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

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®
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

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 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. One DMA channel sup­plies data to the gate array for jet firing; the other DMA channel is used to receive data through the parallel port via the gate array, or the serial port when using a high speed serial mode. One timer generates a servo interrupt every millisecond; the other is used for timing the Stepper Motor.
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.
OPERATION
THEORY OF

Gate Array

PAR A LLEL
PORT
GATE
ARRAY
STATIC
RAM
Figure 2-6. Gate Array.
SERVO
CONTROLLER
TO
CARRIAGE
PWA
Theory of Operation 2-7
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. It is a static RAM-based field pro­grammable 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 down­loaded 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 informa­tion 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.
2-8 Theory of Operation
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 is then reprogrammed.
The normal method of downloading new firmware is to send the unit the files containing the code using either the GO.EXE utility or print­ing 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
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.
OPERATION
THEORY OF
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 or later. 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
Serial EEPROM
Serial EEPROM is an Electrically Erasable, Programmable, Read Only Memory which provides storage for calibration constants and user configuration data entered from the host computer.
An 8K bit serial nonvolatile EEPROM stores calibration and configura­tion information. It retains data while the unit is off.

Stepper Motor Controller

DATA BUS
WAVEFORM
GENERATOR
COMPARATOR
DRIVER
CURRENT
SENSE
STEPPER
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 com­mands 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 output of the waveform generator is changed by the micropro­cessor, the motor moves 1 “micro-step”.
2-10 Theory of Operation
Each circuit contains four main functions (see Figure 2-7):
1. Reference waveform generator
The microprocessor uses a D/A (digital to analog) converter to set the desired level for the current in the stepper motor winding. The output of the D/A converter varies in time to create a 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.
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.
OPERATION
THEORY OF
4. Power driver
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

Servo Motor Controller

GATE
ARRAY
MOTOR DRIVER
MAIN PWA
SERVO
CONNECTOR
CARRIAGE
CONNECTOR
SERVO
MOTOR
ENCODER
CARRIAGE
Figure 2-8. Servo Motor Controller.
The Carriage Assembly 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 adjust­ments 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 quadra­ture 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.
2-12 Theory of Operation
DETECTOR 2 DETECTOR 1
ENCODER STRIP
OUTPUT OF DETECTOR 1
OUTPUT OF DETECTOR 2
COMPOSITE TRANSITION-TRIGGERED OUTPUT OF BOTH DETECTORS
OPERATION
THEORY OF
4 OUTPUT PULSES PER OPTICAL LINE
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

Interface Circuits: Serial & Parallel

SERIAL
CONNECTOR
TRANSCEIVER
MICRO-
PROCESSOR
GATE
ARRAY
PARALLEL
CONNECTOR
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 limitations 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.
2-14 Theory of Operation

Carriage Assembly Circuits

OPTICAL ENCODER
TRAILING
CABLE
CONNECTION
FROM MPWA
TRAILING
CABLE
CARRIAGE
PWA
INKJET
DRIVERS
CARRIAGE ASSEMBLY
Figure 2-11. Carriage Assembly Circuits.
The Carriage Assembly contains:
1) Carriage PWA
2) Optical Sensors
3) Paper Sensor
4) Inkjet Cartridges
OPTICAL SENSOR
PAPER SENSOR
CARTRIDGE 1
CARTRIDGE 2
CARTRIDGE 3
CARTRIDGE 4
OPERATION
THEORY OF
The Carriage PWA contains the logic and drive circuitry for the firing of the inkjet cartridges. It also establishes an interface path for the optical sensor and paper sensor to communicate with the 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
The paper sensor circuitry senses for the presence of loaded media. It does this automatically during the start-up and load sequences. It also constantly monitors the media during printing to determine if the media has run out.
If no paper is sensed, the paper sensor sends this information to the MPWA, which immediately begins an ‘out of paper’ subroutine. This subroutine stops the printer from printing until more media is loaded.
The sensor also checks for the size of the media loaded so it can deter­mine the proper printing parameters.

