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NOVAJET 500
User Manual
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Kodak NOVAJET 500, NOVAJET 700, NOVAJET 630 User Manual

®
NOVAJET®
500/630/700 SERIES
COLOR INKJET
PRINTER
SER VICE MANUAL
Part Number 213526-01
Copyright © 1999-2002 Eastman Kodak Company. All 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 p art of this manual may be copied or distributed, transmitted, transcribed, stored in a retrieval system, or translated in any human or comput­ing language, in any form or by any means, electronic, mechanical, 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 Rev A May 1999 2st Edition Rev B October 2001
ii
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 TELEVI­SION INTERFERENCE FOR CLASS B DEVICE
This equipment has been tested and found to comply with the limits for a class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interfer­ence 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 the equipment into an outlet on a circuit different from
that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for
help.
Changes or modifications not expressly approved by ENCAD, Inc. could void the user’s authority to operate the equipment.
v
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 equipment 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 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 the equipment into an outlet on a circuit different from
that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for
help.
Changes or modifications not expressly approved by ENCAD, Inc. could void the user’s authority to operate the equipment.
vi
VDE Statement
Hiermit wird bescheinigt, daß der NOVAJET 500/630/700 in Übereinstimmung mit den Bestimmungen der BMPT-AmstbIVfg 234/1991 funkentstört ist. Der vorschriftsmäßige Betrieb mancher Geräte (z.B. Meßsender) kann allerdings gewissen Einschränkungen unterliegen. Beachten Sie deshalb die Hinweise in der Bedienungsanleitung.
Dem Zentralamt für Zulassungen im Fernmeldewesen würde dan Inverkehrbringen dieses Gerätes angezeigt und die Berechtigung zur Überprüfung der Serie auf die Einhaltung der Bestimmungen eingeräumt.
ENCAD, Inc. U.S.A
vii
Material Safety Data Sheet
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.
viii
WARRANTY OR DAMAGE CLAIMS
United States
ENCAD®, Inc., warrants its printers ("PRODUCT") 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 warran­ties, expressed or implied, including but not limited to, implied 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 Prod­ucts subjected to normal wear and tear, when operated according to ENCAD instructions.
This Warranty does not cover damage to the Product resulting from the following:
• Accident or negligence.
• Unauthorized modification of the Product.
• Adverse environmental conditions.
• Service of the Product by other than an ENCAD authorized service provider.
• Unauthorized or improper use, including but not limited to: – Use in applications for which the Product was not designed. – Using cartridges or ink other than those supplied by ENCAD or authorized
ENCAD resellers.
– Using media other than that supplied by ENCAD or authorized ENCAD
resellers.
– Lubricating any part of the printer.
Internationally: Contact your dealer or distributor for warranty information.
ix
Table of Contents
Chapter 1 General Description ............................................................ 1-1
Introduction ...............................................................................................................1-1
Overview ................................................................................................................... 1-3
Related Publications .......................................................................................... 1-3
Electrostatic Discharge (ESD) Sensitivity ................................................................. 1-3
Warnings, Cautions and Notes ................................................................................. 1-4
Printer Specifications ................................................................................................ 1-5
Contents of this Service Manual ................................................................................1-6
Technical Support ..................................................................................................... 1-8
Chapter 2 Theory of Operation ............................................................ 2-1
Introduction ............................................................................................................... 2-1
NovaJet 500/630/700 Printers General Block Diagram .............................................. 2-1
Paper (Media) Axis Drive .......................................................................................... 2-3
The Carriage Axis Drive............................................................................................. 2-4
Media Feed and Take-Up System ............................................................................. 2-5
Main Printed Wiring Assembly (MPWA) ................................................................... 2-6
Microprocessor .................................................................................................. 2-7
Gate Array ......................................................................................................... 2-7
Memory Circuits ................................................................................................. 2-8
Flash EEPROM ........................................................................................... 2-8
DRAM .......................................................................................................... 2-9
Serial EEPROM ......................................................................................... 2-10
Stepper Motor Controller................................................................................... 2-10
Servo Motor Controller ...................................................................................... 2-12
Interface Circuits: Serial & Parallel ................................................................... 2-14
Carriage Assembly Circuits .................................................................................... 2-15
Control Panel .......................................................................................................... 2-16
Power Supply ......................................................................................................... 2-17
