bad Feed motor Replace Feed motor faulty wiringleg reseatorreplace 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 Iz Sheet Mode Mode to activate both or Roll Mode to activate feed 5 m motor only under Supply Type from Paper Option Menu Media Feed or Take Up Sensor s Not Operating reflective decal clean decal and or is dirty or blocked clear obstruction reflective decal replace reflective missing decal Troubleshooting 4 15 NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms sensor not replace or reshape aligned correctly sensor bracket sensor bracket bent or misaligned 4 16 Troubleshooting NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Q Troubleshooting 4 17 NovaJet 500 630 700 Ser
66. ENCAD Inc ENCAD NOVAJETe 500 630 700 SERIES COLOR INKJET PRINTER SERVICE MANUAL 500 630 700 Series Service Manual Copyright 1999 2002 Eastman Kodak Company rights reserved KODAK ENCAD and Novajet are trademarks of Eastman Kodak Company Other trademarks and registered trademarks are the property of their respective owners Except as provided below no part of this manual may be copied or distributed transmitted transcribed stored in aretrieval system or translated in any human or comput ing language in any form or by any means electronic mechanical magnetic 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 Certain manuals developed by Encad are in an electronic format to be distributed on CDs or over the internet The registered user of an Encad product whose manual is distributed in this fashion may print one copy for their personal use only Printing history 1st Edition RevA May 1999 2st Edition RevB October 2001 NovaJet 500 630 700 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 500 630 or 700 series printers FEDERAL COMMUNICATIONS COMMISION RADIO AND TELEVI SION INTERFERENCE FOR CLASS B DEVICE This equipment has been tested
67. H DOWN ON ENCODER THEN PULL OUT THIS PIECE OF PLASTIC ONE ON EACH SIDE MUST CLEAR THE RIDGES ON THE UNDERSIDE OF THE HOLDER Figure 5 18 Paper and Encoder Sensor Removal To remove the Paper Sensor a Unlock connector at J3 and remove the flex cable b Turnthe Carriage Assembly over and hold it while firmly grasping the Paper Sensor between thumb and index finger See Figure 5 18 c Pullstraight up on the Paper Sensor and remove it from the Carriage Assembly To remove the Encoder Sensor a Unlockthe connector at J2 and remove the flex cable b Turnthe Carriage Assembly over and lay it with the top side facing down Assembly Disassembly NovaJet 500 630 700 Series Service Manual c Pushdownonthe plastic clip and at the same time push down on the Encoder until the plastic pieces on each side of the Encoder clear the ridges which hold it in place Then pull it straight out Install the Paper Sensor or the Encoder Sensor ALIGN SIDES GROQVES PAPER SENSOR BOARD BETWEEN GROOVES AND PUSH STRAIGHT ROUTE FLEX THROUGH SLOT INSIDE THE CARRIAGE ASSEMBLY 1 PUSH DOWN ON CLIP PUSH ENCODER IN OVER CLIP ENCODER MUST SLIDE PAST THE RIDGES AND SNAP INTO PLACE Figure 5 19 Paper and Encoder Sensor Installation 1 Toinstallthe Paper Sensor Turn the Carriage Assembly so that the bottom side of it is facing up b Route the flex on the Paper Sensor through the slo
68. NovaJet 500 630 700 Series Service Manual FIGURE ITEM PART NAME 6 7 1 CARRIAGE PWA 500 CARRIAGE PWA 630 700 CARRIAGE PWA 736 CARRIAGE PWA 750 6 7 2 ENCODER SENSOR W FLEX 6 7 3 STRAIN RELIEF 6 7 4 PEN CARRIER ASSY PARTIAL 500 505 630 700 736 750 6 7 5 CARRIAGE BUSHING SET 2 6 7 6 PAD BUSHING 500 505 PAD BUSHING 630 700 750 PAD BUSHING NOT USED ON 736 6 7 7 CARRIAGE BUSHING SET 2 750 6 7 8 BUSHING 750 PART 214807 01 214803 02 212151 05 212151 04 209578 101 215659 00 217557 00 217555 00 217565 00 209568 205534 212426 00 209568 216876 00 6 7 9 HOUSING PRELOAD BUSHING 750 217047 00 6 7 10 FERRITE FLEX CABLE 6 7 11 SPRING PAD 104 JET 500 505 208 JET 630 700 736 750 6 7 12 PAPER SENSOR W FLEX 6 7 13 PWB FLEX 104 JET W ID 500 505 209173 400 PWB FLEX QUAD 630 700 PWB FLEX QUAD 736 750 CARRIAGE COMPLETE 500 505 CARRIAGE COMPLETE 630 700 CARRIAGE COMPLETE 736 750 6 14 Parts List 210809 207520 207572 207180 211824 04 215174 00 217556 00 217554 00 217564 00 NovaJet 500 630 700 Series
69. RE PRESSURE IS GAUGE PLACED ON THE REAR OF THE CARTRIDGE T T 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 Ensure that the micrometer can be read from the BACK of the printer gt z m z 2 z Q Figure 3 17 Test Cartridge Installed Maintenance 3 23 NovaJet 500 630 700 Series Service Manual 3 24 Remove the hardware securing the support bracket of the ink delivery system to the chain support Move the support bracket towards the center of the printer until the larger holes on the support bracket line up with the holes on the chain support See Figure 3 18 Figure 3 18 Support Bracket Placement 6 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 Carriage is moved without lifting up on the measuring tip This ac tion could also take the micrometer out of alignment and foul the results of the alignment 7 While lifting up the measuring tip of the micrometer slide the Carriage to the left side of the stabilizer 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
70. Service Manual PARTS LIST SEN IRA A A EEN oy Figure 6 7 Carriage Assembly Parts Breakdown 6 15 Parts List NovaJet 500 630 700 Series Service Manual 6 16 FIGURE ITEM 6 8 6 8 6 8 6 8 6 8 6 8 6 8 6 8 6 8 6 8 6 8 Parts List 1 QC 10 PART NAME PARTS FOR NJ 500 505 630 700 INK DELIVERY SYSTEM 60 INK DELIVERY SYSTEM 42 CARTRIDGE TUBE ASSY SET OF 4 BLUE FOR 500 505 GRAY FOR 500 505 BLUE FOR 630 700 FITTING FEMALE BLUE FITTING FEMALE GRAY PARTS FOR NJ 736 750 COVER TUBING ee ACTUATOR VALVE CLIP VALV E eitis VALVE ASSEMBLY BLUE VALVE ASSEMBLY GRAY 186 INK DELIVERY SYSTEM 60 INK DELIVERY SYSTEM 42 INK DELIVERY SYSTEM 36 PART 212544 02 212560 02 215990 00 215989 00 215992 00 215991 00 207789 214244 00 214245 00 215969 00 214886 01 214521 00 215703 01 215702 01 216920 00 217918 00 215504 01 215505 01 218156 00 216921 00 216923 00 218116 00 NovaJet 500 630 700 Series Service Manual PARTS LIST Figure 6 8 Carriage Cover Parts Breakdown 6 17
71. Stepper Motor Winding Resistance Check 3 13 Power Feed and Take Up Motor Winding Resistance 3 14 Banding Hardware vs Software isses isis tete aee e daa aae doe 3 15 Common Banding Causes 3 16 Alignments Adjustrments E 3 18 Slide Shaft Profile 3 18 Head Height Alignment Procedure 3 22 Color 3 26 Deadband Alignments nace 3 29 Deadband Alignment for 500 Series 3 32 Color Deadband Alignment for 630 700 3 33 Paper Axis Calibration 3 35 Diagnostics 3 37 Limited Access 3 40 Firmware Download Upgrading for the 3 41 Firmware Download Upgrading for the 3 42 Internal Cabling and Signal Flow Diagrams 3 44 Chapter 4 4 1 p TH 4 1 4 1 Initialization 4 2 Media Does NOt o 4 2 Intern
72. VER THIS POST COMPRESSION SPRING FRAME TENSIONER CARRIAGE BELT ON 9 THIS NOTCH IN THE END THE C BRACKET THIS NOTCH IN THE FRAME TENSIONER MUST FIT IDLER PULLEY ASSEMBLY SIDE WITH THICKER OUTER RING PLASTIC MUST FACE UP Figure 5 15 Frame Tensioner 9 Slhdethel CarriagelAssembly land DriveiBelt offithe leftiside ofithe Slide Shaft 10 Onceithe CarriagelAssembly s removed from Shaft turn thatlyoulcanisee the Mee 5 16 CARRIAGE BELT RIGHT POST OF BELT CLAMP LEFT POST OF BELT CLAMP Figure 5 16 Carriage Belt Clamp 5 26 Assembly Disassembly NovaJet 500 630 700 Series Service Manual 11 Toldisengage the Carriage theiBeltiClamp pushithe Carriage Beltlaway from theleftipostiof theiBelti Clamp and gently liftt p untilithebottomiedge of theiCarriage clearsitheltop of theleft post 12 Push fromithe right post of Belt Clamp and gently lift finish removing the Carriage Belt from theiBeltiClamp Failure touse niapproved antistaticlbag foristorage or shipmentimay causeldamagelto the MPCBiand affect thelWarranty 13 PlacetheiCarriagelAssembly ini nESD antistatic bagin preparation forishipmentito ENCAD for repair ifit stolbeistored your facility
73. al ERROR Carriage Axis 4 3 Xi NovaJet 500 630 700 Series Service Manual Table of Contents cont Chapter 4 Troubleshooting cont Internal ERROR Encoder Sensor Failure 4 5 Internal ERROR Paper Sensor Failure sss 4 5 Internal ERROR Auto Sensor 4 6 Internal ERROR MPCB 2rd ee rite itr cence 4 6 Unrecognized Cartridges Error emnes 4 6 Image Skews or MOVES i ii irte erento atu 4 7 Does Not Prini Ee eee tes ted dee sends 4 7 Ink Cartridge 8 4 7 4 9 Printer Output is Banding Horizontal 4 9 Printer Output is Banding 4 11 Printer Output is Banding Horizontally and 4 11 Keypad Locked Up or Not Functioning Properly 4 11 NOISY Operation e 4 12 Line Quality Degraded 4 13 Fan Does NotPower Up ied nerd eet 4 14 Media Take Up Motor Not Operating Sensor Works 4 14 Media Feed Motor Not Operating Sensor Works 4 15 Me
74. at thelguidesion the inside ofthe belt dreiinserted in the pulley grooves andithat the belt 15 motitwisted 8 Movelthe Carriagel Assembly backland forth toicheck the Carriage Beltitension 5 20 Assembly Disassembly NovaJet 500 630 700 Series Service Manual 9 Reinstallithe Right Sideplateiwith four screws anda 2 Phillips screwdriver Press thelside plateidown and towards tthe back oflthe printer before tightening l l orqueito 15 n Ib 10 Ensurefthatiallicableiendings reiprotruding through thelcable Sideplate 11 Bracket with assemblies using four screws 12 theigrounding strap from the MPCBito theiside plate 13 ReconnectithePowerlSupply AC Entry Module bylieattaching theiquickidisconnecticonnection Push the quick disconnect assemblyibehindithe Power SupplyiBracket andiaut of sight 14 Perform steps bithrough 13 ofithe InstallitherMPCB procedure to reinsertithe removed connections from the M PCB 15 Perform ssteps4 through 10 ofithe Install the Left Right Covers procedure to nstall the Right Covers Remove the Ink Delivery System NOTE The following procedure covers tems whosel xactiloca tion nd or ppearance may differitlhenithoseshown in theillustrations when refering to thelNovaJet 750 print
75. aterials Also included is a description of the use of Warnings Cautions and Notes as used in this manual and chapter contents 1 6 General Description NovaJet 500 630 700 Series Service Manual 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 8 7 m o Q 2 U z 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 Ifthe problem happens to be the wiring between assemblies standard troubleshooting techniques will have to be implemented to correct the problem 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 500 630 700 Color Inkjet Printers Illustrated parts breakdown drawings are included to help clarify and identify parts for ordering Special kits and adjustment jigs may also be required ORIENTATION Instru