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
Cut
Pause
Reset
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
Feed Media Menu
*
Setup Menu
Figure 2-12. Main Menu.
Utility Menu

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. A 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 5V supply powers the logic circuits.
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 condi­tions on any output over the full range of input voltage. Overvoltage protection is 20%-30% above nominal for the 24V output.
OPERATION
THEORY OF

Beeper and Fans

The beeper contains built-in driver circuitry so that it beeps under 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
On the NovaJet 500/505/630/700 printers a media drying fan assembly is attached to the lower part of the printer legs that is 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 is loaded on the printer.
The fans will not actually engage until a print command is first estab­lished. This commmand can be from a sent print job or any onboard commands that require printing to complete that function. The fans will automatically shutdown approximately 20 minutes after the print is 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 is 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.
2-18 Theory of Operation

Maintenance

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.
3
Scheduled maintenance can be thought of as preventive maintenance since its purpose is to prolong the life of the printer. It is not intended to repair or isolate an existing problem, though it can sometimes be helpful in detecting a condition due to a weakened component that has not yet completely failed.
Below is a list of scheduled maintenance checks and their recom­mended periodicity.
Clean external areas: as required Clean service station: 20-30 plot hours Clean cartridge jet area & 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
MAINTENANCE
3-1

Cleaning Procedures

Always turn the printer OFF, remove the power cord and the interface cable before cleaning the printer. An electri­cal shock hazard may be present if these 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.
WARNING
CAUTION
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 determined by the environment in which the printer is used.
Service Station Cleaning
Ink and dust may build up on the service station, resulting in contami­nation which may smear the prints. The service station is cleaned as follows:
1. Turn the printer OFF. Disconnect the power cord and interface
2. Raise the printer lid.
3. Carefully move the carriage toward the center of the printer.
3-2 Maintenance
cable.
4. Using a cotton 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. If the 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
CAUTION
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.
Printer problems can be caused by an accumulation of dirt or other contamination on the slide shaft. This contamination may lead to drag on the carriage. 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.
To clean the slide shaft:
1. Turn the printer OFF. Disconnect the power cord and interface cable.
2. Raise the printer lid.
MAINTENANCE
3. Moisten a clean cloth or paper wipe with NovaKlean™.
Maintenance 3-3
4. Wipe the length of the slide shaft with the moistened cloth or wipe.
5. Manually move the carriage assembly from side to side.
6. Wipe the shaft again to remove any deposits left from the carriage.
7. 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 detrimen­tal effect has been observed in the field.
To clean the Encoder Strip:
1. Disconnect the power cord and interface cable.
2. Slightly dampen a cotton swab with NovaKlean™ and wipe
3. Slightly dampen a cotton swab with isopropyl alcohol and wipe
4. Reconnect the power cord and interface cable.
3-4 Maintenance
along the length of the encoder strip on both sides.
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.
ENCODER STRIP
COTTON SWAB
Figure 3-1. Encoder Strip Cleaning.
Cartridge Jet Area & Dimples Cleaning
CARTRIDGE
DIMPLE
AREA
MAINTENANCE
Figure 3-2. Cartridge Dimple Region.
Maintenance 3-5
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.
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 overlooked.
Follow this up by gently dabbing the jet plate area on the bottom of the cartridge.
NOTE
Flex Cable Contact Cleaning
3-6 Maintenance
Flex Cable
Contacts
Figure 3-3. Flex Cable Contacts.
Cleaning the flex cable contact area is very important due to the ease of which this area can become dirty. 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 con­tact 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
The 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 cause erroneous prints or even damage to the MPWA. All 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 if 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
Maintenance 3-7
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. All 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, connec­tions, or any of the components on the assembly.

Reseat Connectors on MPWA and Carriage Board

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
CAUTION
Integrated circuits may become weakened or damaged by electrical discharge. Do not touch or work near integrated circuits without wearing an ESD wrist strap.
CAUTION
Ribbon connectors can be easily damaged if incorrectly handled. Observe extreme caution when handling the ribbon connectors to avoid damage.
J9
J8
J1
J7
J15
J2
J15
J12
J3
J13
J4
J5
J6
J15
Figure 3-4. Main PWA Connection Locations.
MAINTENANCE
J15
Table 3-1. Main PWA Connections.
J1 Stepper Motor J10 not used J2 Servo Motor J11 not used J3 Leg Harness J12 Display Data J4 AutoLoad Sensor J13 Keypad J5 Vacuum Fan #1 J14 Serial I/O Port J6 Vacuum Fan #2 J15 Power Supply J7 Trailing Cable J16 not used J8 Power Supply Cooling Fan J17 SIMM Sot J9 Parallel I/O Port J18 SIMM Slot
Maintenance 3-9
J5
J2
J1
J4
J3
Figure 3-5. Carriage PWA Connection Locations.
Table 3-2. Carriage PWA Connections.
J1 Black Drivers J5 Encoder Sensor J2 Cyan Drivers J6 Trailing Cable J3 Magenta Drivers J7 Paper Sensor J4 Yellow Drivers
3-10 Maintenance
J6
J7
Figures 3-4 and 3-5 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 shown 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
MAINTENANCE
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 environ­ment 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