Beeper and Fans .................................................................................................... 2-17
Chapter 3 Maintenance ........................................................................ 3-1
Introduction ............................................................................................................... 3-1
Scheduled Maintenance ........................................................................................... 3-1
Cleaning Procedures .......................................................................................... 3-2
External Cleaning .........................................................................................3-2
x
Table of Contents (cont)
Chapter 3 Maintenance (cont)
Service Station Cleaning .............................................................................. 3-2
Slide Shaft Cleaning..................................................................................... 3-3
Linear Encoder Strip Cleaning ...................................................................... 3-4
Cartridge Jet Area & Dimples Cleaning ........................................................ 3-5
Flex Cable Contact Cleaning ........................................................................3-6
Clean and Inspect Stepper Motor Gears....................................................... 3-7
Clean and Inspect MPWA ............................................................................ 3-7
Clean and Inspect Carriage Assembly ......................................................... 3-8
Reseat Connectors on MPWA and Carriage Board .............................................3-8
Replace Carriage Bushings .............................................................................. 3-11
Servo Motor Winding Resistance Check ................................................................. 3-12
Stepper Motor Winding Resistance Check .............................................................. 3-13
Power Feed and Take-Up Motor Winding Resistance Check ................................... 3-14
Banding: Hardware vs Software ............................................................................... 3-15
Common Banding Causes ......................................................................... 3-16
Alignments/Adjustments ......................................................................................... 3-18
Slide Shaft Profile Adjustment .......................................................................... 3-18
Head Height Alignment Procedure .................................................................... 3-22
Color Calibration ............................................................................................... 3-26
Deadband Alignments ...................................................................................... 3-29
Deadband Alignment (for 500 Series) ......................................................... 3-32
Color Deadband Alignment (for 630/700) .................................................... 3-33
Paper Axis Calibration ...................................................................................... 3-35
Diagnostics Menu ................................................................................................... 3-37
Limited Access Menu ............................................................................................. 3-40
Firmware Download/Upgrading for the PC ............................................................... 3-41
Firmware Download/Upgrading for the MAC ............................................................ 3-42
Internal Cabling and Signal Flow Diagrams ............................................................. 3-44
Chapter 4 Troubleshooting .................................................................. 4-1
Introduction ............................................................................................................... 4-1
No Power ........................................................................................................... 4-1
Initialization Failure............................................................................................. 4-2
Media Does Not Move ........................................................................................ 4-2
Internal ERROR “Carriage Axis Failure” .............................................................. 4-3
xi
Table of Contents (cont)
Chapter 4 Troubleshooting (cont)
Internal ERROR “Encoder Sensor Failure” .......................................................... 4-5
Internal ERROR “Paper Sensor Failure” .............................................................. 4-5
Internal ERROR “Auto-Sensor Failure” ................................................................4-6
Internal ERROR “MPCB Failure” ......................................................................... 4-6
Unrecognized Cartridges Error ............................................................................ 4-6
Image Skews or Moves ...................................................................................... 4-7
Does Not Print.................................................................................................... 4-7
Ink Cartridge Misfiring ......................................................................................... 4-7
Paper Skewing ................................................................................................... 4-9
Printer Output is Banding (Horizontal) ................................................................ 4-9
Printer Output is Banding (Vertical) .................................................................. 4-11
Printer Output is Banding (Horizontally and Vertically)...................................... 4-11
Keypad Locked-Up or Not Functioning Properly ............................................... 4-11
Noisy Operation ............................................................................................... 4-12
Line Quality Degraded ...................................................................................... 4-13
Fan Does Not Power Up ................................................................................... 4-14
Media Take-Up Motor Not Operating, Sensor Works ........................................ 4-14
Media Feed Motor Not Operating, Sensor Works ............................................. 4-15
Media 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 Series) .........................................................4-20
Chapter 5 Assembly\Disassembly ...................................................... 5-1