76. 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 pinch rollers or the rollguides on the back of the printer these possible faulty areas deal with a rotational movement that if faulty will generate a consistent banding pattern The MPWA and Carriage PWA can also cause this type of error to incur gt Z m z gt Software banding 18 characterized by inconsistent banding lines These banding lines are generated by the software when the applica tion incorrectly interprets the media advancing ink firing sequence of the expected print file Because it 1s not directly tied to a mechanical movement the bands become inconsistent in both frequency and duration The possible causes are the printer driver the original software package or the RIP if one is used To eliminate the chance that itis the printer driver 1 Remove any RIP or network systems and connect the printer directly to the computer 2 Printatest file approved by ENCAD that uses only the printer driver software and the ENCAD printer Maintenance 3 15 N
77. carriage 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 carriage assembly Color Test The Color Test prints a wide swath of each 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 1096 25 3596 5096 6596 75 and 10096 Continuous Test Continuous Test sends the printer into test loop that will perform a series of tests continuously Powering down and restarting the printer 18 the only way of exiting this test loop 3 38 Maintenance NovaJet 500 630 700 Series Service Manual The Continuous Test will first prime the cartridges followed by a serial port test parallel port test a fast deadband display and a color calibration display The deadband and color calibration displays are 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 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 remove
78. ctions 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 Carriage Axis respectively follow the standard of AutoCAD absolute coordinates up and down for X left to right for Y General Description 1 7 NovaJet 500 630 700 Series Service Manual Technical Support ENCAD offers full technical support and service for its various prod ucts If you are unable to find the answer to your question in either the User s Guide Service Manual or other related publications check out ENCAD s Knowledge Base located on ENCA D s website support ENCAD Website http www encad com Additional 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 858 452 4350 or 877 ENCAD TS 862 2387 Help Desk FAX 858 558 4672 International users contact your local ENCAD service provider See details on your ENCAD registration card 1 8 General Description Theory of Operation 2 Introduction This chapter explains the mechanical and electrical theory of operation ofthe ENCAD NovaJet 500 630 700 Series Color Inkjet printers The NovaJet 500 630 700 Series is a PowerPC 33M Hz microproces
79. d 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 Z2 Test while depressed turns on the suction fan inside the platen near the center of the printer The 42 inch printer does not have this second suction fan therefore the Fan 2 Test is disabled gt z m z 2 z Legs Test Tests the condition of the leg harness connections and the components of the power feed and take up system Maintenance 3 39 NovaJet 500 630 700 Series Service Manual Limited Access Menu 3 40 A menu that is not accessable to the operators can be activated in the Service Menu as shown in Figure 3 31 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 Calibration Menu About Diagnostics Menu Exit ENTER 16753 TO GET y Clear NVRAM Clock Reset Exit Figure 3 32 NVRAM Clear and Clock Reset Menu Maintenance NovaJet 500 630 700 Series Service Manual This menu allows the technician to clear the NVRAM and to reset the system clock Clear Clearing the is required anytime that MPWA is to be permanently removed from a printer The NVRAM is a section of nonvolatile memory that stores printer size information The MPW
80. d Figure 3 34 shows all connections of the leg harness assembly 3 44 Maintenance NovaJet 500 630 700 Series Service Manual NO L INO YOSNAS YOSNAS AST dyol CNS SSANUVH 931 ONI3S LINDUD NIYIN MAINTENANCE AlddNS ee Avo vlel3S CQVdA3 9 1514 AVE 318 2 HOLMS UMd 8 OV Figure 3 33 MPWA Connections Diagram 3 45 Maintenance NovaJet 500 630 700 Series Service Manual SUJANA Qavog NWA 924 3 TvOlldO 318vO NNIVAL Figure 3 34 Carriage PWA Connections Diagram Maintenance 3 46 NovaJet 500 630 700 Series Service Manual MAINTENANCE AldIN3SSV 3 AJANA cL cL cL cL L SS3N3IVH O11 H A NVI ON Qavog NIVIA SS3N3I VH Figure 3 35 Leg Harness Connections Diagram 347 Maintenance NovaJet 500 630 700 Series Service Manual Al8A3SSs vans 554 931 99999 9 NV3 BAMIG 8 3 Aver _____
81. data busses It has two built in serial ports a two channel DMA Direct Memory Access controller a timer module clock 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 channel sup plies 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 millisecond the other is used for timing the Stepper Motor NOILVaadO m 2 lt E A 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 PARALLEL PORT SERVO CONTROLLER TO CARRIAGE STATIC PWA RAM Figure 2 6 Gate Array Theory of Operation 2 7 NovaJet 500 630 700 Series Service Manual 2 8 The gate array contains the hardware logic for jet firing monitoring changes in the Carriage Assembly position controlling DMA through the parallel port and generating the PWM Pulse Width Modulation waveforms for the servo controller The gate array is a Xilinx device I
82. 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 vii NovaJet 500 630 700 Series Service Manual Material Safety Data Sheet viii ENCAD QIS Quality Imaging 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 ENCAD Inc at 6059 Cornerstone Court West San Diego CA 92121 3734 619 452 4350 International users should contact their local dealer or distributor NovaJet 500 630 700 Series Service Manual WARRANTY OR DAMAGE CLAIMS United States ENCAD S 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 impli
83. dia Feed and Take Up Motors Not Operating Both Sensors Working 4 15 Media Feed or Take Up Sensor s Not Operating 4 15 Initialization Troubleshooting 500 Series 4 18 Initialization Troubleshooting 630 700 4 20 Chapter 5 AssemblyMDisassembly 5 1 riferito EE 5 1 Remove the Left Top and Right Covers 5 2 Install the Left Top and Right 5 6 Remove the Keypad and Display 2222 222 1 12 12444 0400 5 7 Install the Keypad and 5 9 Remove Extra Memory SIMM 2 22 1 nemi oen ami Dares 5 10 Install Extra Memory 5 11 Remove the MPCB Main Printed Circuit Board 5 11 mstallthe T 5 14 Remove Power Supply Cooling Fan and AC Entry Module 5 15 Install the Power Supply Cooling Fan and AC Entry Module 5 17 Xii NovaJet 500 630 700 Series Service Manual Table of Contents cont Chapter 5 Assembly Disassembly cont Remove Servo 5 18 install
84. ed Follow this up by gently dabbing the jet plate area on the bottom of the cartridge Flex Cable Contact Cleaning Flex Cable Contacts Figure 3 3 Flex Cable Contacts 3 6 Maintenance NovaJet 500 630 700 Series Service Manual Cleaning the flex cable contact area is very important due to the ease of which this area can become dirty The flex for the yellow cartridge is deceiving because it is not readily apparent that it is 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 NovaKlean Clean and Inspect Stepper Motor Gears gt z m z 2 z stepper motor gears can become dirty and after time if not cleaned up it could cause wide banding in the print This will reduce the quality of the intended output Clean the motor gears with a stiff brush to knock off any debris A cotton swab soaked NovaKlean can be used to remove any ink that may have accumulated on the gears Clean and Inspect MPWA Foreign material on the MPWA could short out electrical signals being developed on the MPWA and
85. ed warranties 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 e Unauthorized modification of the Product Adverse environmental conditions e Service of the Product by other than an ENCAD authorized service provider e Unauthorized or improper use including but not limited to Use 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 500 630 700 Series Service Manual Table of Contents Chapter 1 General Description ennnen
86. embly is driven by the Servo Motor The speed of the Carriage Assembly is controlled by varying the duty cycle of the signal applied to the controller The microprocessor checks the position of the Carriage Assembly approximately 1 000 times per second during the servo interrupt It then updates the PWM pulse width modulator register in the gate array which sets the duty cycle to make adjust ments to the Carriage Assembly speed A linear optical encoder is used to monitor the Carriage 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 quadra ture signals It gives an effective resolution of 600 lines per inch See figure 2 9 for a graphical representation of quadrature signals For 300 dpi resolution one of the detectors is not used Theory of Operation NovaJet 500 630 700 Series Service Manual DETECTOR 2 lt DETECTOR 1 OUTPUT OF DETECTOR 1 PLI LI LE LE LI LIE LILI L OUTPUT OF DETECTOR 2 10 COMPOSITE TRANSITION TRIGGERED OUTPUT OF BOTH DETECTORS 4 OUTPUT PULSES PER OPTICAL LINE AYOSHL
87. emove allink reservoirs Figure 5 2 Left Cover Assembly Removal Installation 11 Withia 2 Phillipsiscrewdriver remove theitwolscrews securing the thelLeft Baseplatelanditheltwolscrews securing it toithe Left Sideplate Figure 5 2 12 Reachunderithe Support Bracketianddepress and retractingstop assembly thatisecures the Left Cover Assembly to the Support Bracket 13 Carefully Left Cover Assembly up and ioffithe printer 54 Assembly Disassembly NovaJet 500 630 700 Series Service Manual the lLeft Cover Assembly NovaJet 750 version 10 Disconnecti nd remove reservoirs Figure 5 3 Left Cover Removal Installation NovaJet 750 11 Remove the tjwo screws securing the Left Coverito the Left Frame See tthe upper portioniof Figure 5 3 12 Support Bracketianddepress and holdithe retractingstop ssemblythatisecures the Left Cover Support Bracket gt o lt 13 Insert flathead Screwdriver intolthelgap between theLefti overland shown nithe lower portion Figure 5 3 land twist Inserti nd twist ntoiasmany gaps necessary loosenithe cover from the ERES 14 Carefully lift theil eftiCover