Servo Motor Winding Resistance Check

Figure 3-7. Servo Motor.
1. Disconnect the servo motor connection from J2 on the MPWA.
2. Using a standard ohmmeter or multimeter, connect the meter leads to the two wires going to the motor.
3. While manually rotating the servo motor, monitor the readings on the meter. The acceptable range is 6-30 ohms. Typically, the reading is 7-11 ohms.
4. If the measurement is found to be unsatisfactory, replace the servo motor.
3-12 Maintenance

Stepper Motor Winding Resistance Check

7.2-8.0
RED
WIRE
Figure 3-8. Stepper Motor.
7.2-8.0 ohms
ohms
MAINTENANCE
1. Disconnect the stepper motor connection from J1 on the MPWA.
2. Using a standard 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. If either measurement is out of tolerance, replace the stepper motor.
Maintenance 3-13
Power Feed and Take-Up Motor Winding
Resistance Check
Figure 3-9. Power Feed and Take-Up Motor.
1. Remove the feed and/or take-up roll from the printer.
2. Using Phillips screwdriver, remove the four screws that secure the cradle idler from the right leg.
3. Ease the cradle idler off of the leg enough to disconnect the motor wires from the leg harness.
4. 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.
5. If the measurement is found to be unsatisfactory, replace the motor.
6. Perform the same procedure on the remaining motor.
3-14 Maintenance

Banding: Hardware vs Software

The technician must be able to identify whether the banding that is being observed is related to either a hardware or a software problem. The two examples in Figure 3-10 represent classic types of hardware and software banding errors.
HARDWARE SOFTWARE
Figure 3-10. Examples of Banding.
Hardware banding is usually characterized by consistent banding strips as shown. It signifies a slippage in the media’s normal move­ment that is possibly due to the stepper motor, lower drive shaft assembly, pinch rollers, or the rollguides on the back of the printer. All these possible faulty areas deal with a rotational movement that, if faulty, will generate a consistent banding pattern. The MPWA and Carriage PWA can also cause this type of error to incur.
Software banding is characterized by inconsistent banding lines. These banding lines are generated by the software when the applica­tion incorrectly interprets the media advancing/ink firing sequence of the expected print file. Because it is not directly tied to a mechanical movement, the bands become inconsistent in both frequency and duration. The possible causes are the printer driver, the original software package, or the RIP, if one is used. To eliminate the chance that it is the printer driver:
1) Remove any RIP or network systems and connect the printer directly to the computer.
MAINTENANCE
2) Print a test file approved by ENCAD that uses only the printer driver software and the ENCAD printer.
Maintenance 3-15
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 is to rotate the image 90 degrees and see if the banding rotates or remains in the same orientation as the previ­ous 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
4. Lower quality print modes normally cause slight bands, to avoid
5. Air bubbles in the ink delivery system. This indicates a loss of
6. Improper priming. The lower secondary chamber within the
3-16 Maintenance
the inkjet cartridge head nozzles. Run the 100% color test and re-prime or replace the cartridge if necessary.
this banding, switch to 4-pass or 6-pass printing modes.
negative pressure within the ink cartridge or ink delivery system, check all quick release fittings and connections for possible leaks and ensure that the cartridge is primed properly.
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.
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 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.
10. Cartridge failures can 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
Maintenance 3-17
14. Inkjet sputter. If the cartridge heater is set too high, inkjet sputter may occur causing intermittent white spots throughout the print.
15. Improper grounding 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. polyester­based 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 is 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 (i.e. RGB images with CMYK images).

Alignments/Adjustments

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 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.
3-18 Maintenance
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” (37.5cm) 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” (37.4cm) 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 Modified Novajet Cartridge for newer products Modified Novajet 4/Pro/Pro 50 Cartridge - Not Used Platen/Carriage Shaft Mounting Block Calibration Jo Block (1.434”) - Not used Plastic Gauge Card (0.011”) - Not used
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. Connect the dial gauge micrometer to the Shaft mounting block as shown in Figure 3-11.
ZERO
GAUGE
TIGHTEN SET
SCREW (NOT
SHOWN)
SHAFT MOUNTING BLOCK
MAINTENANCE
Figure 3-11. Dial Gauge Micrometer Assembly.
Maintenance 3-19
2. Place gauge 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
FIRST
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.
MEASURE
LAST
ADJUST IF
NECESSARY
MEASURE SECOND
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
THESE ARE THE TURNBUCKLE
SCREWS. POSITION GAUGE
IN BETWEEN THE SCREWS
AND AS CLOSE TO CENTER
AS POSSIBLE.
THIS IS THE INNER SCREW. POSITION GAUGE DIRECTLY IN FRONT OF IT.
Figure 3-13. Slide Shaft Profile Adjustment.
For example: If the Left = 0, Right = +0.004”, then the center should
be adjusted to + 0.002”. This will ensure a smooth plane of travel for the carriage assembly. There are no adjustments on either end of the shaft in all models.
MAINTENANCE
Maintenance 3-21

