User manual | NOTE - Printertec

60 inch
42 inch
SERVICE MANUAL
®
NOVAJET® PRO 600e
COLOR INKJET
PRINTER
SERVICE MANUAL
Part Number 210596
NovaJet PRO 600e Service Manual
Copyright © 1998 ENCAD®, Inc. All rights reserved.
ENCAD® and NovaJet® are trademarks of ENCAD, Inc.
Other trademarks and registered trademarks are the
property of their respective owners.
Except as provided below, no part of this manual may be
copied or distributed, transmitted, transcribed, stored in
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
iv
Rev A
May 1998
NovaJet PRO 600e Service Manual
FCC Statement (U.S.A.)
The United States Federal Communications Commision has specified
that the following notice be brought to the attention of the users of the
NOVAJET PRO 600e 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
NovaJet PRO 600e Service Manual
VDE Statement
Hiermit wird bescheinigt, daß der NOVAJET PRO 600e 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
vi
NovaJet PRO 600e Service Manual
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.
vii
NovaJet PRO 600e Service Manual
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.
viii
NovaJet PRO 600e Service Manual
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 PRO 600e Printer 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 Circuit Board (MPCB) ........................................................................... 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
Keypad ................................................................................................................... 2-16
Power Supply ......................................................................................................... 2-17
Beeper and Fans .................................................................................................... 2-17
Chapter 3 Maintenance ....................................................................... 3-1
Introduction ............................................................................................................... 3-1
Scheduled Maintenance ........................................................................................... 3-1
ix
NovaJet PRO 600e Service Manual
Table of Contents (cont)
Chapter 3 Maintenance (cont)
Cleaning Procedures .......................................................................................... 3-2
External Cleaning ......................................................................................... 3-2
Slide Shaft Cleaning..................................................................................... 3-2
Service Station Cleaning .............................................................................. 3-3
Linear Encoder Strip Cleaning ...................................................................... 3-4
Cartridge Dimples Cleaning .......................................................................... 3-5
Flex Cable Contact Cleaning........................................................................ 3-6
Clean and Inspect Stepper Motor Gears....................................................... 3-7
Clean and Inspect MPCB ............................................................................. 3-7
Clean and Inspect Carriage Assembly ......................................................... 3-8
Reseat Connectors on MPCB and Carriage Board .............................................. 3-8
Replace Carriage Bushings .............................................................................. 3-10
Servo Motor Winding Resistance Check ................................................................. 3-11
Stepper Motor Winding Resistance Check.............................................................. 3-12
Power Feed and Take-Up Motor Winding Resistance Check ................................... 3-13
Banding: Hardware vs Software ............................................................................... 3-14
Common Banding Causes ................................................................................ 3-15
Alignments/Adjustments ......................................................................................... 3-17
Slide Shaft Profile Adjustment .......................................................................... 3-17
Head Height Alignment Procedure .................................................................... 3-20
Color Calibration ............................................................................................... 3-24
Deadband Alignment ........................................................................................ 3-27
Paper Axis Calibration ...................................................................................... 3-30
Diagnostics Menu ................................................................................................... 3-32
Limited Access Menu ............................................................................................. 3-34
Firmware Download/Upgrading for the PC ............................................................... 3-36
Firmware Download/Upgrading for the MAC ............................................................ 3-37
Internal Cabling and Signal Flow Diagrams ............................................................. 3-38
Chapter 4 Troubleshooting ................................................................. 4-1
Introduction ............................................................................................................... 4-1
No Power ........................................................................................................... 4-1
Media Does Not Move ........................................................................................ 4-2
x
NovaJet PRO 600e Service Manual
Table of Contents (cont)
Chapter 4 Troubleshooting (cont)
Internal ERROR “Carriage Axis Failure” .............................................................. 4-3
Internal ERROR “Encoder Sensor Failure” .......................................................... 4-4
Internal ERROR “Paper Sensor Failure” .............................................................. 4-4
Internal ERROR “Auto-Sensor Failure”................................................................ 4-4
Internal ERROR “Trailing Cable Failure” .............................................................. 4-5
Internal ERROR “MPCB Failure” ......................................................................... 4-5
Does Not Print.................................................................................................... 4-5
Ink Cartridge Misfiring ......................................................................................... 4-5
Paper Skewing ................................................................................................... 4-7
Printer Output is Banding ................................................................................... 4-7
Keypad Locked-Up or Not Functioning Properly ................................................. 4-8
Noisy Operation ................................................................................................. 4-9
Line Quality Degraded ...................................................................................... 4-10
Fan Does Not Power Up ................................................................................... 4-11
Media Take-Up Motor Not Operating, Sensor Works ........................................ 4-11
Media Feed Motor Not Operating, Sensor Works ............................................. 4-12
Media Feed and Take-Up Motors Not Operating, Both Sensors Working .......... 4-12
Media Feed or Take-Up Sensor(s) Not Operating .............................................. 4-13
Initialization Troubleshooting ................................................................................... 4-14
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 ....................................................................... 5-5
Remove the Keypad, Display, and Display Power Converter ...................................... 5-6
Install the Keypad, Display, and Display Power Converter ......................................... 5-8
Remove Extra Memory (SIMM) ................................................................................. 5-9
Install Extra Memory (SIMM) .................................................................................. 5-10
Remove the MPCB (Main Printed Circuit Board) ..................................................... 5-10
Install the MPCB .................................................................................................... 5-13
Remove Power Supply, Cooling Fan, and AC Entry Module .................................... 5-14
Install the Power Supply, Cooling Fan, and AC Entry Module ................................. 5-16
Remove Servo Motor ............................................................................................... 5-17
xi
NovaJet PRO 600e Service Manual
Table of Contents (cont)
Chapter 5 Assembly/Disassembly (cont)
Install Servo Motor .................................................................................................. 5-19
Remove the Ink Delivery System............................................................................. 5-20
Install the Ink Delivery System ................................................................................ 5-23
Remove the Carriage Assembly, Carriage Belt, and the Frame Tensioner................ 5-23
Install the Carriage Assembly, Carriage Belt, and the Frame Tensioner .................. 5-26
Remove the Carriage PCB ...................................................................................... 5-28
Install the Carriage PCB ......................................................................................... 5-30
Remove the Paper Sensor or the Encoder Sensor .................................................. 5-30
Install the Paper Sensor or the Encoder Sensor...................................................... 5-32
Replacing the Carriage Bushings ............................................................................ 5-33
Remove the Service Station .................................................................................... 5-35
Install the Service Station ....................................................................................... 5-35
Remove the Trailing Cable Assembly ...................................................................... 5-36
Install the Trailing Cable Assembly ......................................................................... 5-36
Remove the Stabilizer Bracket and Encoder Strip ................................................... 5-37
Install the Stabilizer Bracket and Encoder Strip ...................................................... 5-39
Remove the Y-Arm Assembly, Pinch Rollers, Slide Shaft, and Auto-Load Sensor ... 5-39
Install the Y-Arm Assembly, Pinch Rollers, Slide Shaft, and Auto-Load Sensor ...... 5-41
Remove the Lower Roller Assembly, Stepper Motor and Vacuum Fan ..................... 5-43
Install the Lower Roller Assembly, Stepper Motor and Vacuum Fan ........................ 5-46
Remove the Media Take-Up and Feed Sensor Brackets and Sensors ..................... 5-49
Install the Media Take-Up and Feed Sensor Brackets and Sensors ........................ 5-51
Remove the Media Take-Up and Feed Motors ......................................................... 5-51
Install the Media Take-Up and Feed Motors ............................................................ 5-52
Remove the Media Drying Fans .............................................................................. 5-54
Install the Media Drying Fans ................................................................................. 5-54
Chapter 6 Parts List ............................................................................. 6-1
Index ............................................................................................... Index-1
xii
NovaJet PRO 600e Service Manual
List of Illustrations
Figure
Page
Chapter 1 General Description
1-1.