Introduction ............................................................................................................... 5-1
Remove the Left, Top, and Right Covers .................................................................... 5-2
Install the Left, Top, and Right Covers ....................................................................... 5-6
Remove the Keypad and Display .............................................................................. 5-7
Install the Keypad and Display.................................................................................. 5-9
Remove Extra Memory (SIMM) ............................................................................... 5-10
Install Extra Memory (SIMM) .................................................................................. 5-11
Remove the MPCB (Main Printed Circuit Board) ..................................................... 5-11
Install the MPCB .................................................................................................... 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
Table of Contents (cont)
Chapter 5 Assembly/Disassembly (cont)
Remove Servo Motor ............................................................................................... 5-18
Install Servo Motor .................................................................................................. 5-20
Remove the Ink Delivery System .............................................................................5-21
Install the Ink Delivery System................................................................................ 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 Carriage PCB ...................................................................................... 5-29
Install the Carriage PCB ......................................................................................... 5-31
Remove the Paper Sensor or the Encoder Sensor .................................................. 5-31
Install the Paper Sensor or the Encoder Sensor...................................................... 5-33
Replacing the Carriage Bushings ............................................................................ 5-34
Remove the Service Station .................................................................................... 5-36
Install the Service Station ....................................................................................... 5-36
Remove the Trailing Cable Assembly ...................................................................... 5-37
Install the Trailing Cable Assembly ......................................................................... 5-37
Remove the Stabilizer Bracket and Encoder Strip ...................................................5-38
Install the Stabilizer Bracket and Encoder Strip ...................................................... 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 Sensor ...... 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 .............................................................................. 5-54
Install the Media Drying Fans ................................................................................. 5-55
Remove the Thermal Dryer Assembly (NovaJet 750) ............................................... 5-56
Install the Thermal Dryer Assembly (NovaJet 750) .................................................. 5-57
Chapter 6 Parts List .............................................................................. 6-1
xiii
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 Diagram ................................................................................... 2-2
2-2. Paper (Media) Axis Drive ................................................................................. 2-3
2-3. Carriage Axis Drive ..........................................................................................2-4
2-4. Power Feed and Take-Up System ................................................................... 2-5
2-5. Main Printed Wiring Assembly ........................................................................2-6
2-6. Gate Array ...................................................................................................... 2-7
2-7. Stepper Motor Controller ............................................................................... 2-10
2-8. Servo Motor Controller ................................................................................... 2-12
2-9. Quadrature Signal Generation ....................................................................... 2-13
2-10. Interface Circuits ........................................................................................... 2-14
2-11. Carriage Assembly Circuits........................................................................... 2-15
2-12. Main Menu .................................................................................................... 2-16
Chapter 3 Maintenance
3-1. Encoder Strip Cleaning ................................................................................... 3-5
3-2. Cartridge Dimple Region ..................................................................................3-5
3-3. Flex Cable Contacts ....................................................................................... 3-6
3-4. MPWA Connection Locations ......................................................................... 3-9
3-5. Carriage PWA Connection Locations ............................................................ 3-10
3-6. Ribbon Connector Locking Mechanism ......................................................... 3-11
3-7. Servo Motor ................................................................................................... 3-12
3-8. Stepper Motor ............................................................................................... 3-13
3-9. Power Feed and Take-Up Motor .................................................................... 3-14
3-10. Examples of Banding .................................................................................... 3-15
3-11. Dial Gauge Micrometer Assembly ................................................................. 3-19
3-12. Measurement Positions for Slide Shaft .......................................................... 3-20
3-13. Slide Shaft Profile Adjustment ....................................................................... 3-21
3-14. Carrier Head Height Tolerance ....................................................................... 3-22
3-15. Setting Up Tools from Height Gauge Kit ........................................................ 3-22