Head Height Alignment Procedure

Perform this procedure only when the encoder strip stabilizer has been removed from the Y-Arm or whenever the alignment is in question.
The head height alignment procedure is to ensure that the correct amount of distance exists between the cartridge jet plate and the Platen. See Figure 3-14.
HEAD HEIGHT
Figure 3-14. Carriage Head Height Tolerance.
CARTRIDGE JET PLATE
PLATEN
1. Remove the lid and the right cover of the printer. See Chapter 5 for procedures.
2. Obtain the 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
TO FACE BACKWARDS
TIGHTEN SET
SCREWS
ENSURE TIP EXTENDS
BELOW CARTRIDGE
1/4" (6mm)
MICROMETER DIAL GAUGE
TEST CARTRIDGE
MEASURING TIP EXTENDER
Figure 3-15. Setting Up Tools from Height Gauge Kit.
3-22 Maintenance
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.
0
ZERO
GAUGE
ENSURE PRESSURE IS PLACED ON THE REAR OF THE CARTRIDGE
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.
MAINTENANCE
Figure 3-17. Test Cartridge Installed.
Maintenance 3-23
5. 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.
CAUTION
7. While lifting up the measuring tip of the micrometer, slide the
8. Move the left end of the stabilizer bracket until the reading
3-24 Maintenance
Damage may occur to the micrometer gauge if the Carriage is moved without lifting up on the measuring tip. This ac­tion could also take the micrometer out of alignment and foul the results of the alignment.
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 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 +/- 3.
CAUTION
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 read­ing 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 con­tain a jet plate assembly. A difference had to be calcu­lated to compensate for the lack of a jet plate assembly on the test cartridge.
MAINTENANCE
9. Tighten the screw on the left side of the stabilizer.
10. 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.
11. Move the left end of the stabilizer bracket until a correct reading is observed. Read only the RED numbers on the micrometer gauge.
12. Tighten the screw on the stabilizer that is next to the Carriage.
13. Continue performing steps 10 through 12 until all four of the stabilizer screws have been adjusted.
Maintenance 3-25
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 are installed. Figure 3-18 is a representation of how a color calibration looks when printed.
Y
M
COLOR VERTICAL HEAD-TO-HEAD CALIBRATION
-6 -5 -4 -3 -2 -1 0 1 2 3 4
COLOR HORIZONTAL HEAD-TO-HEAD CALIBRATION
Current Heads (Y, M, C)
Figure 3-19. Color Calibration.
C
C
M
Y
56
3-26 Maintenance
The “Current Heads (Y, M, C)” view represents the alignment of the heads as they are currently entered. This is just an overview of all heads and how they are aligned. Do not attempt to align the heads using this view.
The “Color Horizontal 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.
To perform the Color Calibration:
1. Select “Utility Menu” from the Main Menu. This brings up the Utility Menu as shown in Figure 3-19.
MAINTENANCE
Prime
Access Cartridge
Color Calib Menu
Calibration Menu
Figure 3-20. Utility Menu.
*
Display Settings
Print Settings
Service Menu
Exit
Maintenance 3-27
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
Magenta Vertical
Yellow Vertical
Calib Print Test
Figure 3-21. Color Calib Menu.
3. Select “Calib Print Test” to print the color calibration plot as shown in Figure 3-18.
4. When the plot is complete, select “Cyan Vertical” at the Color Calib Menu. This brings up the options menu for the cyan vertical adjustment as shown in Figure 3-21.
Cyan Vertical
Next Option
*
*
Cyan Horizontal
Magenta Horizontal
Yellow Horizontal
Exit
Cancel
5. Observe the plot and using either “Prev Option” or “Next
3-28 Maintenance
<>
selected
Prev Option
Figure 3-22. Cyan Vertical Options Menu.
Option”, rotate through the selections until the one that best aligns the cyan color on the plot is selected. Press “Ok” to accept the selection and return to the Color Calib Menu.
Ok
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 All Lines Tests Single Line Test
Figure 3-23. Slow Deadband.
MAINTENANCE
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 vertical lines printed. No difference between the top and bottom set of lines to the center set of lines would be appearant.
The SLOW DEADBAND calibration is a precision test that checks the firing time of the jets as related to the forward and reverse direction.
Allowable values for the Slow Deadband calibration is -2, -1, 0, 1 and 2.