NovaJet PRO 600e Inkjet Printers ................................................................... 1-1
Chapter 2 Theory of Operation
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-11.
2-12.
General Block Diagram ................................................................................... 2-2
Paper (Media) Axis Drive ................................................................................. 2-3
Carriage Axis Drive .......................................................................................... 2-4
Power Feed and Take-Up System ................................................................... 2-5
Main Printed Circuit Board .............................................................................. 2-6
Gate Array ...................................................................................................... 2-7
Stepper Motor Controller ............................................................................... 2-10
Servo Motor Controller ................................................................................... 2-12
Quadrature Signal Generation ....................................................................... 2-13
Interface Circuits ........................................................................................... 2-14
Carrier Assembly Circuits ............................................................................. 2-15
Main Menu .................................................................................................... 2-16
Chapter 3 Maintenance
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
3-15.
3-16.
Encoder Strip Cleaning ................................................................................... 3-5
Cartridge Dimple Region .................................................................................. 3-5
Flex Cable Contacts ....................................................................................... 3-6
MPCB Connection Locations .......................................................................... 3-9
Carriage Connection Locations ........................................................................ 3-9
Ribbon Connector Locking Mechanism ......................................................... 3-10
Servo Motor ................................................................................................... 3-11
Stepper Motor ............................................................................................... 3-12
Power Feed and Take-Up Motor .................................................................... 3-13
Examples of Banding .................................................................................... 3-14
Dial Gauge Micrometer Assembly ................................................................. 3-18
Measurement Positions for Slide Shaft .......................................................... 3-19
Slide Shaft Profile Adjustment ....................................................................... 3-20
Carrier Head Height Tolerance ....................................................................... 3-21
Setting Up Tools from Height Gauge Kit ........................................................ 3-21
Zeroing the Micrometer Gauge ...................................................................... 3-22
xiii
NovaJet PRO 600e Service Manual
List of Illustrations (cont)
Figure
Page
Chapter 3 Maintenance (cont)
3-17.
3-18.
3-19.
3-20.
3-21.
3-22.
3-23.
3-24.
3-25.
3-26.
3-27.
3-28.
3-29.
3-30.
3-31.
3-32.
Test Cartridge Installed .................................................................................. 3-22
Color Calibration............................................................................................ 3-25
Utility Menu ................................................................................................... 3-26
Color Calib Menu........................................................................................... 3-26
Cyan Vertical Options Menu .......................................................................... 3-27
Deadband Slow/Fast ..................................................................................... 3-27
Service Menu ................................................................................................ 3-28
Calibration (Deadband) Menu ........................................................................ 3-29
Calibration Menu ........................................................................................... 3-31
Paper Axis Test ............................................................................................ 3-31
Diagnostics Menu ......................................................................................... 3-32
Accessory Menu ........................................................................................... 3-33
NVRAM Clear and Clock Reset Menu ........................................................... 3-35
MPCB Connections Diagram ......................................................................... 3-39
Carriage PCB Connections Diagram .............................................................. 3-40
Leg Harness Connections Diagram ............................................................... 3-41
Chapter 4 Troubleshooting
4-1.
Carriage Board LED D2 Location ................................................................... 4-15
Chapter 5 Assembly/Disassembly
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
5-9.
5-10.
5-11.
xiv
Right Cover Assembly Removal/Installation ..................................................... 5-3
Left Cover Assembly Removal/Installation ....................................................... 5-4
Keypad and Display Removal/Installation ........................................................ 5-7
Keypad Grounding Connection ........................................................................ 5-8
Extra Memory (SIMM) Removal/Installation ..................................................... 5-9
MPCB Removal ............................................................................................. 5-12
Power Supply Removal ................................................................................. 5-15
Cooling Fan/AC Entry Module Removal ......................................................... 5-16
Slacken Carriage Belt ................................................................................... 5-18
Electronics Cover Removal ............................................................................ 5-21
Disconnect Ink Delivery System Link ............................................................ 5-22
NovaJet PRO 600e Service Manual
List of Illustrations (cont)
Figure
Page
Chapter 5 Assembly/Disassembly (cont)
5-12.
5-13.
5-14.
5-15.
5-16.
5-17.
5-18.
5-19.
5-20.
5-21.
5-22.
5-23.
5-24.
5-25.
5-26.
5-27.
5-28.
Strain Relief Removal/Installation .................................................................. 5-24
Frame Tensioner ........................................................................................... 5-25
Carriage Belt Clamp ...................................................................................... 5-25
Carriage PCB Removal/Installation ................................................................ 5-29
Paper and Encoder Sensor Removal ............................................................. 5-31
Paper and Encoder Sensor Installation .......................................................... 5-32
Carriage Bushing Removal ............................................................................ 5-34
Carriage Bushing Installation ......................................................................... 5-34
Service Station Removal ................................................................................ 5-35
Stabilizer Bracket Installation/Removal .......................................................... 5-38
Y-Arm Installation/Removal ........................................................................... 5-40
Pinch Roller .................................................................................................. 5-41
Inner Platen Assembly/Disassembly ............................................................. 5-44
Stepper Motor Removal/Installation ............................................................... 5-46
Inside Platen, Right Side ............................................................................... 5-48
Media Take-Up and Feed Sensor Removal .................................................... 5-50
Media Take-Up and Feed Motor Removal ...................................................... 5-53
Chapter 6 Parts List
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
Left Side Parts Breakdown .............................................................................. 6-3
Platen and Above Parts Breakdown ................................................................ 6-5
Right Side Parts Breakdown ........................................................................... 6-7
Inner Platen Parts Breakdown ......................................................................... 6-9
Carriage Assembly Parts Breakdown ............................................................ 6-11
Power Feed and Take-Up Parts Breakdown ................................................... 6-13
xv
NovaJet PRO 600e Service Manual
List of Tables
Table
Page
Chapter 1 General Description
Chapter 2 Theory of Operation
Chapter 3 Maintenance
Chapter 4 Troubleshooting
4-1.
Troubleshooting Table...................................................................................... 4-1
Chapter 5 Assembly/Disassembly
Chapter 6 Parts List
xvi
General Description
1
GENERAL
DESCRIPTION
Figure 1-1. NovaJet PRO 600e Inkjet Printers.
Introduction
This manual provides service information for the ENCAD®, Inc.