88. emove the Carriage Assembly Carriage Belt and the Frame Tensioner procedures to remove the Carriage Assembly from the Slide Shaft Assembly Disassembly NovaJet 500 630 700 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 Stabilizer Bracket and Encoder Strip procedures to remove the Stabilizer Bracket Assembly 6 Disconnect the Load Sensor connector at the J4 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 24 1 gt o m lt Figure 5 24 Y Arm Installation Removal 8 The pinch rollers are held on by a small clamp located on the back of the Y Arm Assembly See Figure 5 25 While holding the pinch roller remove the C clamp and move the pinch roller towards the front of the Y Arm Assembly until it clears the back of the Y Arm Bracket Assembly Disassembly 5 41 NovaJet 500 630 700 Series Service Manual 5 42 10 11 12 13 Figure 5 25 Pinch Roller Spin the back of the pinch roller to either side and remove the back spring Carefully tilt the back of the pinch roller upwards This brings the front of the pinch roller down away from the Slide Shaft Carefully remove the spring that is
89. emove 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 any Foam Blocks so that it does not tear Itis very important to have an intact Foam Block to produce sufficient vacuum inside the Platen to properly hold down the media 4 Using the accesses gained by removing the Right Sideplate and the Service Station remove the right 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 System procedures to remove the Ink Delivery System 5 44 Assembly Disassembly NovaJet 500 630 700 Series Service Manual 6 Remove the screws that secure the Left Sideplate Assembly to the Platen Remove the Left Sideplate Assembly and the left Foam Block See Figure 5 24 NOTE The 42 1nch model has one Vacuum Fan and Exhaust assembly while the 60 inch has two sets of Vacuum Fans and Exhausts 7 Using a 1 Phillips screwdriver remove the four screws the bottom of the Platen which holds the Fan Exhaust s in place 8 Onthe NovaJet 750 remove the Platen Plug from under the Platen 9 Onthe NovaJet 750 remove the black flat head screws from the top of the Platen that holds the Center Support in p
90. er 1 Performisteps l through 3iand 10ithrough 13 of theiRemoveithe Left andiRightiCoversprocedures ito remove the Top and Left Covers 1 gt o m lt Assembly Disassembly 5 21 NovaJet 500 630 700 Series Service Manual Figure 5 11 Chain Support Bracket Removal 2 Removethelcrews securing theiChain Support Bracket SupportiBracket See Figure 8 11 3 MovelthelWarriage tothe center of the SlideiShaft Figure 5 12 Carriage Cover Removal 5 22 Assembly Disassembly 4 Withaflatheadiscrewdriver press the Carriage Delivery System tab located inithe theiCarriagelAssembly Figure sidelofithe CarriageWover ntil ticomeslpartiway CarriagelAssembly Then 6 NovaJet 500 630 700 Series Service Manual upper slot 5 12 Cover p olthe Tnk dn the leftisideldf On the front on the front loffiofithe rightisidelofithe Carriage Cover ndimoveithe Carriage Cover slightly toithe left thatithelback of1ticlears theiBack Support Bracket Disconnect the Ink Delivery System Bracket from Sideplateusingiazz2Phillipsiscrewdriver CarefullyislideithelInkiDelivery System Gutidfithe printer Install the Ink Delivery System 1 Secure the Ink Delivery System Bracket to the Left Sideplate using twolscrews Position
91. ermined by the environment in which the printer is used Service Station Cleaning Ink and dust may build up on the service station resulting in contami nation which may smear the prints The service station 1s cleaned as follows 1 Turnthe printer OFF Disconnect the power cord and interface cable 2 Raisethe printer lid 3 Carefully move the carriage toward the center of the printer Maintenance NovaJet 500 630 700 Series Service Manual 4 Usingacotton swab dampened with water wipe the seals and the rubber wiper in the service station until no more ink residue or dust can be removed 5 With a dry swab wipe all moisture from the seals and wipers 6 Close the lid and reconnect the power cord and interface cable 7 Ifthe service station is filling with ink or very dirty it can be removed and rinsed under warm water To remove pull the tab on the right side of the service station and lift out Wash dry thoroughly and replace by placing the left side in first then pushing down on the right side until the tab locks it in place Slide Shaft Cleaning Use only NovaKlean or 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 gt z m z 2 z Printer problems be caused by an accumulation of dirt or other contamination on the slide shaft This contamination may lead to drag on the carr
92. ervice Station farther to the right might be required to release the left side of the Service Station Install the Service Station 1 install the Service Station position the Service Station inside the Right Cover and place the left side of the Service Station into the Platen Push down on the right side of the Service Station until the Service Station snaps into place Slide the Carriage Assembly to the right and back into the home position Lower the Top Cover 5 36 Assembly Disassembly NovaJet 500 630 700 Series Service Manual 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 Ifyou have not already removed the Carriage Assembly from the Slide Shaft you will need to perform Steps 3 through 7 of the Removing the Carriage Assembly Carriage Belt and the Frame Tensioner procedures in order to remove the Electronics Cover and release the left end of the Trailing Cable from the Carriage PCB 3 Disconnect the Trailing Cable Assembly connector at the J6 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 4 The Trailing Cable Assembly is secured to the Stabilizer Bracket by two pieces of double sided tape Remove the Trailing Cable Assembly from the Stabilizer Bracket 5 Removethe ferrite
93. escribing the concern CAUTIONS Cautions depict that the following steps or procedures can cause damage to the equipment if not properly followed 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 NOTES Notes are placed before a procedure to inform the service 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 NovaJet 500 630 700 Series Service Manual Printer Specifications The specifications and performance characteristics of the NovaJet 500 630 700 Series Color Inkjet Printers are as follows Max Printing Area 42inch 60inch Norm 40 8 58 8 1 04m 1 49m Extend 41 61 59 61 1 06m 1 51m Language Emulation HP RTL EN RTL HP GL 2 Buffer 32 MB installed 630 700 8 MB installed 500 series upgradeable to 128 MB Power Requirements Input Voltage 90 264 VAC 48 63 Hz Output Power 20 W idle 140 W typical 215 W maximum Resolution 630 700 series 600x600 dpi or 300x300 dpi addressable 500 series 300x300 dpi Baud Rates 9600 19200 38400 Accuracy 0 2 line length using ROLL feed and 4 mil drafting matte film Interface Centronics parallel IEEE 1284 RS 422 serial Network Opti
94. et 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Line Quality Degraded ink cartridges dirty or clogged cartridge dimple region dirty or damaged color calibration needed deadband calibration needed in bidirectional printing mode debris or ubrication on slide shaft leaks or bubbles in ink delivery lines dirty encoder strip carriage bushings worn drive belt worn clean 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 carriage bushings replace drive belt Troubleshooting 4 13 o NovaJet 500 630 700 Series Service Manual 4 14 Table 4 1 Troubleshooting Table cont Symptoms Line Quality Degraded cont Fan Does Not Power Up Media Take Up Motor Not Operating Sensor Works Troubleshooting drive belt slipping on idler vacuum fan not operating MPCB has 24 VDC at J3 pins 1 2 power not being applied to fan printer not in Take Up Mode bad connection to the motor bad Take Up motor faulty wiring leg harness MPCB replace frame tensioner spring or idler replace fan assembly 1 reseat connection at MP
95. ext Option rotate through the selections until the exact value of the measurement found in step 5 18 selected Press to accept the selection and return to the Calibration Menu 3 36 Maintenance NovaJet 500 630 700 Series Service Manual Diagnostics Menu The Diagnostics Menu is located in the Service Menu shown in Figure 3 23 and 1s seen in Figure 3 29 Servo PWM Test Carriage Test Servo Cycle Test Color Test Accessory Menu Continuous Test Exit Figure 3 30 Diagnostics Menu gt z m z 2 z tests under the Diagnostics Menu should 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 30 Fan 1 Test Fan Z2 Test Legs Test Figure 3 31 Accessory Menu Maintenance 3 37 NovaJet 500 630 700 Series Service Manual 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 Carriage The test performs three complete cycles of the carriage assembly and lists the average PWM the maximum PWM and the position of the carriage where the maximum PWM occured Servo Cycle Test Tests the servo motor by moving the
96. ght end of the Carriage PCB See Figure 5 17 5 Slide the Carriage PCB to the right to remove the tab on the left end of the Carriage PCB from the slot in the Carriage Assembly Assembly Disassembly 5 30 NovaJet 500 630 700 Series Service Manual Failure to use an approved antistatic bag for storage or shipment may cause damage to the Carriage PCB and affect the Warranty 6 Placethe Carriage PCB in an ESD bag antistatic bag in preparation for shipment to ENCAD for replacement or repair or if itis to be stored at your facility for repair Install the Carriage PCB 1 Put the tab on the left end of the Carriage PCB into slot in the left side of the Carriage Assembly See Figure 5 17 2 Ensurethat no flex cables are underneath the Carriage PCB 3 Pushdown the right end of the Carriage PCB until the latch snaps into place 4 Reattach all flex cables on the Carriage PCB 5 Perform the Install the Carriage Assembly Carriage Belt and the Frame Tensioner procedures to reinstall the Carriage Assembly Remove the Paper Sensor or the Encoder Sensor 1 Performthe Remove the Carriage Assembly Carriage Belt and the Frame Tensioner procedures to remove the Carriage Assembly from the Slide Shaft gt o m lt Assembly Disassembly 5 31 NovaJet 500 630 700 Series Service Manual 5 32 2 3 TO REMOVE PAPER SENSOR BOARD GRASP HERE AND PULL UP PUSH DOWN ON CLIP PUS