The Single Line Test and All 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 All Line Test prints all lines at the same time. These tests were designed primarily to be used in manufactoring only.
The deadband test on a NovaJet 500 series printer will look like the display in Figure 3-22 and the procedures to adjust the values are in the following section.
Maintenance 3-29
Allowable values for the Deadband calibration on the 500 series printers is 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. To make adjustments, if needed, see the Color Deadband Calibration section.
Allowable values for the Color Deadband calibrations on the 630/700 series printers is 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 “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 for the 500 series
3-30 Maintenance
Calibration Menu
Diagnostics Menu
Figure 3-24. Service Menu.
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.
*
Cartridge Info.
About
Test Print
Exit
Deadband Test
Slow Db Test
Single Line Test
All Lines Test
Figure 3-25. Calibration (Deadband) Menu (500 Series).
Deadband Test
Slow Db Test
Figure 3-26. Calibration (Deadband) Menu (630/700 Series).
Single Line Test
All Lines Test
*
*
Deadband
Slow Deadband
Exit
Slow Deadband
Exit
MAINTENANCE
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 is similiar to the menu depicted in Figure 3-21.
6. 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.
7. Continue performing steps 4 through 6 until the slow deadband adjustment is correct.
Maintenance 3-31
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 calcula­tions.
To 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
5. When the plot is complete, select “Deadband” at the Calibration
6. Observe the plot and using either “Prev Option” or “Next
7. Continue performing steps 4 through 6 until the slow deadband
3-32 Maintenance
deadband test is performed for the 500 series printers. Select “Deadband Test” to run the deadband test.
Menu. This brings up the options menu for the deadband adjustment. This menu is similiar to the menu depicted in Figure 3-21.
Option”, rotate through the selections until the value you want is selected. Press “Ok” to accept the selection and return to the Calibration Menu.
adjustment is correct.
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 calcula­tions.
To 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.
MAINTENANCE
2. Select the “Calibration Menu” from the Utility Menu. This brings up the Calibration Menu as shown in Figure 3-26.
Use Calib XY
Paper Axis Test
Color Db Menu
Figure 3-27. Calibration Menu.
3. Select the “Color Db Menu” from the Calibration Menu.
4. The Color Db Menu is shown in Figure 3-27 and is where the color deadband test is performed.
*
Open Jet Menu
Paper Axis
Exit
Maintenance 3-33
Black Deadband
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 test is 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.
*
Color Db Test
Exit
3-34 Maintenance
NOTE
The 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 ap­pear to be accepted because it will be displayed in the current settings section the next time this test is run. In actuality, the system will default to the closest allowable setting as listed above.
6. Observe the plot and using either “Prev Option” or “Next Option”, rotate through the selections until one that seems closer to the correct value is selected. Press “Ok” to accept the selection and return to the Color Db Menu.
7. 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.
To perform the paper axis procedure:
1. Select “Utility Menu” from the Main Menu. This brings up the Utility Menu as shown in Figure 3-19.
2. From the Utility Menu, select “Calibration Menu”. This brings up the Calibration Menu as shown in Figure 3-26.
3. 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 is entered in step 7.
4. From the Calibration Menu, select “Paper Axis Test”. This runs the paper axis test which prints out two “T” figures that are mirrored from each other and about 33” apart. See Figure 3-28.
MAINTENANCE
Maintenance 3-35
Figure 3-29. Paper Axis Test.
5. With a precision drafters measuring stick, measure the exact distance from each of the “T” intersections.
33"
6. Select “Paper Axis” at the Calibration Menu. This brings up
7. Using either “Prev Option” or “Next Option”, rotate through the
3-36 Maintenance
the options menu for the paper axis adjustment. This menu is similiar to the menu depicted in Figure 3-21.
selections until the exact value of the measurement found in step 5 is selected. Press “Ok” to accept the selection and return to the Calibration Menu.