NovaJet® PRO 600e Color Inkjet Printer. The NovaJet® PRO 600e
printer comes in two sizes: a 42 inch model and a 60 inch model.
It is written for service personnel who possess analog and digital
circuitry experience. Chapter 2, Theory of Operation, should be read
and thoroughly understood before troubleshooting/calibrating the
printers.
1-1
NovaJet PRO 600e Service Manual
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 for more details.
Both RS-422 serial and Centronics parallel connections are provided
to interface with the host computer. Commands sent from the host
computer can be in several forms including HP-RTL and Encad RTL
formats.
Drivers are supplied to support Windows-based PC’s (3.XX, 95, and
NT) as well as Macintosh and Power PC computers.
These printers expand upon ENCAD’s tradition of delivering fast,
high-quality 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
Media Drying System
Quick Ink Changeover
Self-Aligning Pinch Rollers
PowerPC 33 MHz Microprocessor
8 User Configurable Settings
208 Jet Ink Cartridges
Ink Priming System
500ml Ink Reservoirs
Smart Cartridges
1-2
General Description
NovaJet PRO 600e Service Manual
Overview
Related Publications
The following publication contains additional information which may
be useful in servicing the ENCAD, Inc. NovaJet PRO 600e Color
Inkjet Printers:
•
ENCAD NovaJet PRO 600e User Guide,
P/N 210131
•
ENCAD NovaJet PRO 600e Quick Start Guide,
P/N 210058
•
ENCAD NovaJet PRO 600e Connectivity Guide,
P/N 210611-1
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 PCBs (Printed Circuit Boards) associated with the NovaJet PRO
600e printers have components sensitive to ESD (electrostatic discharge). Care must be taken to avoid damage to any of the components
by following current ESD handling procedures and practices.
Always use an approved ESD grounding strap when handling or
working with PCBs.
General Description
1-3
GENERAL
DESCRIPTION
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.
NovaJet PRO 600e Service Manual
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:
Followed by a paragraph describing the concern.
CAUTION - Cautions depict that the following steps or procedures can
cause damage to the equipment if not properly followed. Extreme care
should be observed when following the procedures and to exercise
standard safety procedures. They are indicated by:
Followed by a paragraph describing the concern.
NOTE - 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
NovaJet PRO 600e Service Manual
Printer Specifications
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
ENCAD RTL
Buffer:
32 MB installed
upgradeable to 64 MB
Power Requirements:
Input Voltage:
90-246 VAC
47-63 Hz
Output Power:
20 W idle
140 W typical
215 W maximum
Baud Rates:
9600, 19200, 38400
Resolution:
600x600 dpi or
300x300 dpi, addressable
Weight:
60” 88 lbs 135 lbs (boxed)
42” 72 lbs 117 lbs (boxed)
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
10BaseT, 10Base2
Print Server
Environment:
Operating:
59° to 95° F
(15° to 35° C)
10% to 70% RH
non-condensing
Storage:
-5° to 140° F
(-21° to 60° C)
5% to 80% RH
non-condensing
Dimensions:
Height 44” (1.12m)
Width 77” (1.96m)
42 inch
95” (2.41m)
60 inch
Depth 28” (0.71m)
General Description
1-5
GENERAL
DESCRIPTION
The specifications and performance characteristics of the NovaJet
PRO 600e Color Inkjet Printers are as follows:
NovaJet PRO 600e Service Manual
Contents of this Service Manual
Figures are used in this manual to clarify procedures. They are for
illustrative purposes only and may not necessarily be drawn to
scale.
Material in this manual may be repeated in various chapters so that
each chapter can “stand alone”. This allows information to be
located without having to refer back and forth between chapters.
Figures and tables are easily located and cross-referenced, and are
listed in the front of the manual under List of Illustrations and List
of Tables.
This manual is divided into six chapters as:
Chapter 1 GENERAL DESCRIPTION - Contains a general
description of the ENCAD NovaJet PRO 600e printer.
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.
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.
1-6
General Description
NovaJet PRO 600e Service Manual
GENERAL
DESCRIPTION
Chapter 5 ASSEMBLY/DISASSEMBLY - Contains detailed
procedures to remove and replace printer parts and
assemblies.
Chapter 6 PARTS LIST - Contains a complete listing of all
field replacable parts and assemblies for the NovaJet
PRO 600e Color Inkjet Printer. Illustrated parts
breakdown drawings are included to help clarify and
identify parts for ordering. Special kits and adjustment
jigs may also be required.
ORIENTATION - Instructions in this manual are based on the
assumption that the service person is facing the front of the
printer. References to top view, back view, and so forth are
consistent with this engineering standard. References to the
X Axis and Y Axis (Paper Axis and Carrier Axis, respectively)
follow the standard of AutoCAD™ absolute coordinates: up and
down for X, left to right for Y.
General Description
1-7
NovaJet PRO 600e Service Manual
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 Technical Bulletins located on ENCAD’s bulletin board or
the Internet:
ENCAD BBS:
ENCAD Website:
(619) 452-2653 or
(619) 452-3768
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:
Help Desk FAX:
(619) 452-4350
(619) 546-0659
International Users contact your local ENCAD service provider. see
details on your ENCAD registration card.
1-8
General Description
Theory of Operation
2
Introduction
This chapter explains the mechanical and electrical theory of operation
of the ENCAD NovaJet PRO 600e Color Inkjet printer.
NovaJet PRO 600e Printer General Block
Diagram
Figure 2-1 illustrates the major functional areas of the printer.
The NovaJet PRO 600e printer consists of three mechanical assemblies:
1. Paper (Media) Axis Drive
2. Carriage Axis Drive
3. Media Feed and Take-Up System
and four main electrical assemblies:
1. MPCB (Main Printed Circuit Board)
2. Carriage Assembly
3. Keypad
4. Power Supply
2-1
THEORY OF
OPERATION
The NovaJet PRO 600e is a PowerPC 33MHz microprocessor-based
digital printer that receives plotting instructions from a host computer
through either the RS-422 serial interface or the Centronics parallel
interface.
NovaJet PRO 600e Service Manual
Figure 2-1. General Block Diagram.
2-2
Theory of Operation
NovaJet PRO 600e Service Manual
Paper (Media) Axis Drive
THEORY OF
OPERATION
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.
Misaligned pinch wheels is a main cause of skewing of the media. For
that reason the NovaJet PRO 600e was designed with self aligning
pinch rollers. As the media is fed forward, the rollers are aligned
correctly. However, these pinch rollers will not stay aligned while the
media is being fed backwards.
Theory of Operation
2-3
NovaJet PRO 600e Service Manual
The Carriage Axis Drive
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
off set from each other, and reading the leading and trailing edges of the
lines, a resolution of 600 dpi can be obtained.
The stepper and servo motors are controlled from the main printed
circuit assembly by the microprocessor.
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Theory of Operation
NovaJet PRO 600e Service Manual
Media Feed and Take-Up System
THEORY OF
OPERATION
Figure 2-4. Power Feed and Take-Up System.
The media feed and take-up system comprises of two optical sensors and
two dc motors. See Figure 2-4.