3-16. Zeroing the Micrometer Gauge ...................................................................... 3-23
xiv
List of Illustrations (cont)
Figure Page
Chapter 3 Maintenance (cont)
3-17. Test Cartridge Installed .................................................................................. 3-23
3-18. Support Bracket Placement .......................................................................... 3-24
3-19. Color Calibration ............................................................................................ 3-26
3-20. Utility Menu................................................................................................... 3-27
3-21. Color Calib Menu........................................................................................... 3-28
3-22. Cyan Vertical Options Menu.......................................................................... 3-28
3-23. Slow Deadband ............................................................................................. 3-29
3-24. Service Menu ................................................................................................ 3-30
3-25. Calibration (Deadband) Menu (500 Series)..................................................... 3-31
3-26. Calibration (Deadband) Menu (630/700 Series) .............................................. 3-31
3-27. Calibration Menu ........................................................................................... 3-33
3-28. Color Db Menu .............................................................................................. 3-34
3-29. Paper Axis Test ............................................................................................ 3-36
3-30. Diagnostics Menu ......................................................................................... 3-37
3-31. Accessory Menu ........................................................................................... 3-37
3-32. NVRAM Clear and Clock Reset Menu ........................................................... 3-40
3-33. MPWA Connections Diagram........................................................................ 3-45
3-34. Carriage PWA Connections Diagram............................................................. 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 D5 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 ....................................................... 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) Removal/Installation ................................................... 5-10
5-7. MPCB Removal ............................................................................................. 5-13
5-8. Power Supply Removal ................................................................................. 5-16
xv
List of Illustrations (cont)
Figure Page
Chapter 5 Assembly/Disassembly (cont)
5-9. Cooling Fan/AC Entry Module Removal ......................................................... 5-17
5-10. Slacken Carriage Belt ................................................................................... 5-19
5-11. Chain Support Bracket Removal .................................................................... 5-22
5-12. Cariage Cover Removal ................................................................................. 5-22
5-13. Chain Support Bracket Adjustment ............................................................... 5-24
5-14. Strain Relief Removal/Installation .................................................................. 5-25
5-15. Frame Tensioner ........................................................................................... 5-26
5-16. Carriage Belt Clamp ...................................................................................... 5-26
5-17. Carriage PCB Removal/Installation ................................................................ 5-30
5-18. Paper and Encoder Sensor Removal ............................................................. 5-32
5-19. Paper and Encoder Sensor Installation .......................................................... 5-33
5-20. Carriage Bushing Removal ............................................................................ 5-35
5-21. Carriage Bushing Installation ......................................................................... 5-35
5-22. Service Station Removal ................................................................................ 5-36
5-23. Stabilizer Bracket Installation/Removal .......................................................... 5-39
5-24. Y-Arm Installation/Removal ........................................................................... 5-41
5-25. Pinch Roller .................................................................................................. 5-42
5-26. Stepper Motor Removal/Installation ............................................................... 5-47
5-27. Inside Platen, Right Side ............................................................................... 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
6-1. Left Side Parts Breakdown .............................................................................. 6-3
6-2. Left Side Parts Breakdown (NovaJet 750) ........................................................ 6-5
6-3. Platen and Above Parts Breakdown ................................................................ 6-7
6-4. Right Side Parts Breakdown ........................................................................... 6-9
6-5. Right Side Parts Breakdown (NovaJet 750) ................................................... 6-11
6-6. Inner Platen Parts Breakdown ....................................................................... 6-13
6-7. Carriage Assembly Parts Breakdown ............................................................ 6-15
6-8. Carriage Cover Parts Breakdown ................................................................... 6-17
6-9. Service Station Parts Breakdown .................................................................. 6-19
6-10. Power Feed and Take-Up Parts Breakdown ................................................... 6-21
xvi
List of Tables
Table Page
Chapter 1 General Description
Chapter 2 Theory of Operation
Chapter 3 Maintenance
3-1. MPWA Connections Table .............................................................................. 3-9
3-2. Carriage PWA Connections Table ................................................................. 3-10
Chapter 4 Troubleshooting
4-1. Troubleshooting Table ......................................................................................4-1
Chapter 5 Assembly/Disassembly
Chapter 6 Parts List
xvii
This Page Intentionally Left Blank
xviii