97. going into the Slide Shaft from the top of the pinch roller Remove the pinch roller 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 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 Assembly Disassembly NovaJet 500 630 700 Series Service Manual Install the Y Arm Assembly Pinch Rollers Slide Shaft and Auto Load Sensor 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 2 Routethe Load Sensor wires through the four wire clamps on the back part of the Y Arm Bracket 3 Install the Slide Shaft and two supports to the Y Arm Assembly using four screws Torque to 8 in lbs 4 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 5 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 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
98. gstopl ssembly 5 6 Assembly Disassembly NovaJet 500 630 700 Series Service Manual Applyingitooiuch torquettotthellower Screws can Cause theimounts foritheistandoffsionithe cover tiolbreak re quiringi replacement 8 Usinga 2Phillipsiscrewdriver screwslocatedion ithe leftside torqueton5in lbs landithree locatedu nderthebaseplate torque 1 3 Tolinstallithe Top Cover 9 10 Cover Secure with two Insertithe pin located on corresponding hole Assembly While depressing stop ssembly on the left isidelof Cover lower Cover intoposition andisecureitito the Assembly by releasing retracting Remove the Keypad and Display 1 Performisteps lthrough 9 Covers procedureltoremovelthe Covers Turn theiRightiCoverlAssembly wrench remove the fourlkepnuts securingithe ESD Shieldiand groundiconnections See Figure 5 4 RemoveithelESD Shield Top And Right 1 4 Withia 1 4 socket wrench remove standoffs securelthe LCD DisplaylAssemblyitoitheKeypad Remove Assembly
99. iage Extreme drag results in a carriage axis failure fault and will stop the carriage motion These problems may be eliminated by maintaining and cleaning the slide shaft at intervals determined by the environmental conditions Do not use any lubrication clean the slide shaft 1 Turnthe printer OFF Disconnect the power cord and interface cable 2 Raisethe printer lid 3 Moisten a clean cloth or paper wipe with NovaKlean Maintenance 3 3 NovaJet 500 630 700 Series Service Manual Wipe the length of the slide shaft with the moistened cloth or wipe Manually move the carriage assembly from side to side Wipe the shaft again to remove any deposits left from the carriage Close the cover and reconnect the power cord and interface cable turn the printer ON and perform the PRIME procedure Be sure that the carriage moves freely on the slide shaft Linear Encoder Strip Cleaning Clean the linear encoder strip every 75 100 plot hours every 50 plot hours if GO ink is being used or as necessary to remove any buildup of debris NovaKlean followed by isopropyl alcohol should be used You may notice that it tends to fog the encoder strip however no detrimen tal effect has been observed in the field clean the Encoder Strip 1 2 Disconnect the power cord and interface cable Slightly dampen a cotton swab with NovaKlean and wipe along the length of the encoder strip on both sides Slightly
100. iaslighti ngle strip thelhead of theiscrewl ritoldause Encoder Strip 1 55 gt o m gy lt 12 Lower the Trailing back into place Assembly Disassembly 5 19 NovaJet 500 630 700 Series Service Manual 13 Whileholding theiServo Motor emovetthe frontiscrew Servo Motor 14 Lower the motor toldlear theipulley ssemblyifromithe carefully bring the motor dut of the printer Install Servo Motor 1 Reinsertithe Servo Motortinder the Platen withithe connector facing side ofthe Platen Guideltthe pulleyup through theigpeningin thelPlaten 2 OncetheServoMotor pulley s through the Platen push up onithe ServolMotorandialign the screw holes withithe screw holei penings 3 Insertthel frontiscrew into the ServolMotorland tighten 1 thelway 4 Lifttipigentlyandiholdthe right endiofitthe Trailing Cable Makelsure lthe screw doesnot the lmotorlatian angle and be Gareful motto Strip thethead thelscrewlor toldauseidamageltoithelEncoder Strip 5 Insertthelbackscrew nto the ServolMotor and tighten it 6 Tighteniboth screws on thelServoMotorlto 151n lb ofitorque 7 DepressithebackiofitheiFrame Tensionerl nd wrap thelCarriage Beltidver fhe Servo Motor pulley MakelSure th
101. ies Service Manual Initialization Troubleshooting 500 Series 4 18 sequence that the printer follows during initialization power up is as follows 1 Power supply turns on LED D2 on carriage turns on 2 Readsthe Flash ROM information 3 Performs memory test with installed SIMMs 4 Writes the Flash ROM data into RAM for quicker execution of the code Starts executing instructions from RAM Loads MPCB gate array with boot code data Checks for a valid ROM If the ROM is not valid waits for a ROM image to be downloaded 7 Steps 2 4 performed again 8 Loads MPCB gate array with ROM code data 9 Loads gate array on the carriage board LED D2 goes out as soon as the carriage board gate array is programmed 10 Turns on power supply cooling fan 11 Moves carriage 12 Checks and measures media size if loaded 13 Turn on display To troubleshoot using the D2 LED With the power off move the carriage away from the service station and snap the carriage cover off just enough to view the LED located in Figure 4 1 Turn the unit After a short delay the LED D2 will light Ensure that the LED extinguishes after about 3 4 seconds Turn the unit off immediately after the LED extinguishes to ensure no damage occurs to the carriage or carriage cover due to the carriage movement as stated in step 11 Snap the cover back onto the carriage Troubleshooting NovaJet 500 630 700 Series Service
102. informa tion it receives from the media feed and take up sensors The MPWA also controls the dryer assembly It activates only the fans required to cover the width of the loaded media The fan assembly also contains an interlock circuit optical sensors are designed to inform the MPWA 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 2 5 NovaJet 500 630 700 Series Service Manual Main Printed Wiring Assembly MPWA STEPPER MOTOR CONTROLLER CARRIAGE PWA FLASH EEPROM DATA BUS SERVO MOTOR CONTROLLER DYNAMIC SERIAL EEPROM SERIAL INTERFACE CIRCUITS PARALLEL Figure 2 5 Main Printed Wiring Assembly Main Printed Wiring Assembly MPWA 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 2 6 Theory of Operation NovaJet 500 630 700 Series Service Manual Microprocessor The microprocessor an IBM PowerPC is the central processor unit which supervises system functions executes the printer firmware manipulates data and controls input output
103. ining the code using either the GO EXE utility or print ing the file to the unit This requires using an appropriate host utility and can be done through the serial port for Macintosh users or the parallel port for PC users See Firmware Downloading in Chapter 3 for the procedures DRAM U 5 AYOSHL DRAM is Dynamic Random Access Memory which provides temporary storage of the microprocessor calculation and input output data It is also a faster type of memory then the Flash EEPROM That s 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 installed on the MPWA The SIMM size for the 500 series is 8 Megabyte and for the 630 700 series is 32 Megabyte The following SIMM sizes are supported 4MB 1Mx32 8MB 2Mx32 16MB 4Mx32 32MB 8Mx32 and 64MB 16Mx32 The SIMMs must have a minimum operating speed of 70ns and conform to JEDEC Standard 21 D release 4 orlater Remove the Right Cover to install additional memory see Chapter 5 for installation 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 manufacturers use these signals so they disable them Theory of Operation 2 9
104. ion at the J5ilocationiby graspingthe Vacuum Fan connector withthumb forefinger andpullingistraightiout Disconnect the Vacuum Fan 2 theJ6 location 60 anch modelidnly byigrasping the Vacuum Fan 2 connector with thumb andforefingerl ndipulling straightiout Disconnectithe Trailing cablelconnection at thetJ 7location Uselthe thumb and forefinger to pull tip and remove the TrailingiCable from connector Disconnect Cooling Fan connection atithelJ8 location by grasping theiPowerlSupply Cooling connector with thethumb forefingeri nd pulling straight out Withia 2 Phillipsiscrewdriver disconnect groundistraps going by removing thelscrew located near Using care removel theiMPCB byi nscrewing the remaining screws securing the the bracketiusing ia 2 Phillipssscrewdriver SeelFigure5 7 Assembly Disassembly NovaJet 500 630 700 Series Service Manual Figure 5 7 MPCB Removal Failure tol sel ni pproved antistaticibagiforistoragel r shipmentimay causeldamageltolthe MPCBiandiaffectithe Warranty EE gt 1 m lt 15 Placetthe MPCBinlan ESD bag antistaticlbag in preparationifor shipmentito ENCAD for repair
105. ions of using the serial interface with a Macintosh computer system ENCAD does not recommend using this port for production usage with the new printers Hesitation may result if using this port and that can degrade the quality of the output print Possible solutions for the Macintosh computer user include using a print server device with an established network or installing a parallel port add on card in the computer to interface with the printer The serial port is still required to download new firmware to the printer with a Macintosh computer The serial port is compatible with RS 422 devices when an appropriate adapter cable is used This cable is available from ENCAD The NovaJet 750 printer ships with a high speed print server that attaches to the parallal port for network compatibility Theory of Operation NovaJet 500 630 700 Series Service Manual Carriage Assembly Circuits TRAILING OPTICAL ENCODER ucc EE OPTICAL SENSOR TRAILING PAPER SENSOR CARTRIDGE 1 1 INKJET CARTRIDGE 2 DRIVERS CARTRIDGE 3 CARTRIDGE 4 CARRIAGE ASSEMBLY Figure 2 11 Carriage Assembly Circuits The Carriage Assembly contains 1 Carriage PWA 2 Optical Sensors 9 PaperSensor 4 Inkjet Cartridges The Carriage PWA contains the logic and drive circuitry for the firing of theinkjet cartridges It also establishes an interface path for the optical sensor and paper sensor