Diagnostics Menu

The Diagnostics Menu is located in the Service Menu (shown in Figure 3-23) and is seen in Figure 3-29.
Servo PWM Test
Servo Cycle Test
Accessory Menu
Figure 3-30. Diagnostics Menu.
All tests under the Diagnostics Menu should be performed by competent technicians only. The types of tests that can be per­formed 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#1Test
*
*
Carriage Test
Color Test
Continuous Test
Exit
MAINTENANCE
Fan#2Test
Legs Test
Figure 3-31. Accessory Menu.
Exit
Maintenance 3-37
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 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: 10%, 25%, 35%, 50%, 65%, 75%, and 100%.
Continuous Test - The Continuous Test sends the printer into a test
loop that will perform a series of tests continuously. Powering down and restarting the printer is the only way of exiting this test loop.
3-38 Maintenance
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. The Loopback Test Cable is listed in Chapter 6.
After completing the deadband display, the test will begin again with the prime and continue until power is removed.
Fan #1 and Fan #2 Tests - Tests the operation of the fans on the
printer. Fan #1 Test (while depressed) turns on the power supply cooling fan and the suction fan inside the platen on the right side of the printer. Fan #2 Test (while depressed) turns on the suction fan inside the platen near the center of the printer. The 42 inch printer does not have this second suction fan, therefore, the Fan #2 Test is disabled.
Legs Test - Tests the condition of the leg harness connections
and the components of the power feed and take-up system.
MAINTENANCE
Maintenance 3-39

Limited Access Menu

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
Diagnostics Menu
PRESS
*
Code 1
Code 2
Code 3
Code 4
ENTER "16753" TO GET...
Clear NVRAM
Clock Reset
*
About
Exit
Code 5
Code 6
Code 7
Exit
*
Exit
3-40 Maintenance
Figure 3-32. NVRAM Clear and Clock Reset Menu.
This menu allows the technician to clear the NVRAM and to reset the system clock.
Clear NVRAM - Clearing the NVRAM is required anytime that a MPWA is to be permanently removed from a printer. The NVRAM is a section of nonvolatile memory that stores printer size information. The MPWA is the identical for both printers but it will have to learn which size printer it is installed in. Clearing the NVRAM allows the MPWA to relearn which size printer it is 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

The normal method of downloading new firmware is to send the file as if it was a standard print job.
To 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. Turn the 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. Go to a 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
Maintenance 3-41
For NT3.5x or NT4.0 systems click on “Start” - “Pro­grams”, “Command Prompt.” At the “dos” prompt go to the location of the .ROM (i.e.: if the .ROM file is on a floppy disk, type A: and press Enter.
Then type: PRINT /D:LPT1 A:\XXXX.ROM and press Enter.
6. 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.
7. After hearing the single beep, remove power from printer for 15­20 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.
NOTE
8. If the 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

The normal method of downloading new firmware is to send the file as if it was a standard print job.
1. Power OFF printer, wait 15 seconds.
2. Connect an Image Writer II cable between the printer and MAC.
3. Turn the printer ON.
3-42 Maintenance
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”
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.
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
Maintenance 3-43