General Description

1
DESCRIPTION
GENERAL

Introduction

This manual provides service information for the ENCAD®, Inc. NovaJet® 500, NovaJet 630 and the NovaJet 700 Series of Color 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. All three NovaJet 500/ 630/700 printer series comes in two sizes: a 42 inch model and a 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 digital circuitry experience. Chapter 2, Theory of Operation, should
Figure 1-1. NovaJet 500/630/700 Series Inkjet Printers.
1-1
be read and thoroughly understood before troubleshooting/calibrating the printers.
The printers support pre-cut and roll media. Media size is automati­cally 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.XX, 95/98, and NT) as well as Macintosh and Power PC computers.
These printers expand upon ENCAD’s tradition of delivering fast, high­quality color or monochrome graphics for a variety 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 & 630 series) Optional Powered Take-Up Roll System (500 & 630 series) Media Drying System (optional on the 500 & 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 & 700 series) Ink Priming System 4 500ml Ink Reservoirs (8 for the NovaJet 750) Smart Cartridges Odometer Function Improved Septum Connector Design
1-2 General Description

Overview

Related Publications

Printers draw according to instructions issued from a “host” com­puter. Every printer is engineered to understand a specific set of instructions and to execute each instruction in a precise manner. In addition, most printers are designed to execute predetermined characters automatically without a specific line-by-line instruction from the program. These characters are part of the printer’s perma­nent memory.
The following publication contains additional information which 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
DESCRIPTION
GENERAL
Copies of these and other ENCAD, Inc. publications may be ob­tained by contacting your nearest authorized ENCAD, Inc. dealer or by contacting ENCAD’s Technical Support and Service Department.

Electrostatic Discharge (ESD) Sensitivity

All 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

Warnings, Cautions and Notes

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 defini­tion 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 proce­dures and to exercise standard safety procedures. They are indicated by:
WARNING
Followed by a paragraph describing 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:
CAUTION
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.
1-4 General Description

Printer Specifications

The specifications and performance characteristics of the NovaJet 500/630/700 Series Color Inkjet Printers are as follows:
DESCRIPTION
GENERAL
Max Printing Area:
42 inch 60 inch
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 Option: 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-SCFI-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
Environment:
Operating:
59° to 95° F (15° to 35° C) 10% to 70% RH non-condensing
Storage:
-5° to 140° F (-21° to 60° C) 5% to 80% RH non-condensing

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.
Weight:
60” 88 lbs 135 lbs (boxed) 42” 72 lbs 117 lbs (boxed)
Dimensions:
Height 44” (1.12m)
Width 77” (1.96m)
42 inch
95” (2.41m) 60 inch
Depth 28” (0.71m)
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 materials. 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
Chapter 2 THEORY OF OPERATION - Functional
descriptions of the overall printer and major assemblies are contained in this chapter.
Chapter 3 MAINTENANCE - This chapter covers the
scheduled maintenance, cleaning procedures and alignment/adjustments recommended to perform on the printers. Diagnostics and a signal flow diagram are also listed.
Chapter 4 TROUBLESHOOTING - A table containing
problems that could occur and possible causes and repairs is found in this chapter. This table is not intended to be a complete listing of troubleshooting procedures. It will isolate the problem down to the lowest replacable assembly. If the problem happens to be the wiring between assemblies, standard 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.
DESCRIPTION
GENERAL
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 - Instructions in this manual are based on the assumption that the service person is facing the front of the printer. References to top view, back view, and so forth are consistent with this engineering standard. References to the X Axis and Y Axis (Paper Axis and Carriage Axis, respectively) follow the standard of AutoCAD™ absolute coordinates: up and down for X, left to right for Y.
General Description 1-7