106. ket gt on m 5 lt 5 WhilelholdingitheiPowerSupply n place removelthefouriscrews securing theiPowerlSupply Bracket SeeiFigure 5 8 6 SlhidetheiPowerlSupply outidfithe Power Supply Bracket Assembly Disassembly 5 15 NovaJet 500 630 700 Series Service Manual Figure 5 8 Power Supply Removal Cooling Module 7 Usingazg2 Phillipsscrewdriver removelthe fouriScrews located below the Baseplate securingitheiPowerSupply Bracket Right Power Supply Bracket 8 Usinga amp ZlIPhillipsiscrewdriveriandia 1 4 wrench rocket remove from the Right Baseplate Figure5 9 5 16 Assembly Disassembly NovaJet 500 630 700 Series Service Manual Figure 5 9 Cooling Fan AC Entry Module Removal 8 Using all 4 wrench socket disconnect Entry Module ground fromithe ground stud RightiBaseplate 9 Removethe ACiEntry Module by the securingitabs modulelis released Install the Power Supply Cooling Fan and AC Entry Module Tolinstallithe Entry Module 1 Insertithe AC Entry Module ntoithe Entry Module hole Right Baseplateifrom the backlofitthe printer Press in ntilitisnaps securely into place IXIGINASSV 2
107. l procedures to remove the Carriage Assembly from the Slide Shaft Assembly Disassembly NovaJet 500 630 700 Series Service Manual CARRIAGE BUSHING LATCH Figure 5 20 Carriage Bushing Removal Use a flat tip screwdriver to push up on the latch which holds the Carriage Bushing in place See Figure 5 20 Pull the Carriage Bushing out of the Carriage Assembly Repeat Steps 2 and 3 for the other Carriage Bushing A Figure 5 21 Carriage Bushing Installation gt 7 m 0 lt 1 55 Orient the new Bushing as shown in Figure 5 21 so that the metal tab on top of the Bushing goes into the Carriage Assembly first Push the Bushings in until they snap into place Perform the Reinstall the Carriage Assembly Carriage Belt and the Frame Tensioner procedures to reinstall the Carriage Assembly if Carriage was removed Assembly Disassembly 5 35 NovaJet 500 630 700 Series Service Manual Remove the Service Station SERVICE STATION Figure 5 22 Service Station Removal Place the Top Cover in the open position Move the Carriage Assembly to the left side of the Slide Shaft 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 22 Raise the right side of the Service Station out of the Platen Lift out the left side of the Service Station from the Platen and remove the Service Station Moving the S
108. lace Remove the Center Support through the Platen Plug hole 10 While holding the Vacuum Fan through the hole left when the Exhaust assembly was removed remove the 3 screws on the bottom of the Platen that holds the Vacuum Fan in place using a 2 Phillips screwdriver Do not allow the screws to come out at an angle 11 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 1 55 1 gt o m lt It may be necessary to loosen do not remove 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 remov ing the Lower Drive Roller Assembly Assembly Disassembly 5 45 NovaJet 500 630 700 Series Service Manual It may be necessary to loosen do not remove the screws that secure the left 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 The Fan Assemblies will be removed at the same time that the Lower Drive Roller Assembly is removed Exer cise extreme care that the fan assemblies do not drop out of the Platen when removing the Lower Drive Roller As sembly 12 Carefully slide the Lower Drive Roller Assembly and the Fan Assemblies out of the left side of
109. leshooting reseat encoder sensor cable replace encoder sensor reattach connections correctly use Figure 9 4 for reference reseat paper sensor cable replace trailing cable replace paper sensor check servo motor connections reseat trailing cable 4 5 o NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Internal ERROR Auto Sensor Failure auto sensor reseat auto cable unseated sensor cable bad auto replace auto sensor sensor Internal ERROR MPCB Failure bad MPCB replace MPCB Unrecognized Cartridges Error faulty connection check cartridges of cartridge ID chip to flex cable wrong cartridges check cartridges installed carriage flex check flex driver cable disconnected cable connections trailing cable reseat trailing connections cable faulty trailing replace trailing cable cable faulty carriage replace carriage PCB PCB 4 6 Troubleshooting NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Image Skews or Moves Does Not Print Ink Cartridge Misfiring dirty encoder strip bad connection between computer and printer firmware is corrupted faulty quad flex cable bad MPCB cartridge low on ink firing rate set too fast clean encoder strip top and bottom reseat cable connections on compu
110. n assembly off of the printer Install the Thermal Dryer Assembly NovaJet 750 1 Carefully place the Thermal Dryer Assembly onto the support brackets See Figure 5 30 Secure and torque to 15 in lbs 2 Attach the data cable to the right side of the Thermal Dryer Assembly gt 7 m 0 lt 1 55 3 Attach the Thermal Dryer Assembly power cord the to back of the printer Assembly Disassembly 5 57 NovaJet 500 630 700 Series Service Manual This Page Intentionally Left Blank 5 58 Assembly Disassembly Parts List 6 This chapter lists the items and their associated numbers for the parts and assemblies of the NovaJet 500 630 700 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 disassembly procedures to aquire the necessary parts and properly install them into the printer The parts and assemblies may be ordered through your local authorized dealer or ENCAD Inc s Technical Support and Service department o pz o NovaJet 500 630 700 Series Service Manual 6 2 FIGURE ITEM 6 1 6 1 6 1 6 1 6 1 6 1 6 1 6 1 6 1 Parts List 1 COVER W DOOR LEFT 209220 7 COVER W DOOR LEFT 736 209220 10 RESERVIOR ASSEMBLY WITH CAP AND TUBE ASSEMBLY
111. nce NovaJet 500 630 700 Series Service Manual Stepper Motor Winding Resistance Check gt Z gt Figure 3 8 Stepper Motor 5 m 1 Disconnect the stepper motor connection from J1 on the MPWA 2 Usingastandard ohmmeter or multimeter measure between pins 1 red wire and 3 3 The reading 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 Maintenance 3 13 NovaJet 500 630 700 Series Service Manual Power Feed and Take Up Motor Winding 3 14 Resistance Check Figure 3 9 Power Feed and Take Up Motor Remove the feed and or take up roll from the printer Using Phillips screwdriver remove the four screws that secure the cradle idler from the right leg Ease the cradle idler off of the leg enough to disconnect the motor wires from the leg harness Using a standard ohmmeter or multimeter measure between the and connections on the motor While manually rotating the servo motor monitor the readings on the meter The acceptable range is 25 40 ohms Typically the reading is 29 36 ohms If the measurement is found to be unsatisfactory replace the motor Perform the same procedure on the remaining motor Maintenance NovaJet 500 630 700 Series Service Manual Banding Hardware vs Software The technician must be able to identify whether the
112. nd theiSlideShaft Insertithe Strain Relief with TrailingiCable Gntolthe Carriage Assemblyiby sliding t firmly place 1 5 15 Placethe Trailing Cable nto the J 1 connector lock of ontothe Strain Relief Support ntilitisnaps on thelCarriage PCB iMakelsurelthe silver fingersionithe Trailing Cable are fully slide both sides Connector lock shut inserted nto atithelsame time Placetherightiside ofthe back ofithe Electronics Coverunder TrailingiCableSupportiAssembly press down ofitheiElectronicsiCover until thelatches Assembly SlideitheiCar thelends iSnapintolthe Carriage riagelAssembly toldboutitheimiddle ofithe Slide Shaft andistretch outithe Carriage Belt Insert theCarriage Belt ntotthelFrame Tensioner the belt extendsia boutan nchipastthelFrame Tensioner Holdingithe Carriage Belt PulleylAssembly intoithe loop theTdleriPulley Assembly with the thickeriouter ring andiFrame Tensioner nsertithe Idler ofthe Delt Makelsure that the side of facingl p ISeeiFigure 5 165 Oncetthe Idler Pulley the Idler Pulley Assembly n place and pull t ntoithe Frame Tensioner so that the FramelTensioner Insertthe Co mpression Spring into thelgpeningin theiback Frame Tensioner so thatitheiend ofitheispring fits insidethe opening
113. ndimechanisms llustra tionslareprovided Steps iforl achireplaceablepartimay dependionpartslalready removed in previous disassembly directions Tt is recommended through leach procedure beforelbeginning ssembliesiorimechanisms The following listiof recommended toldisassemble and iveassemblethefprinter 1 Phillips TorqueScrewdriver 2 Phillips Torque Screwdriver 1 Slotted TorqueScrewdriver z22Slotted Torque Screwdriver Z1iPhillipsScrewdriver Z2 PhillipsScrewdriver 1 SlottediScrewdriver 2 Slotted Screwdriver Wrench 1 4 Screwdriver SocketiHead 1 4 WireiCutters Needle Nose Pliers X ACTO Knife ESDWristiStrap The followingimaterialsidrelalso required Isopropyl Alcohol Cotton Swabs Lint Free ClothidriTissue DoubleiSided Tape 1 16 thick 3 4 wide LoctitelBlackmax P N 200172 gt on m lt AlHardware Kit s available for theiprinters BeeChapter 692 this manualfortheipart number 5 1 NovaJet 500 630 700 Series Service Manual Alwaysturntheprinter OFF remove the powerlcord and the nterfaceicablelbefore beginning danyldisassembly pro cedures An lectricalishockihazardimay if theselprecautions remot followed Remove the Left Top and Right Covers
114. nt has been tested and found to comply with the limits for a class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference 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 interference to radio communica tions User Instructions vi 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 Reorient or relocate the receiving antenna 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 Consult dealer 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 500 630 700 Series Service Manual VDE Statement Hiermit wird bescheinigt da amp der NOVAJET 500 630 700 in bereinstimmung mit den Bestimmungen der BMPT AmstbIVfg 234 1991 funkentst rt ist Der vorschriftsmaRige Betrieb mancher Ger te z B kann allerdings gewissen Einschr nkungen unterliegen Beachten Sie