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 and Figure 3-34 shows all connections of the leg harness assembly.
3-44 Maintenance
J1
1
J7
TRAILING
STEPPER
2
3
CABLE
MOTOR
4
5
1
J8
+24V
0V/+24V
COOLING
LEG HARNESS
ENABLE
J4
MAIN
LOAD
SENSOR
+5V
GND
1
2
CIRCUIT
PRINTED
SENSOR OUT
3
4
BOARD
J5
FAN 1
VACUUM
+24V
0V/+24V
1
2
FAN 2
VACUUM
+24V
0V/+24V
J6
1
2
3
3
SERVO
MOTOR
J2
6
1
J3
2
3
MAINTENANCE
2
J9
FAN
PARALLEL
J12
J13
J14
SERIAL
KEYPAD
DISPLAY
J15
P2
1
GND
+24V
1
2
2
3
GND
GND
3
4
4
SWITCHING
1
2
P1
LINE
NEUT
AC INPUT
& PWR SWITCH
Figure 3-33. MPWA Connections Diagram.
Maintenance 3-45
SUPPLY
POWER
3
GND
1
2
3
4
5
CART COM
3
4
+5V
5
EXB
6
EXA
6
TRAILING CABLE
J7
+24V
+24V
CART COM
J1
1
2
7
CART COM
7
8
CLK+
8
MAIN
BOARD
CIRCUIT
PRINTED
21
22
23
24
25
23
+24V
CART COM
24
25
26
+24V
26
9
10
11
12
13
14
15
16
17
18
19
20
+5V
CART COM
HEAD STROBE
18
19
DAN
PSIN/PWM
21
22
20
CART COM
CLK-
GND
DATA 1-
DATA 1+
9
10
11
12
13
DATA 2+
14
DATA 2-
CART COM
15
16
LATCH
17
3-46 Maintenance
PCB
CARRIAGE
1
2
3
J2
J1
EXA
GND
1
2
OPTICAL
ENCODER
4
EXB
+5V
3
4
SENSOR
1
2
3
4
J4
YELLOW
J5
MAGENTA
J3
PSIN
+5V
+5V
GND
J1
1
2
3
4
PCB
PAPER
SENSE
J7
J6
CYAN
BLACK
DRIVERS
CARTRIDGE
Figure 3-34. Carriage PWA Connections Diagram.
LEG HARNESS
PLATEN HARNESS
J3
1
1
+24V
FEED SENSOR
1
DRYER FAN 1
FEED SENSOR
2
3
4
2
3
4
GND
+24V
2
3
TAKE-UP SENSOR
5
5
GND
TAKE-UP SENSOR
4
5
DRYER FAN 6
DRYER FAN 3
DRYER FAN 2
DRYER FAN 5
DRYER FAN 4
DRYER FAN 7
MAINTENANCE
ASSEMBLY
16
16
N.C.
16
17
17
+24V
DRYING FAN 1
17
18
18
18
DRYER FAN
19
20
21
22
23
24
25
26
19
20
21
22
23
24
25
26
DRYING FAN 7
DRYING FAN 5
DRYING FAN 3
DRYING FAN 6
DRYING FAN 4
DRYING FAN 2
N.C.
N.C.
21
19
22
20
23
24
25
26
FEED MOTOR
TAKE-UP MOTOR
6
7
8
9
10
11
12
13
14
15
6
7
8
9
10
11
12
13
14
15
FEED RTN
FEED PWR
TAKE-UP RTN
TAKE-UP PWR
N.C.
6
7
8
9
10
11
FAN INTLK
N.C.
N.C.
N.C.
12
13
14
15
MAIN
BOARD
CIRCUIT
PRINTED
Figure 3-35. Leg Harness Connections Diagram.
Maintenance 3-47
DRYER
THERMAL
SUBA SSE MBLY
3
J1
SUPPLY SENSOR
TAKE -U P SENSOR
LEG HAR NESS
PLATEN HARNESS
123456789
123456789
GND
+24V
+24V
SUPPLY SENSOR
TAKE-UP SENSOR
123456789
J6
SUPPLY MOTOR
GND
SUPPLY RTN
+5V DRYER
+24V SUPPLY PWR
+24V TAKE-UP PWR
71121114
TAKE-UP MOTOR
1011121314151617181920212223242526
1011121314151617181920212223242526
TAKE-UP RTN
DRYER GND
DRYER +24V
1011121314151617181920
DRYER FAN 1
DRYER FAN 8
N.C.
N.C.
N.C.
N.C.
13
DRYER FAN 7
N.C.
N.C.
N.C.
2122232425
N.C.
N.C.
26
Figure 3-36. Leg Harness Connections Diagram (750).
3-48 Maintenance
MAIN
WIRING
PRINTED
ASSEMBLY

Troubleshooting

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.
4
SHOOTING
TROUBLE-
Table 4-1. Troubleshooting Table.
Symptoms Possible cause Solution

No Power

• printer not ON depress power switch
• faulty power replace power cord
cord
• AC input not replace AC entry
present at power module supply
4-1
Table 4-1. Troubleshooting Table (cont).
Symptoms Possible cause Solution
No Power (cont) • DC output replace power

Initialization Failure

voltage not supply present (see Figure 3-32 for pin-out)
• DC voltage replace MPCB present at MPCB
• SIMM unseated, reseat or replace defective or missing SIMM
• faulty take up or replace motor feed motor (if installed)

Media Does Not Move

4-2 Troubleshooting
• faulty leg harness disconnect at J3 on cable MPCB to test,
replace as necessary
• power supply replace power defective supply
• trailing cable replace trailing defective cable
• perform Stepper replace stepper Motor Winding motor if out of Resistance check tolerance
• rough motion bad bearings ­while spinning replace stepper stepper motor motor
Table 4-1. Troubleshooting Table (cont).
Symptoms Possible cause Solution
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
lubricated) slide Cleaning procedure shaft
SHOOTING
TROUBLE-
• perform Servo replace servo motor
Motor Winding Resistance check
• check servo bad bearings -
motor for smooth replace servo motor movement
• obstruction in remove obstruction
path of carriage (may or may not be visible)
Troubleshooting 4-3
Table 4-1. Troubleshooting Table (cont).
Symptoms Possible cause Solution
Internal ERROR • dirty encoder perform Encoder “Carriage Axis strip Strip Cleaning Failure” (cont) procedure
• dirt under the remove carriage carriage bushings bushings and clean
• damaged replace encoder encoder strip strip
• bad encoder replace encoder sensor sensor
• worn carriage replace carriage bushings bushings
• loose trailing remove power and cable connections reseat trailing cable
connections at the MPCB and the carriage assembly
4-4 Troubleshooting
• cutter assembly replace cutter malfunction assembly
• damaged 1) check idler/ carriage drive tension assembly belt system
2) check carriage belt
• faulty trailing replace trailing cable cable
Table 4-1. Troubleshooting Table (cont).
Symptoms Possible cause Solution