The motors are used to advance the media feed roll and the media takeup roll dependant upon the signals they receive from the MPCB. The
MPCB generates the control signals for the motors from the information
it receives from the media feed and take-up sensors.
The optical sensors are designed to inform the MPCB when there is not
a proper amount of slack in the media by sensing the ‘curl’ of the media
at the bottom of its loop. This method is used so that all approved forms
of media (including transparent backlit media) is able to take advantage
of the power feed and take-up system.
Theory of Operation
2-5
NovaJet PRO 600e Service Manual
Main Printed Circuit Board (MPCB)
Figure 2-5. Main Printed Circuit Board.
The Main Printed Circuit Board (MPCB) consists of six functional
areas:
2-6
1.
Microprocessor (CPU)
2.
Gate Array
3.
Memory Circuits
4.
Stepper Motor Controller
5.
Servo Motor Controller
6.
Interface Circuits: Serial & Parallel
Theory of Operation
NovaJet PRO 600e Service Manual
Microprocessor
A divide-by-two circuit generates the 33MHz system clock from a
66MHz crystal reference (X1).
The chip select generator is programmed to generate chip selects at
the appropriate addresses, with the appropriate data size (byte, word)
and with the appropriate number of wait states.
Gate Array
Figure 2-6. Gate Array.
Theory of Operation
2-7
THEORY OF
OPERATION
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.
NovaJet PRO 600e Service Manual
The gate array contains the hardware logic for dot 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 internal RAM storage.
Each time power is turned on, this information must be downloaded
from the system ROM. This type of gate array allows for the flexibility
of upgrading the logic by simply downloading the new system software.
Memory Circuits
Memory is used to retain large amounts of information. This 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.
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Theory of Operation
NovaJet PRO 600e Service Manual
The system firmware is stored in Flash EEPROM. The Flash
EEPROM allows the firmware to be upgraded by downloading the files
containing the new firmware. It can be erased and reprogrammed
more than 10,000 times. The term “Flash” means that bytes cannot be
individually erased. A block or the whole device is erased at the same
time and the block or whole device is then reprogrammed.
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.
The printer also has two 72-pin 32-bit SIMM sockets for DRAM. The
printer is supplied with a SIMM of 32 Megabytes installed on the
MPCB. 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. Recommended SIMM’s to be used are listed in the
User Guide.
Theory of Operation
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THEORY OF
OPERATION
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.
NovaJet PRO 600e Service Manual
Serial EEPROM
Serial EEPROM is an Electrically Erasable, Programmable, Read Only
Memory which provides storage for calibration constants and user
configuration data entered from the host computer.
An 8K bit serial nonvolatile EEPROM stores calibration and configuration information. It retains data while the unit is off.
Stepper Motor Controller
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”.
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Theory of Operation
NovaJet PRO 600e Service Manual
Each circuit contains four main blocks (see Figure 2-7):
1. Reference waveform generator
The microprocessor uses a D/A (digital to analog) converter to set
the desired level for the current in the stepper motor winding. The
output of the D/A converter varies in time to create a reference
waveform. This reference waveform is centered around 10V.
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.
4. Power driver
An H-bridge allows the supply voltage to be applied across the
winding in either polarity to drive the current to the desired
value.
Theory of Operation
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THEORY OF
OPERATION
2. Motor current sense
NovaJet PRO 600e Service Manual
Servo Motor Controller
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.
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Theory of Operation
NovaJet PRO 600e Service Manual
THEORY OF
OPERATION
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
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NovaJet PRO 600e Service Manual
Interface Circuits: Serial & Parallel
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 printer
port. It has an eight pin Mini-DIN connector. The data (TXD, RXD)
signals meet RS-422 electrical specifications, and the control signal
(DTRCLK) meets the RS-423 electrical specifications. The control
signal can be configured as a 1MHz clock for high speed serial communications with a Macintosh.
The serial port is compatible with RS-422 devices when an appropriate
adapter cable is used. This cable is available from ENCAD.
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Theory of Operation
NovaJet PRO 600e Service Manual
Carriage Assembly Circuits
THEORY OF
OPERATION
Figure 2-11. Carriage Assembly Circuits.
The Carriage Assembly contains:
1)
2)
3)
4)
Carriage PCB
Optical Sensors
Paper Sensor
Inkjet Cartridges
The Carriage PCB contains the logic and drive circuitry for the firing of
the inkjet cartridges. It also establishes an interface path for the optical
sensor and paper sensor to communicate with the MPCB.
The optical sensors receive their inputs from the optical encoder strip
and sends this data to the MPCB. The MPCB uses this information to
determine the horizontal position of the carrier assembly so that accurate printing can be established.
Theory of Operation
2-15
NovaJet PRO 600e Service Manual
The paper sensor circuitry senses for the presence of loaded media. It
does this automatically during the start-up and load sequences. It also
constantly monitors the media during printing to determine if the
media has run out.
If no paper is sensed, the paper sensor sends this information to the
MPCB, which immediately begins an ‘out of paper’ subroutine. This
subroutine stops the printer from printing until more media is loaded.
The sensor also checks for the size of the media loaded so it can determine the proper printing parameters.
Keypad
The Keypad is located on the right side of the printer and consists of 8
variable-action control buttons and an LCD graphics display. The
control buttons are assigned different functions and are dependant upon
the selections that are presently shown on the graphics display. There
are four buttons on the left of the display and four buttons on the right,
with the display showing up to eight possible selections.
Figure 2-12. Main Menu.
Figure 2-12 shows the keypad after the printer has been turned on and
finished the start up process. As seen in the figure, the control buttons
are assigned to the corresponding command that is displayed closest to
the physical location of the button.
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Theory of Operation
NovaJet PRO 600e Service Manual
Power Supply
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.
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 on the NovaJet PRO 600e series
printers.
A single fan, located behind the power supply, is used for cooling the
power supply. Air blows over the power supply and the heated air is
forced out the back 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
THEORY OF
OPERATION
An internal UL recognized switching power module supplies power for
the NovaJet PRO 600e printer. 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 MPCB 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.
NovaJet PRO 600e Service Manual
A 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 drying assembly can also be disabled through the printers firmware
via the keypad.
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Theory of Operation
Maintenance
3
Introduction
This chapter contains general maintenance and cleaning instructions for the NovaJet PRO 600e.
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.
Below is a list of scheduled maintenance checks and their recommended periodicity.
Clean external areas:
Clean slide shaft:
Clean service station:
Clean encoder strip:
Clean cartridge dimples:
Clean flex cable contacts:
Clean and inspect motor gears:
Clean and inspect MPCB:
Clean and inspect carrier assembly:
Reseat connectors on MPCB:
Reseat connectors on carriage board:
Replace carriage bushings:
weekly, or
as required
monthly
biweekly
monthly
if prime fails
if prime fails,
or cartridge
is replaced
annually
annually
annually
annually
annually
semiannually
3-1
MAINTENANCE
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.
NovaJet PRO 600e Service Manual
Cleaning Procedures
Always turn the printer OFF, remove the power cord and
the interface cable before cleaning the printer. An electrical shock hazard may be present if these procedures are
not followed.