115. o bad bearings motor for smooth replace servo motor movement obstruction in remove obstruction path of carriage may or may not be visible Troubleshooting 4 3 NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Internal ERROR Carriage Axis Failure cont Troubleshooting dirty encoder strip dirt under the carriage bushings damaged encoder strip bad encoder sensor worn carriage bushings loose trailing cable connections cutter assembly malfunction damaged carriage drive belt system faulty trailing cable perform Encoder Strip Cleaning procedure remove carriage bushings and clean replace encoder strip replace encoder sensor replace carriage bushings remove power and reseat trailing cable connections at the MPCB and the carriage assembly replace cutter assembly 1 check idler tension assembly 2 check carriage belt replace trailing cable NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Internal ERROR Encoder Sensor Failure Internal ERROR Paper Sensor Failure encoder sensor cable unseated bad encoder sensor servo motor and vaccuum fan connections to MPCB are switched paper sensor cable unseated bad trailing cable bad paper sensor servo motor disconnected trailing cable connection is faulty Troub
116. on via 10 100BaseT 10Base2 Print Server Certifications Safety CSA CSE NRTL equivalent to UL1950 TUV GS EN 50 082 1 EN 60 950 UL1950 NOM 019 SCFT 1993 IEC 950 AS NZS 3260 EMI FCC Class A B CSA C108 8 EN 55 022 Class A B CE Mark CISPR 22 Class A B AS NZS 3548 General Description 1 5 m o Q 2 U z NovaJet 500 630 700 Series Service Manual Environment Weight Operating 60 88lbs 135 lbs boxed 59 to 95 F 42 712lbs 117 lbs boxed 15 to 35 C 10 to 70 RH Dimensions non condensing Height 44 1 12m Storage Width 77 1 96m 5 to 140 42 inch 21 to 60 C 5 to 80 RH 95 2 41m non condensing 60 inch Depth 28 0 71m Contents of this Service Manual Figures are used in this manual to clarify procedures 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 500 630 700 printers This includes printer specifications and related m
117. on Menu 4 The Color Db Menu is shown in Figure 3 27 and is where the color deadband test 18 performed Maintenance 3 33 NovaJet 500 630 700 Series Service Manual Black Deadband Color Db Test Cyan Deadband Magenta Deadband Yellow Deadband Figure 3 28 Color Db Menu Select Color Db Test to run the color deadband test The test consists of 12 default calibration settings When the testis run it will print out a pattern of 5 calibration lines for each of the 12 settings It will print this pattern in black first followed by cyan magenta and then yellow Also printed will be the current settings for each of the four colors as well as the slow deadband setting 5 When the plot is complete select Black Deadband at the Color Db Menu This brings up the options menu for the black deadband adjustment This menu is similiar to the menu depicted in Figure 3 21 NOTE only acceptable values for the color deadband adjustments are 12 20 28 36 44 52 60 68 76 84 92 and 100 Any other value entered will ap pear to be accepted because it will be displayed in the current settings section the next time this testis run In actuality the system will default to the closest allowable setting as listed above 3 34 Maintenance NovaJet 500 630 700 Series Service Manual Observe the plot and using either Prev Option or Next Option rotate through the selections until one that seems closer to the correc
118. or Inkjet Printers The NovaJet 500 series includes the NovaJet 500 and NovaJet 505 printers The NovaJet 700 series includes the NovaJet 700 NovaJet 736 and NovaJet 750 printers three NovaJet 500 630 700 printer series comes in two sizes a 42 inch model and 60 inch model The NovaJet 736 printer comes only as a 36 inch model The service manual is written for service personnel who possess analog and digitalcircuitry experience Chapter 2 Theory of Operation should 1 1 NovaJet 500 630 700 Series Service Manual beread and thoroughly understood before troubleshooting calibrating the printers The printers support pre cut and roll media Media size is automati cally determined and hardclip limits are set accordingly Pre cut media uses different maximum plotting areas than roll media See the Printer Specifications in the User Guide for more details on the media size printable area Both RS 422 serial and Centronics parallel connections are provided to interface with the host computer For proper operations the NovaJet 750 must be connected to a 100BaseT network print server Commands sent from the host computer can be in several forms including HP GL 2 HP RTL and EN RTL formats Drivers are supplied to support Windows based PC s 3 95 98 and as well as Macintosh and Power PC computers These printers expand upon ENCAD s tradition of delivering fast high quality color or monochrome graphics for a variety
119. otor drive belt and tensioning assembly are the compo nents that actually drive the carriage assembly The servo motor drives the belt back and forth allowing the attached carriage assembly to be repositioned as required The tensioning assembly 18 spring controlled and allows the proper amount of tension on the belt The linear optical encoder strip 1s used to obtain the printers accuracy along the axis of the printer Itis made with 150 parallel lines per inch etched intoit By utilizing two optical encoder sensors that are slightly offset 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 wiring assembly MPWA by the microprocessor 24 Theory of Operation NovaJet 500 630 700 Series Service Manual Media Feed and Take Up System R FLECTOR SENSORS p REFLECTOR U m 2 30 AYOSHL Figure 2 4 Power Feed and Take Up System The media feed and take up system comprises of two optical sensors two dc motors and a dryer assembly See Figure 2 4 The NovaJet 750 uses a thermal drying system while all other models use a blower drying system as shown above Motors are used to advance the media feed roll and the media take up roll dependant upon the signals they receive from the MPWA The MPWA generates the control signals for the motors from the
120. ounding or earthing An improper A C outlet power ground may cause banding due to excessive noise on the line between the neutral and ground Ensure the outlet has a clean zero ground potential with minimal noise between the neutral and ground 16 Static electricity Using certain types of media i e polyester based media static electricity buildup within the media roll may effect the un roll resistance and cause momentary banding to occur However this has not been tested 17 Data corruption may also effect banding If you are using a parallel cable that 1s too long or improperly shielded the data being sent to the printer may get corrupted and cause artifacts in the print 18 Overlapping images of different types on the same print may create color bands between the images at the overlaps 1 RGB images with CMYK images Alignments Adjustments 3 18 The ENCAD NovaJet 500 630 700 printers are designed with a minimum of maintenance requirements in mind Calibrations include color calibration deadband alignment and X axis calibration The mechanical adjustment requirements include the slide shaft profile and cartridge head height adjustments They do not require any electrical alignments Slide Shaft Profile Adjustment The NovaJet 500 630 700 printers Slide Shaft height is factory set and is firmly mounted on the outer sides and only has adjustments in the middle portion of the shaft to remove any bowing of the shaft s
121. ovaJet 500 630 700 Series Service Manual 3 16 If the test file prints correctly the problem lies in either the software package that generated the print or the RIP if used A simple test to determine if the banding is caused by the computer RIP application or the printer 18 to rotate the image 90 degrees and see ifthe banding rotates or remains in the same orientation as the previ ous print If the banding does not rotate then look for causes in the printer If the banding does rotate with the image then look for causes in the computer RIP or application Common Banding Causes 1 Uneven drying Adjust the drying time to compensate for varying ink percentages and media types Dry time values range from 10 seconds to 60 minutes This is especially important in higher humidity environments 2 The RIP Raster Image Processor and print cycles We recommend printing to a file first and then queuing the file to the printer to avoid the RIP and print cycle delays that can cause banding while printing 3 Uneven inkjet kogation partial clogging or orifice restriction on the inkjet cartridge head nozzles Run the 100 color test and re prime or replace the cartridge if necessary 4 Lower quality print modes normally cause slight bands to avoid this banding switch to 4 pass or 6 pass printing modes 5 Air bubbles in the ink delivery system This indicates a loss of negative pressure within the ink cartridge or ink delivery system
122. r 5 43 Remove the Lower Roller Assembly Stepper Motor and Vacuum Fan 5 44 Install the Lower Roller Assembly Stepper Motor and Vacuum Fan 5 47 Remove the Media Take Up and Feed Sensor Brackets and Sensors 5 50 Install the Media Take Up and Feed Sensor Brackets and Sensors 5 52 Remove the Media Take Up and Feed Motors 5 52 Install the Media Take Up and Feed Motors 5 54 Remove the Media Drying Fans aee cd detta a cre de ad d bit 5 54 Install the Media Drying Fats rot ird torre deo rer dd 5 55 Remove the Thermal Dryer Assembly 750 5 56 Install the Thermal Dryer Assembly NovaJet 750 5 57 Chapter 6 Parts 6 1 xiii NovaJet 500 630 700 Series Service Manual List of Illustrations Figure Page Chapter 1 General Description 1 1 NovaJet 500 630 700 Series Inkjet Printers 1 1 Chapter 2 Theory of Operation 2 1 General Block DIagratm eec rte e 2 2 2 2 Paper Media Axis DVO 0 Lettere a 2 3 2 9 Carriage Axis 2 4 2 4 Power Feed and Take Up System
123. r firmware control The beeper alerts the user to error conditions There exists three types of fans that can be on the NovaJet 500 630 700 series printers A single fan located behind below for the NovaJet 750 the power supply is used for cooling the power supply Air blows over the power supply and the heated air is forced out of the printer 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 printing process The 60 inch model has an additional suction fan located near the center of the printer inside the platen Theory of Operation 2 17 NovaJet 500 630 700 Series Service Manual 2 18 On the NovaJet 500 505 630 700 printers a media drying fan assembly 18 attached to the lower part of the printer legs that 18 used to speed up the drying time of the ink that is deposited onto the media This is to ensure that the ink is completely dry before the media is rolled onto the take up reel The 42 inch model has five drying fans while the 60 inch version has seven The drying fan assembly has been designed to keep power consumption down to a minimum by only activating the amount of fans that are required to dry the size of media that 1s loaded on the printer The fans will not actually engage until a print command is first estab lished This commmand can be from a sent print job or any