Internal ERROR “Encoder Sensor Failure”

• encoder sensor reseat encoder
cable unseated sensor cable
• bad encoder replace encoder
sensor sensor

Internal ERROR “Paper Sensor Failure”

• servo motor reattach connections
and vaccuum fan correctly (use Figure connections to 3-4 for reference) MPCB are switched
• paper sensor reseat paper
cable unseated sensor cable
• bad trailing cable replace trailing cable
SHOOTING
TROUBLE-
• bad paper replace paper
sensor sensor
• servo motor check servo motor
disconnected connections
• trailing cable reseat trailing cable
connection is faulty
Troubleshooting 4-5
Table 4-1. Troubleshooting Table (cont).
Symptoms Possible cause Solution

Internal ERROR “Auto-Sensor Failure”

Internal ERROR “MPCB Failure”

Unrecognized Cartridges Error

•auto-sensor reseat auto­cable unseated sensor cable
• bad auto- replace auto­sensor sensor
• bad MPCB replace MPCB
• faulty connection check cartridges of cartridge ID chip to flex cable
4-6 Troubleshooting
• 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
Table 4-1. Troubleshooting Table (cont).
Symptoms Possible cause Solution

Image Skews or Moves

• dirty encoder clean encoder
strip strip (top and
bottom)

Does Not Print

• bad connection reseat cable
between computer connections on and printer computer and
printer
• firmware is refresh EEPROM
corrupted firmware with new
download
• faulty quad flex replace quad flex
cable cable or complete
carriage assembly
• bad MPCB replace MPCB
SHOOTING
TROUBLE-

Ink Cartridge Misfiring

• cartridge low on refill or replace
ink cartridge
• firing rate set adjust firing rate
too fast lower (optimum
is 5)
Troubleshooting 4-7
Table 4-1. Troubleshooting Table (cont).
Symptoms Possible cause Solution
Ink Cartridge • ink drop out lower ink pre-heat Misfiring (cont) (ink starvation settings
resembling intermittent banding)
• flex contacts 1) perform Flex dirty or damaged Cable Contact
Cleaning procedures
2) replace carriage assembly
• cartridge dimple 1) perform area dirty or Cartridge Dimple damaged Cleaning procedure
2) replace cartridge
• cartridge not reseat cartridge seated correctly
• bad cartridge replace cartridge
• service station 1) perform Service dirty or not Station Cleaning properly sealing procedures cartridge jet area
2) replace seal on service station
• bad carriage replace carriage assembly assembly
• bad MPCB replace MPCB
4-8 Troubleshooting
Table 4-1. Troubleshooting Table (cont).
Symptoms Possible cause Solution

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 Output is Banding (Horizontal)

• if banding is 1) inspect and/or
consistent replace stepper
motor (perform Stepper Motor Winding Resistance Check)
SHOOTING
TROUBLE-
2) inspect and/or replace stepper motor gears and/or lower roller assembly
3) replace MPCB
• check amount replace or refill
of ink in cartridges cartridges
• cartridges need perform Prime
to be primed
Troubleshooting 4-9
Table 4-1. Troubleshooting Table (cont).
Symptoms Possible cause Solution
Printer Output is • color calibration perform Color Banding (Horizontal) required Calibration (cont)
• paper axis perform Paper Axis calibration Test Calibration required
• faulty or corrupt reload firmware firmware
• cartridge dimple 1) perform area dirty or Cartridge Dimple damaged Cleaning procedure
2) replace cartridge
• flex cable 1) perform Flex contacts dirty or Cable Contact damaged Cleaning
4-10 Troubleshooting
2) replace carriage assembly
• carriage check carriage assembly assembly for proper obstructed movement along
Y-arm
• carriage belt is reinstall, check loose, too tight, tension assembly, worn, or damaged and/or replace belt
• carriage bushings replace bushings worn or damaged
• corrupted clear NVRAM NVRAM
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