External Cleaning
Do not use abrasive cleansers of any sort on the surfaces
of the printer. Damage to the surface may result.
The exterior surfaces of the printer may be cleaned with a soft cloth
which has been dampened. For more persistent stains, a small
amount of liquid detergent may be used. Cleaning intervals are
determined by the environment in which the printer is used.
Slide Shaft Cleaning
Use only isopropyl alcohol on the slide shaft of the printer.
Damage to the stainless steel slide shaft may result if
cleaned with water and not completely dried off.
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Maintenance
NovaJet PRO 600e Service Manual
Printer problems can be caused by an accumulation of dirt or other
contamination on the slide shaft. This contamination may lead to drag
on the 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 and remove the power cord.
2. Raise the printer lid.
3. Moisten a clean cloth or paper wipe with isopropyl alcohol.
5. Manually move the carriage assembly from side to side.
6. Wipe the shaft again to remove any deposits left from the
carrier.
7. Close the cover and reconnect the power cord, turn the printer
ON and perform the PRIME procedure. Be sure that the
carrier moves freely on the slide shaft.
Service Station Cleaning
Ink and dust may build up on the service station, resulting in
contamination which may smear the prints. The service station is
cleaned as follows:
1. Turn the printer OFF. Disconnect the power cord and
interface cable.
2. Raise the printer dust cover.
3. Carefully move the carriage toward the center of the printer.
Maintenance
3-3
MAINTENANCE
4. Wipe the length of the slide shaft with the moistened cloth or
wipe.
NovaJet PRO 600e Service Manual
4. Using a cotton swab dampened with distilled 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 full of ink or very dirty it can be
removed and rinsed under warm water in the sink. 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.
Linear Encoder Strip Cleaning
Clean the linear encoder strip monthly or as necessary to remove any
buildup of debris. Distilled water or isopropyl alcohol may be used. You
may notice that it tends to fog the encoder strip; however, no detrimental effect has been observed in the field.
To clean the Encoder Strip:
1. Disconnect the power cord and interface cable.
2. Slightly dampen a cotton swab with distilled water or isopropyl
alcohol and wipe along the length of the encoder strip on both
sides.
3. Reconnect the power cord and interface cable.
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Maintenance
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MAINTENANCE
Figure 3-1. Encoder Strip Cleaning.
Cartridge Dimples Cleaning
Figure 3-2. Cartridge Dimple Region.
Maintenance
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NovaJet PRO 600e Service Manual
The cartridge dimple area can easily be contaminated by oils and dirt on
fingers and hands or ink spilled onto them. This causes the cartridges
to not receive some of the electrical signals for a proper firing of the jets.
This can be seen as a misfiring of the cartridge.
NOTE
Care should be used when handling the cartridges. Avoid
touching the cartridges on the dimple area or on the inkjet
holes on the bottom. The oils and dirt on fingers and
hands can contaminate the area and result in misfiring
of the inkjets.
Clean the cartridge dimple area by gently dabbing the area with a lint
free cloth or cotton swab saturated with isopropyl alcohol.
Flex Cable Contact Cleaning
Figure 3-3. Flex Cable Contacts.
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Maintenance
NovaJet PRO 600e Service Manual
Cleaning the flex cable contact area is very important due to the ease
of which this area can become dirty. This also causes the cartridges
to not receive all of the electrical signals for a proper firing of the jets.
This can be seen as a misfiring of the cartridge.
NOTE
Care should be used when handling the flex cable 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 isopropyl alcohol.
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 isopropyl alcohol
can be used to remove any ink that may have accumulated on the
gears.
Clean and Inspect MPCB
Foreign material on the MPCB could short out electrical signals being
developed on the MPCB and cause erroneous prints or even damage to
the MPCB. All electrical circuits should be free of foreign material,
especially those materials with conductive properties.
Clean the MPCB by blowing the objects away or gently brush them
aside with a soft brush if required.
Inspect the MPCB for any damage to the board, connections, or any of
the components on the board. Replace board if inspection reveals any
damage or flaws that could effect the function of the MPCB.
Maintenance
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MAINTENANCE
Clean and Inspect Stepper Motor Gears
NovaJet PRO 600e Service Manual
Clean and Inspect Carriage Assembly
Foreign material on the carriage assembly could short out signals being
developed on the carriage assembly and cause erroneous prints or even
damage to the carriage assembly. A very common problem is where ink
has been spilled onto the carriage assembly. 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 MPCB and Carriage
Board
Integrated circuits may become weakened or damaged by
electrical discharge. Do not touch or work near integrated
circuits without wearing an ESD wrist strap.
Ribbon connectors can be easily damaged if incorrectly
handled. Observe extreme caution when handling the
ribbon connectors to avoid damage.
Many problems can be corrected simply by removing and reseating
connections found in circuit assemblies. This process helps to clean
the contacts and can dissipate any static electrical charges that
might have developed.
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Maintenance
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MAINTENANCE
Figure 3-4. MPCB Connection Locations.
Figure 3-5. Carriage Connection Locations.
Maintenance
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NovaJet PRO 600e Service Manual
Figures 3-4 and 3-5 shows the locations of all the connectors on the
MPCB 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.
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.
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Maintenance
NovaJet PRO 600e Service Manual
Servo Motor Winding Resistance Check
1. Disconnect the servo motor connection from J2 on the MPCB.
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.
5. If the measurement is found to be unsatisfactory, replace the
servo motor.
Maintenance
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MAINTENANCE
Figure 3-7. Servo Motor.
NovaJet PRO 600e Service Manual
Stepper Motor Winding Resistance Check
Figure 3-8. Stepper Motor.
1. Disconnect the stepper motor connection from J1 on the MPCB.
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.
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Maintenance
NovaJet PRO 600e Service Manual
Power Feed and Take-Up Motor Winding
Resistance Check
MAINTENANCE
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.
Maintenance
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NovaJet PRO 600e Service Manual
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.
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 MPCB and Carriage PCB 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.
2) Print a test file approved by ENCAD that uses only the printer
driver software and the ENCAD printer.
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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
2. The RIP (Raster Image Processor) and print cycles. We
recommend printing to a file first and then queuing the file to
the printer to avoid the RIP and print cycle delays that can
cause banding while printing.
3. Uneven inkjet kogation (partial clogging or orifice restriction)
on the inkjet cartridge head nozzles. Run the 100% color test
and re-prime or replace the cartridge if necessary.
4. Lower quality print modes normally cause slight bands, to
avoid this banding, switch to 4-pass or 6-pass printing modes.
5. Air bubbles in the ink delivery system. This indicates a loss of
negative pressure within the ink cartridge or ink delivery
system, check all quick release fittings and connections for
possible leaks and ensure that the cartridge is primed
properly.
6. Improper priming. The lower secondary chamber within the
cartridge may de-prime and then temporarily recover after
entering the service station causing a momentary color drop
out in the print if the cartridge is improperly primed. Please
reference Technical Bulletin #97 for a more detailed
explaination and the corrective priming procedures.
Maintenance
3-15
MAINTENANCE
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.