124. reading Move the left end of the stabilizer bracket until the reading below is observed Read only the RED numbers on the micrometer gauge For NovaJet 500 630 or 700 printers adjust for a reading of 67 3 This equates to a head height of 0 075 For the NovaJet 505 printer adjust for a reading of 17 8 Maintenance 10 11 12 13 NovaJet 500 630 700 Series Service Manual Use extreme care when performing this calibration on the NovaJet 505 printers The actual head height that is to be achieved is 0 125 0 003 The read ing will only be correct if the gage rotated one complete turn before stopping at 17 If the head is adjusted for 0 025 instead of 0 125 head strikes and quality issues will be apparent NOTE The actual measurement is different than the true head height due to the fact that the test cartridge does not con tain a jet plate assembly A difference had to be calcu lated to compensate for the lack of a jet plate assembly on the test cartridge gt z m z 2 z Tighten the screw on the left side of the stabilizer While lifting up the measuring tip of the micrometer slide the Carriage to the 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 Move the left end of the stabilizer bracket until a correct reading is
125. rt the Trailing Cable Assembly into the Strain Relief Assembly Insert the Strain Relief with Trailing Cable onto the Carriage Assembly by sliding it onto the Strain Relief Support until it snaps firmly into place Remove the Stabilizer Bracket and Encoder Strip 5 38 Perform steps 1 through 13 of the Remove the Left Top and Right Covers procedures to remove the Left Top and Right Covers Perform steps 2 through 6 of the Remove the Ink Delivery System procedures to remove the Ink Delivery System Perform the Remove the Carriage Assembly Carriage Belt and the Frame Tensioner procedures to remove the Carriage Assembly from the Slide Shaft Perform steps 3 and 4 of the Remove the Trailing Cable Assembly procedures to remove the Trailing Cable Assembly 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 23 Assembly Disassembly NovaJet 500 630 700 Series Service Manual BRACKET RESTS ON THE TOP OF THE Y ARM ASSEMBLY CHAIN SUPPORT Figure 5 23 Stabilizer Bracket Installation Removal 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 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
126. s 2 15 Control Panel aa SUMAS SANE RS ME 2 16 2 17 ree a 2 17 Chapter 3 Maintenance nane uu oC bu Sn oar eta aaps ai 3 1 3 1 Scheduled 3 1 Cleaning eec eee d 3 2 External GIGAMING MERE 3 2 NovaJet 500 630 700 Series Service Manual Table of Contents cont Chapter 3 Maintenance cont Service Station 32 Slide Shaft Cleaning cione ore ttr ei ete RR E 3 3 Linear Encoder Strip 3 4 Cartridge Jet Area amp Dimples Cleaning 2 3 5 Flex Cable Contact 3 6 Clean and Inspect Stepper Motor Gears 3 7 Clean and Inspect 3 7 Clean and Inspect Carriage Assembly 3 8 Reseat Connectors MPWA and Carriage 3 8 Replace Carriage BUSHINGS enses dn aae 3 11 Servo Motor Winding Resistance 3 12
127. sor based digital printer that receives plotting instructions from a host computer through either the RS 422 serial interface or the Centronics parallel interface NovaJet 500 630 700 Printers General Block Diagram U m 5 AYOSHL Figure 2 1 illustrates the major functional areas of the printers The NovaJet 500 630 700 Series printers consist of three mechanical assemblies 1 Paper Media Axis Drive 2 Carriage Axis Drive 3 Media Feed and Take Up System Mechanical Take Up system is optional on the 500 amp 630 printers and four main electrical assemblies 1 MPCB Main Printed Circuit Board 2 Carriage Assembly 3 Control Panel 4 Power Supply 2 1 NovaJet 500 630 700 Series Service Manual SERVO MoroR CARRIAGE AXIS DRIVE ENCODER SENSOR CONTROL CARRIAGE PANEL PROCESSOR CARRIAGE ASSEMBLY POWER SUPPLY MEMORY TAKE UP CIRCUITS MOTOR AUTO LOAD SENSOR 5 TAKE UP SENSOR PRINT SERVER LOWER PAPER AXIS DRIVE DRIVE STEPPER MOTOR ASSEMBLY LEGEND ELECTRICAL CONNECTION MECHANICAL CONNECTION MAIN DATA BUS lt gt Figure 2 1 General Block Diagram 2 2 Theory of Operation NovaJet 500 630 700 Series Service Manual Paper Media Axis Drive PINCH ROLLERS MEE STEPPER MOTOR LOWER ROLLER SHAFT ASSY lt REDUCTION GEAR Figure 2 2 Paper Media
128. squeezing the sides of the connector to release the quick disconnect latches With a pair of wire cutters cut the wire tie wraps see Figure 5 28 that is securing the sensor leads to the sensor bracket Assembly Disassembly NovaJet 500 630 700 Series Service Manual Remove the sensor by unscrewing the plastic nut off of the front of the sensor Pull the sensor out of the bracket Using a 2 Phillips screwdriver remove the two screws securing the bracket to the leg assembly gt 1 m lt Figure 5 28 Media Take Up and Feed Sensor Removal Assembly Disassembly 5 51 NovaJet 500 630 700 Series Service Manual Install the Media Take Up and Feed Sensor Brackets and Sensors Using a 2 Phillips screwdriver install the two screws securing the bracket to the leg assembly Insert the sensor into the hole on the sensor bracket secure by screwing on the plastic nut onto the front of the sensor Route the sensor wires to the back of the bracket and secure the wires using two wire tie wraps Bringing the wire from under the bracket attach the wire connector to the leg harness plug Push connector in until firmly seated Remove the Media Take Up and Feed Motors 5 52 Remove all media and media rollers from the printer Remove the four screws holding the Cradle Idler to the leg assembly See Figure 5 29 Carefully slide the Cradle Idler assembly out of the leg assembly until the
129. strap Perform Steps through ofthe Removelthe Left Top and Right Covers procedureltotemovelthe Topland Right Covers AT 45 DEGREE CORRECTLY ANGLE FOR INSTALLED INSTALLATION OR REMOVAL Figure 5 6 Extra Memory SIMM Installation Removal The SIMM slotsiarelatia 90 anglelfrom the main circuit board Facingitheitoplof the SIMM push the side clips gently to theioutside away from the SIMM then push the SIMM module towards the eftside of theiprinter untilitheiSIMM becomes free lof the sideidlips pullthe SIMM out being careful damagethe fingers on the top Figurel 6 5 10 Assembly Disassembly NovaJet 500 630 700 Series Service Manual Install Extra Memory SIMM NOTE If youi re nstalling wolSIMM you must installithe onelocatedi n J17 first See Figure3 AiforTocation 1 ThelSIMM slots 90 anglelfrom tihelboard SIMM 45 antoltheconnectorlsishownin Figureb 6 2 Slowlypushithe SIMM 90 angle clips snapi nto place Make sure the SIMMiisifullyiseated 3 Performiteps4through10 of the Left Top and Right Covers procedure to installtthei Righti nd Top Covers Remove the MPCB Main Printed Circuit Board Integrated circuits may becomelweakenedioridamaged by electricalidischarge
130. systems click on Start Pro grams Command Prompt At the dos prompt go to the location of the 1 if the file is on a floppy disk type A and press Enter Then type PRINT D LPT1 A XXXX ROM press Enter Wait approximately 20 to 40 seconds later until you hear a SINGLE beep indicating the download was successful You may encounter a set of double beeps shortly after sending the firmware file but you must wait until you hear the SINGLE beep After hearing the single beep remove power from printer for 15 20 seconds Apply power to the printer The printer should initialize properly Verify firmware revision by sequencing through Utility Menu Service Menu About menu Verify firmware has been incorporated Ifthe firmware download is not successful you may hear more than 1 beep or complete silence Check parallel port connections and return to step 5 Firmware Download Upgrading for the MAC 3 42 normal method of downloading new firmware is to send the file as if it was a standard print job 1 2 Power OFF printer wait 15 seconds Connect an Image Writer II cable between the printer and MAC Turn the printer ON Maintenance NovaJet 500 630 700 Series Service Manual 4 Obtain the latest firmware revision unpack the file and launch the XXX Firmware Utility File names may be different then that listed above Click on File Click on Preferences
131. t in the Carriage Assembly Make sure the flex cable goes all the way through and does not curl under the Carriage PCB 1 55 gt o m lt 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 19 d Push the Paper Sensor board down into the Carriage Assembly until it snaps firmly into place Assembly Disassembly 5 33 NovaJet 500 630 700 Series Service Manual e Turnthe Carriage Assembly over and insert the Paper Sensor flex cable into the connector at J3 f Pushboth sides of the connector lock shut at the same time To install the Encoder Sensor a Turnthe Carriage 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 Pushthe Encoder Sensor in past the ridges until the Encoder Sensor snaps into place d Turnthe Carriage Assembly over and insert the Encoder flex cable into the connector at J2 e Pushboth sides of the connector lock shut at the same time Perform the Carriage Assembly Carriage Belt and the Frame Tensioner Reinstallation procedures to reinstall the Carriage Assembly Replacing the Carriage Bushings 5 34 1 If there is not enough space on both sides of the Slide Shaft to remove the Carriage bushings perform the Carriage Assembly Carriage Belt and the Frame Tensioner Remova