Technical Support

ENCAD offers full technical support and service for its various prod­ucts. If you are unable to find the answer to your question in either the User’s Guide, Service Manual, or other related publications, check out
ENCAD’s Knowledge Base located on ENCAD’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 & Service Dept. 6059 Cornerstone Court West San Diego, CA 92121
Help Desk Telephone: (858) 452-4350 or
Help Desk FAX: (858) 558-4672
(877) ENCAD-TS (362-2387)
International users contact your local ENCAD service provider. See details on your ENCAD registration card.
1-8 General Description

Theory of Operation

Introduction

This chapter explains the mechanical and electrical theory of operation of the ENCAD NovaJet 500/630/700 Series Color Inkjet printers.
The NovaJet 500/630/700 Series is a PowerPC 33MHz microprocessor­based 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

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
OPERATION
THEORY OF
2. Carriage Axis Drive
3. Media Feed and Take-Up System (Mechanical Take-Up system is optional on the 500 & 630 printers.)
and four main electrical assemblies:
1. MPCB (Main Printed Circuit Board)
2. Carriage Assembly
3. Control Panel
4. Power Supply
2-1
CONTROL
PAN EL
POWER SUPPLY
PRINT
SERVER
SERVO
MOTOR
MICRO-
PROCESSOR
GATE
ARRAY
MEMORY
CIRCUITS
MPWA
STEPPER
MOTOR
CARRIAGE AXIS DRIVE
PAPER AXIS DRIVE
FEED
SENSOR
FEED
MOTOR
TAK E-U P
MOTOR
TAK E-U P SENSOR
PAPER
SENSOR
ENCODER
SENSOR
CARRIAGE
PCB
CARRIAGE ASSEMBLY
MEDIA
LOWER
DRIVE
ASSEMBLY
LEGEND
ELECTRICAL CONNECTION
MECHANICAL CONNECTION
MAIN DATA BUS
Figure 2-1. General Block Diagram.
2-2 Theory of Operation

Paper (Media) Axis Drive

PINCH ROLLERS
STEPPER MOTOR
LOWER ROLLER SHAFT ASSY
REDUCTION GEAR
Figure 2-2. Paper (Media) Axis Drive.
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.
OPERATION
THEORY OF
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

The Carriage Axis Drive

ENCODER STRIP
TENSIONING
ASSY
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 motor, drive belt, and tensioning assembly are the compo­nents 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 is spring controlled and allows the proper amount of tension on the belt.
The linear optical encoder strip is used to obtain the printers accuracy along the axis of the printer. It is made with 150 parallel lines per inch etched into it. By utilizing two optical encoder sensors that are slightly 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.
SERVO
MOTOR
BELT
2-4 Theory of Operation

Media Feed and Take-Up System

SENSORS
REFLECTOR
REFLECTOR
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 informa­tion 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.
OPERATION
THEORY OF
The 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

Main Printed Wiring Assembly (MPWA)

CRYSTAL
CONTROL
PANEL
X1
MICRO-
PROCESSOR
(CPU)
STEPPER MOTOR
CONTROLLER
FLASH
EEPROM
DATA BUS
SERIAL
EEPROM
DYNAMIC
RAM
(SIMM)
MEMORY CIRCUITS
GATE
ARRAY
SERVO MOTOR
CONTROLLER
CARRIAGE
PWA
SERIAL
INTERFACE CIRCUITS
PARAL LEL
Figure 2-5. Main Printed Wiring Assembly.
The 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 & Parallel
2-6 Theory of Operation
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