NovaJet PRO 600e Service Manual
7. A flow restriction in the ink delivery system or ink starvation in
the cartridge. Ink starvation in the cartridge can be caused by a
broken valve in a quick release fitting or pinched tube in the
ink supply lines of the tubing/chain assembly. Check the ink
delivery system for any flow restrictions by disconnecting the
ink cartridge needle from the cartridge in question, raise the tip
of the needle and observe the rate that the ink flows back into
the reservoir. The ink should take approximately 1 inch per
second to clear the 3.5 inch cartridge tubing between the
cartridge and the first quick release fitting (flowing back toward
the reservoir), if it takes longer than this, you may need to
replace a defective quick release fitting (near the cartridge or
the reservoir) or tubing/chain assembly.
8. Wiping during a print can sometimes cause a band of lighter
density color in the image. Auto wipe may need to be
temporarily turned off to prevent banding.
9. Operator intervention. If someone lifts up the media on the takeup 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.
3-16
Maintenance
NovaJet PRO 600e Service Manual
14. Inkjet sputter. If the cartridge heater is set too high, inkjet
sputter may occur causing intermittent white spots throughout
the print.
15. Improper 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.
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 PRO 600e 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 PRO 600e printers Slide Shaft height is factory set to
1.418” (36mm) from the top of the Slide Shaft to the Platen surface. The
normal operating range for the height of the Slide Shaft is between
1.390” (35.3mm) to 1.440” (36.6mm). The Slide Shaft is firmly mounted
on the outer sides and only has adjustments in the middle portion of the
shaft, to remove any bowing of the shaft’s profile. The following proce-
Maintenance
3-17
MAINTENANCE
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.
NovaJet PRO 600e Service Manual
dure 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.
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 PROe/PRO 600e/1500 TX Cartridge
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.
Figure 3-11. Dial Gauge Micrometer Assembly.
3-18
Maintenance
NovaJet PRO 600e Service Manual
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).
3. Measure the right side (next to media alignment mark.) and
note the difference. Divide this amount by two.
4. Measure just off the center of the slide shaft and adjust the
center turnbuckle with an open ended wrench if required, for
the average value (the value found in step 3.) See Figure 3-13.
NOTE
The NovaJet PRO 600e 60 inch model has two turnbuckles, so these need to be adjusted together for the center
position.
Maintenance
3-19
MAINTENANCE
Figure 3-12. Measurement Positions for Slide Shaft.
NovaJet PRO 600e Service Manual
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.
Head Height Alignment Procedure
Perform this procedure only when the encoder strip stabilizer has been
removed from the Y-Arm or whenever the alignment is in question.
The head height alignment procedure is to ensure that a 0.065” +/0.003” difference exists between the cartridge jet plate and the Platen.
See Figure 3-14.
3-20
Maintenance
NovaJet PRO 600e Service Manual
Figure 3-14. Carriage Head Height Tolerance.
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.
Figure 3-15. Setting Up Tools from Height Gauge Kit.
Maintenance
3-21
MAINTENANCE
1. Remove the lid and the right cover of the printer. See
Chapter 5 for procedures.
NovaJet PRO 600e Service Manual
3. Place the test cartridge upright on a flat surface and ‘zero’ the
gauge by loosening the knob near the top and turning the dial
until the needle is at the ‘0’ position on the dial. Tighten the
knob. See Figure 3-16.
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.
Figure 3-17. Test Cartridge Installed.
3-22
Maintenance
NovaJet PRO 600e Service Manual
5. Slightly loosen the screws located on the back of the Y-arm
that secures the stabilizer to the Y-arm.
Damage may occur to the micrometer
gauge if the 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.
7. Move the left end of the stabilizer bracket until a reading of
0.075” +/- 0.003” is observed. Read only the RED numbers on
the micrometer gauge.
Maintenance
3-23
MAINTENANCE
6. While lifting up the measuring tip of the micrometer, slide
the Carriage to the left side of the stabilizer. Position it as
close to the screw as possible and drop the measuring tip onto
the platen. Do this a couple of times to ensure an accurate
reading.
NOTE
The measurement of 0.075” instead of 0.065” as stated
earlier is used due to the fact that the test cartridge
does not contain a jet plate assembly. A 0.010” difference had to be added to compensate for the lack of a
jet plate assembly on the test cartridge.
8. Tighten the screw on the left side of the stabilizer.
9. While lifting up the measuring tip of the micrometer, slide
the 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.
10. Move the left end of the stabilizer bracket until a reading of
0.075” +/- 0.003” is observed. Read only the RED numbers on
the micrometer gauge.
11. Tighten the screw on the stabilizer that is next to the
Carriage.
12. Continue performing steps 10 through 12 until all four of the
stabilizer screws have been adjusted.
13. Reposition the Carriage to all of the adjustment positions and
verify that the measurements are correct.
14. Perform steps 6 through 14 as many times as necessary to
correctly accomplish this adjustment.
Color Calibration
This procedure describes how to check that the cartridges are
properly aligned for color plotting and should be followed each time
the ink cartridges are installed. Figure 3-18 is a representation of
how a color calibration looks when printed.
NovaJet PRO 600e Service Manual
MAINTENANCE
Figure 3-18. Color Calibration.
The “Current Heads (Y, M, C)” view represents the alignment of the
heads as they are currently entered. This is just an overview of all
heads and how they are aligned. Do not attempt to align the heads
using this view.
The “Color Horizontal 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.
Maintenance
3-25
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.
Figure 3-19. Utility Menu.
2. From the Utility Menu, select “Color Calib Menu”. This brings
up the color calibration menu and it looks like Figure 3-20.
Figure 3-20. Color Calib Menu.
3. Select “Calib Print Test” to print the color calibration plot as
shown in Figure 3-18.
NovaJet PRO 600e Service Manual
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.
5. Observe the plot and using either “Prev Option” or “Next
Option”, rotate through the selections until the one that best
aligns the cyan color on the plot is selected. Press “Ok” to
accept the selection and return to the Color Calib Menu.
6. Continue until all six calibrations on the Color Calib Menu have
been accomplished.
Deadband Alignment
Deadband calibration compensates for minute differences created
when bidirectional printing is used. Unidirectional printing is not
affected by deadband. There are four types of deadband tests:
slow deadband
fast deadband
fast deadband; vertical lines (all)
fast deadband; vertical lines (one)
Figure 3-22. Deadband Slow/Fast.
Maintenance
3-27
MAINTENANCE
Figure 3-21. Cyan Vertical Options Menu.
Figure 3-22 shows what the display will look like when printing either
the fast or slow test if it is out of alignment. A correctly aligned
printer will appear as if 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 is from -2 to 2, and from 0 to
120 for the Fast Deadband.
The Single Line Test and All Line Test are variations of the Slow and
Fast Tests 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.
To perform the Deadband Alignments
1. Select “Utility Menu” from the Main Menu. This brings up
the Utility Menu as shown in Figure 3-19.
2. Select the “Service Menu” from the Utility Menu. This brings
up the Service Menu as shown in Figure 3-23.
Figure 3-23. Service Menu.