132. t is a static RAM based field pro grammable gate array This means that the logic that it implements is determined by configuration information in an internal RAM storage area Each time power is turned on this information must be down loaded from the system EEROM 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 informa tion 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 128 MB Flash EEPROM 1 MB Serial EEPROM 1KB Flash EEPROM Flash EEPROM is Electrically Erasable Programmable Read Only Memory used to store instructions and data constants which the microprocessor can access and interpret with no loss of information when power is off Theory of Operation NovaJet 500 630 700 Series Service Manual The system firmware is stored in Flash EEPROM The Flash EEPROM allows the firmware to be upgraded by downloading the files containing the new firmware It can be erased and reprogrammed 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 1s then reprogrammed The normal method of downloading new firmware is to send the unit the files conta
133. t value is selected Press Ok to accept the selection and return to the Color Db Menu Continue performing steps 4 through 6 until the all color deadband adjustments are correct Paper Axis Calibration The paper axis calibration procedure ensures that the processing that drives the stepper motor is correct to minimize line length accuracy errors 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 26 gt z m z 2 z From the Calibration Menu select Use Calib XY Ensure that Use Calib XY is set to ON and press Ok This allows the printer to store the data that 1s entered in step 7 From the Calibration Menu select Paper Axis Test This runs the paper axis test which prints out two figures that are mirrored from each other and about 33 apart See Figure 3 28 Maintenance 3 35 NovaJet 500 630 700 Series Service Manual 33 Figure 3 29 Paper Axis Test 5 With a precision drafters measuring stick measure the exact distance from each of the T intersections 6 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 7 Using either Prev Option or N
134. ter Output is Banding Vertical Printer Output is Banding Horizontally and Vertically Keypad Locked Up or Not Func tioning Properly trailing cable connections faulty trailing cable dirty encoder strip bad MPCB firmware problem keypad assembly damaged faulty connection between MPCB and keypad bad MPCB reseat trailing cable replace trailing cable clean encoder strip replace MPCB 1 reset printer 2 refresh or up grade firmware replace keypad assembly reseat or replace connector replace MPCB Troubleshooting 4 11 o NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Noisy Operation Troubleshooting ink or paper debris in printer obstruction in path of carriage carriage bushings worn debris or obstruction in fan drive belt slipping on idler hardware or assemblies loose carriage height too low lower drive shaft gears are dirty or misaligned noisy servo motor noisy stepper motor clean printer remove obstruction clean printer replace carriage bushings clean fan assembly replace frame tensioner spring or idler tighten hardware or assemblies perform Carriage Head Height Adjustment clean and or realign lower drive shaft gears replace servo motor replace stepper motor NovaJ
135. ter and printer refresh EEPROM firmware with new download replace quad flex cable or complete carriage assembly replace MPCB refill or replace cartridge adjust firing rate lower optimum 1s 5 Troubleshooting o NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Ink Cartridge Misfiring cont Troubleshooting ink drop out ink starvation resembling intermittent banding 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 carriage assembly bad MPCB lower ink pre heat settings 1 perform Flex Cable Contact Cleaning procedures 2 replace carriage 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 carriage assembly replace MPCB NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Paper Skewing paper guides not install paper installed guides stepper motor perform Clean and gearing dirty or Inspect Stepper damaged Motor Gears procedure lower roller tighten screws loose securing lower roller Printer Outp
136. tput of the waveform generator is changed by the micropro cessor the motor moves 1 micro step Theory of Operation NovaJet 500 630 700 Series Service Manual Each circuit contains four main functions see Figure 2 7 l Reference waveform generator 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 reference 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 U 5 2 30 AYOSHL 3 Comparator This portion divides the output of the reference waveform generator 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 winding in order to make the actual current match the reference waveform 4 Powerdriver An H bridge allows the supply voltage to be applied across the winding in either polarity used to drive the current level to the desired value Theory of Operation 2 11 NovaJet 500 630 700 Series Service Manual 2 12 Servo Motor Controller SERVO CONNECTOR CARRIAGE CONNECTOR MAIN PWA 1 emen Figure 2 8 Servo Motor Controller The Carriage Ass
137. u Figure 2 12 shows the control panel after the printer has been turned on and completed the start up process As seen in the figure the control buttons are assigned to the corresponding command that is displayed closest to the physical location of the button 2 16 Theory of Operation NovaJet 500 630 700 Series Service Manual Power Supply An internal UL recognized switching power module supplies power for the NovaJet 500 630 700 Series printers It provides a constant 24VDC output from input voltage in the 90 132 VAC and 180 246 VAC ranges power switch turns the power on and off The 24VDC is applied to the MPWA where it is further regulated and separated into 24VDC 13VDC and 5VDC The 24V supply is used for the stepper controller which advances the paper the servo controller which moves the Carriage and power to fire the inkjets The supply powers the logic circuits U m 5 2 30 AYOSHL The power supply is fused using a 6 3A 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 condi tions 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 so that it beeps unde
138. ut is Banding Horizontal if banding is 1 inspect and or consistent replace stepper motor perform Stepper Motor Winding Resistance Check 2 inspect and or replace stepper motor gears and or lower roller assembly o I o 3 replace check amount replace or refill ofinkincartridges cartridges cartridges need perform Prime to be primed Troubleshooting 4 9 NovaJet 500 630 700 Series Service Manual 4 10 Table 4 1 Troubleshooting Table cont Printer Output is Banding Horizontal cont Troubleshooting color calibration required paper axis calibration required faulty or corrupt firmware cartridge dimple area dirty or damaged flex cable contacts dirty or damaged carriage assembly obstructed carriage belt is loose too tight worn or damaged carriage bushings worn or damaged corrupted NVRAM Symptoms perform Color Calibration perform Paper Axis Test Calibration reload firmware 1 perform Cartridge Dimple Cleaning procedure 2 replace cartridge 1 perform Flex Cable Contact Cleaning 2 replace carriage assembly check carriage assembly for proper movement along Y arm reinstall check tension assembly and or replace belt replace bushings clear NVRAM NovaJet 500 630 700 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Prin
139. wn in figure 3 6 To reattach depress the locking mechanism back into the locking position after inserting the ribbon cable end RIBBON LOCKING MECHANISM UNLOCKED LOCKED gt z m z 2 z CONNECTOR ASSEMBLY Figure 3 6 Ribbon Connector Locking Mechanism Replace Carriage Bushings The carriage 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 carriage bushings to last If not replaced the wear on the bushings can result in erratic carriage motion and or carriage axis failures It can even cause the cartridge head height to become uneven To replace the carriage bushings follow the procedures for Carriage Bushing Replacement found in Chapter 5 Maintenance 3 11 NovaJet 500 630 700 Series Service Manual Servo Motor Winding Resistance Check Figure 3 7 Servo Motor 1 Disconnect the servo motor connection from J2 on the MPWA 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 1s 6 30 ohms Typically the reading is 7 11 ohms 4 Ifthe measurement is found to be unsatisfactory replace the servo motor 3 12 Maintena
140. 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 3 8 Maintenance J1 J2 J3 24 95 J6 JT 8 9 NovaJet 500 630 700 Series Service Manual Figure 3 4 Main PWA Connection Locations Table 3 1 Main PWA Connections Stepper Motor Servo Motor Leg Harness AutoLoad Sensor Vacuum Fan 1 Vacuum Fan 2 Trailing Cable Power Supply Cooling Fan Parallel I O Port J10 J11 J12 J13 J14 J15 J16 J17 J18 not used not used Display Data Keypad Serial I O Port Power Supply not used SIMM Sot SIMM Slot Maintenance gt z m z gt z NovaJet 500 630 700 Series Service Manual Figure 3 5 Carriage PWA Connection Locations J1 J2 J3 Table 3 2 Carriage PWA Connections Black Drivers J5 Encoder Sensor Cyan Drivers 46 Trailing Cable Magenta Drivers J7 Paper Sensor Yellow Drivers 3 10 Maintenance NovaJet 500 630 700 Series Service Manual Figures 3 4 and 8 5 shows the locations of all the connectors on the MPWA and carriage board respectively To remove the ribbon cables from their connectors lift the connector s ribbon locking mechanism as sho
141. y 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 Calibration Menu About Diagnostics Menu Cartridge Info Test Print Exit Figure 3 24 Service Menu 3 Select the Calibration Menu from the Service Menu 4 The Calibration Menu is shown in Figure 3 24 for the 500 series and Figure 3 25 for the 630 700 series and is where the deadband tests are performed Select Slow Db Test to run the slow deadband test 3 30 Maintenance NovaJet 500 630 700 Series Service Manual Deadband Test Deadband Slow Db Test Slow Deadband Single Line Test All Lines Test Deadband Test Slow Db Test Slow Deadband gt z m z 2 z Single Line Test All Lines Test Figure 3 26 Calibration Deadband Menu 630 700 Series 5 When the plot is complete select Slow Deadband at the Calibration Menu This brings up the options menu for the slow deadband adjustment This menu 1s similiar to the menu depicted 1n Figure 3 21 Observe the plot and using either Prev Option or Next Option rotate through the selections until the value you want is selected Press Ok to accept the selection and return to the Calibration Menu Continue performing steps 4 through 6 until the slow deadband adjustment 1s correct Maintenance 3 31 NovaJet 500 630

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