NovaJet PRO 600e Service Manual
3. Select the “Calibration Menu” from the Service Menu.
4. The Calibration Menu is shown in Figure 3-24 and is where all
the deadband tests are performed. Select “Deadband Test” to
perform the fast deadband test.
5. When the plot is complete, select “Deadband” at the Calibration
Menu. This brings up the options menu for the fast deadband
adjustment. This menu is similiar to the menu depicted in
Figure 3-21.
NOTE
The values for the fast deadband adjustment is
equivalent to 300 sections per inch. For every
incremented value, the print will move 1/300 of
an inch. Positive values move the middle segment
to the right, while more negative values move the
middle segment to the left.
6. Observe the plot and using either “Prev Option” or “Next
Option”, rotate through the selections until one that seems
closer to the correct value is selected. Press “Ok” to accept the
selection and return to the Service Menu.
Maintenance
3-29
MAINTENANCE
Figure 3-24. Calibration (Deadband) Menu.
7. Continue performing steps 4 through 6 until the fast
deadband adjustment is correct.
8. At the Calibration Menu, select “Slow Db Test” to run the
slow deadband test.
9. When the plot is complete, select “Slow Deadband” at the
Service Menu. This brings up the options menu for the slow
deadband adjustment. This menu is similiar to the menu
depicted in Figure 3-21.
10. 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 Service Menu.
11. Continue performing steps 8 through 10 until the slow
deadband adjustment is 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 3-25.
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.
NovaJet PRO 600e Service Manual
Figure 3-25. Calibration Menu.
Figure 3-26. Paper Axis Test.
Maintenance
3-31
MAINTENANCE
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
3-26.
5. With a precision drafters measuring stick, measure the exact
distance from each of the “T” intersections.
6. Select “Paper Axis” at the Calibration Menu. This brings up
the options menu for the paper axis adjustment. This menu
is similiar to the menu depicted in Figure 3-21.
7. Using either “Prev Option” or “Next Option”, rotate through
the 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 3-27.
Figure 3-27. Diagnostics Menu.
All tests under the Diagnostics Menu should be performed by competent technicians only. The types of tests that can be 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 3-28.
NovaJet PRO 600e Service Manual
Figure 3-28. Accessory Menu.
Servo Cycle Test - Tests the servo motor by moving the carrier
back and forth across the slide shaft. The number of cycles is
selectable and the available options are:
10
100
1,000
10,000
100,000
1,000,000.
Carriage Test - Prints 5 sets of 3 parallel lines to test the
vibration characteristics of the carriage assembly.
Color Test - The Color Test prints a wide swath of color (total of
four) to test for banding. The test is selectable in the amount
of ink that is to be printed. The available are: 10%, 25%,
35%, 50%, 65%, 75%, and 100%.
Maintenance
3-33
MAINTENANCE
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 includes three complete cycles of the
carriage assembly and lists the average PWM, the maximum
PWM, and the position of the carrier where the maximum
PWM occured.
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.
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.
Limited Access Menu
A menu that is not accessable to the operators can be activated in the
Service Menu as shown in Figure 3-29. Press the lower left button in
the Service Menu to bring up the Code Menu. The code to be entered to
bring up the hidden menu is “16753.”
NovaJet PRO 600e Service Manual
MAINTENANCE
Figure 3-29. NVRAM Clear and Clock Reset Menu.
This menu allows the technician to clear the NVRAM and to reset the
system clock.
Clear NVRAM - Clearing the NVRAM is required anytime that a MPCB
is to be permanently removed from a printer. The NVRAM is a section
of nonvolatile memory that stores printer size information. The MPCB
is the identical for both printers but it will have to learn which size
printer it is installed in. Clearing the NVRAM allows the MPCB to
relearn which size printer it is reinstalled into.
Clock Reset - Resets the system clock to “000.” This procedure should
only be accomplished when refurbishing a MPCB and installing it into
another printer.
Maintenance
3-35
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 the NJ PRO 600e printer from
either the BBS or web site. Save both of the files to the same
directory on the hard drive. Double click on 600E.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 600E.ROM and press Enter. The firmware is sent to
the printer as an ordinary print job.
NOTE
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:\600E.ROM
press Enter.
and
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.
NovaJet PRO 600e Service Manual
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.
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.
MAINTENANCE
1. Power OFF printer, wait 15 seconds.
2. Connect an Image Writer II cable between the printer and
MAC.
3. Turn the printer ON.
4. Obtain the latest firmware revision from the ENCAD web site,
unpack the file and launch the “600E Firmware Utility.” File
names may be different then that listed above.
Click on “File”
Click on “Preferences”
Select the appropriate port that the NJ PRO 600e printer is
connected to (either Modem or Printer.)
Drag and Drop the 600E.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.
Maintenance
3-37
5. 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.
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.
Internal Cabling and Signal Flow Diagrams
Figures 3-30 through 3-32 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 3-30 shows all cable connections to the MPCB and the power
supply. Figure 3-31 shows all cable connections to the carriage PCB
and Figure 3-32 shows all connections of the leg harness assembly.
NovaJet PRO 600e Service Manual
MAINTENANCE
Figure 3-30. MPCB Connections Diagram.
Maintenance
3-39
Figure 3-31. Carriage PCB Connections Diagram.
NovaJet PRO 600e Service Manual
MAINTENANCE
Figure 3-32. Leg Harness Connections Diagram.
Maintenance
3-41
This Page Intentionally Left Blank
Troubleshooting
4
Introduction
Chapter 4, Troubleshooting consists of a table that is intended to aide
the technician in troubleshooting the Novajet PRO 600e 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.
Table 4-1. Troubleshooting Table.
Symptoms
Possible cause
Solution
No Power
• printer not ON
depress power
switch
• faulty power
cord
replace power cord
• AC input not
present at power
supply
replace AC entry
module
4-1
TROUBLESHOOTING
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.
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
No Power (cont)
Possible cause
Solution
• DC output
voltage not
present (see
Figure 3-30 for
pin-out)
replace power
supply
• DC voltage
present at MPCB
replace MPCB
• perform Stepper
Motor Winding
Resistance check
replace stepper
motor if out of
tolerance
• rough motion
while spinning
stepper motor
bad bearings replace stepper
motor
• paper sensor
not responding
replace paper
sensor
• media control
switches are
operating correctly
driver corrupted reload printer
driver
• firmware
corrupted
reload firmware
• bad MPCB
replace MPCB
Media Does Not
Move
4-2
Troubleshooting
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
Possible cause
Solution
Internal ERROR
“Carriage Axis
Failure”
perform Slide Shaft
Cleaning procedure
• perform Servo
Motor Winding
Resistance check
replace servo motor
• check servo
motor for smooth
movement
bad bearings replace servo motor
• obstruction in
path of carriage
(may or may not
be visible)
remove obstruction
• dirty encoder
strip
perform Encoder
Strip Cleaning
procedure
• damaged
encoder strip
replace encoder
strip
• bad encoder
sensor
replace encoder
sensor
• worn carriage
bushings
replace carriage
bushings
• loose trailing
cable connections
remove power and
reseat trailing cable
connections at the
MPCB and the
carriage assembly
Troubleshooting
TROUBLESHOOTING
• dirty (or
lubricated) slide
shaft
4-3
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
Internal ERROR
“Carriage Axis
Failure” (cont)
Possible cause
Solution
• cutter assembly
malfunction
replace cutter
assembly
• damaged
carriage drive
belt system
1) check idler/
tension assembly
2) check carriage
belt
Internal ERROR
“Encoder Sensor
Failure”
• encoder sensor
cable unseated
reseat encoder
sensor cable
• bad encoder
sensor
replace encoder
sensor
• paper sensor
cable unseated
reseat paper
sensor cable
• bad paper
sensor
replace paper
sensor
•auto-sensor
cable unseated
reseat autosensor cable
• bad autosensor
replace autosensor
Internal ERROR
“Paper Sensor
Failure”
Internal ERROR
“Auto-Sensor
Failure”
4-4
Troubleshooting
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
Possible cause
Solution
Internal ERROR
“Trailing Cable
Failure”
• trailing cable
cable unseated
power down and
reseat trailing
cable
• bad paper
sensor
replace paper
sensor
• bad MPCB
replace MPCB
• bad connection
between computer
and printer
reseat cable
connections on
computer and
printer
• firmware is
corrupted
refresh EEPROM
firmware with new
download
• bad MPCB
replace MPCB
• cartridge low on
ink
refill or replace
cartridge
• firing rate set
too fast
adjust firing rate
lower (optimum
is 5)
Internal ERROR
“MPCB Failure”
Does Not Print
TROUBLESHOOTING
Ink Cartridge
Misfiring
Troubleshooting
4-5
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
Ink Cartridge
Misfiring (cont)
Possible cause
• flex contacts
dirty or damaged
Solution
1) perform Flex
Cable Contact
Cleaning
procedures
2) replace carriage
assembly
• cartridge dimple
area dirty or
damaged
1) perform
Cartridge Dimple
Cleaning procedure
2) replace cartridge
• cartridge not
seated correctly
reseat cartridge
• bad cartridge
replace cartridge
• service station
dirty or not
properly sealing
cartridge jet area
1) perform Service
Station Cleaning
procedures
2) replace seal on
service station
4-6
Troubleshooting
• bad carriage
assembly
replace carriage
assembly
• bad MPCB
replace MPCB
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
Possible cause
Solution
Paper Skewing
• paper guides not
installed
install paper
guides
• stepper motor
gearing dirty or
damaged
perform Clean and
Inspect Stepper
Motor Gears
procedure
• if banding is
consistent
1) inspect and/or
replace stepper
motor (perform
Stepper Motor
Winding Resistance
Check)
Printer Output
is Banding
TROUBLESHOOTING
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
to be primed
perform Prime
• color calibration
required
perform Color
Calibration
• X-axis
calibration
required
perform X-axis
Calibration
Troubleshooting
4-7
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
Printer Output is
Banding (cont)
Possible cause
• cartridge dimple
area dirty or
damaged
Solution
1) perform
Cartridge Dimple
Cleaning procedure
2) replace cartridge
• flex cable
contacts dirty or
damaged
1) perform Flex
Cable Contact
Cleaning
2) replace carriage
assembly
• carriage belt is
loose, too tight,
worn, or damaged
reinstall, check
tension assembly,
and/or replace belt
• carriage bushings replace bushings
worn or damaged
Keypad LockedUp or Not Functioning Properly
• firmware
problem
1) reset printer
2) refresh or upgrade firmware
• keypad assembly
damaged
replace keypad
assembly
• faulty connection reseat or replace
between MPCB
connector
and keypad
• bad MPCB
4-8
Troubleshooting
replace MPCB
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
Possible cause
Solution
• ink or paper
debris in printer
clean printer
• obstruction in
path of carriage
remove obstruction/
clean printer
• carriage
bushings worn
replace carriage
bushings
• debris or
obstruction in fan
clean fan assembly
• drive belt
slipping on idler
replace frame
tensioner, spring,
or idler
• hardware or
assemblies loose
tighten hardware
or assemblies
• carriage height
too low
perform Carriage
Head Height
Adjustment
• lower drive
shaft gears are
dirty or misaligned
clean and/or realign
lower drive shaft
gears
• noisy servo
motor
replace servo motor
• noisy stepper
motor
replace stepper
motor
Noisy Operation
TROUBLESHOOTING
Troubleshooting
4-9
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
Possible cause
Solution
Line Quality Degraded
• ink cartridges
dirty or clogged
clean and prime
ink cartridges
• cartridge dimple
region dirty or
damaged
clean or replace
cartridge
• color calibration
needed
perform Color
Calibration
• deadband
calibration needed
(in bidirectional
printing mode)
perform Deadband
Calibration
• debris or
lubrication on
slide shaft
clean slide shaft
• leaks or bubbles
in ink delivery
lines
1) reseal/prime ink
delivery lines on
both sides
2) replace ink
delivery lines
4-10
Troubleshooting
• dirty encoder
strip
clean encoder strip
• carriage
bushings worn
replace carriage
bushings
• drive belt worn
replace drive belt
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
Line Quality
Degraded (cont)
Possible cause
Solution
• drive belt
slipping on idler
replace frame
tensioner, spring,
or idler
• vacuum fan not
operating
replace fan
assembly
• MPCB has
24 VDC at J3
pins 1-2
1) reseat connection
at MPCB to fan
Fan Does Not
Power Up
2) replace fan
• power not being
applied to fan
1) reload firmware
2) replace MPCB
• printer not in
Take-Up Mode
put in Take-Up
Mode (under
“Supply Type” from
“Paper Option
Menu”)
• bad connection
to the motor
reconnect Take-Up
motor
• bad Take-Up
motor
Replace Take-Up
motor
• faulty wiring leg
harness
reseat or replace
leg harness
• bad MPCB
replace MPCB
Troubleshooting
4-11
TROUBLESHOOTING
Media Take-Up
Motor Not
Operating,
Sensor Works
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
Possible cause
Solution
Media Feed
Motor Not
Operating,
Sensor Works
• bad connection
to the motor
reconnect Feed
motor
• bad Feed motor
Replace Feed
motor
• faulty wiring leg
harness
reseat or replace
leg harness
• bad MPCB
replace MPCB
• printer is in
Sheet Mode
put in Take-Up
Mode (to activate
both) or Roll Mode
(to activate feed
motor only),
(under “Supply
Type” from
“Paper Option
Menu”)
Media Feed
and Take-Up
Motors Not
Operating,
Both Sensors
Working
4-12
Troubleshooting
NovaJet PRO 600e Service Manual
Table 4-1. Troubleshooting Table (cont).
Symptoms
Possible cause
Solution
• reflective decal
is dirty or blocked
clean decal and/or
clear obstruction
• reflective decal
missing
replace reflective
decal
• sensor not
aligned correctly
(sensor bracket
bent or
misaligned)
replace or reshape
sensor bracket
Media Feed or
Take-Up
Sensor(s) Not
Operating
TROUBLESHOOTING
Troubleshooting
4-13
NovaJet PRO 600e Service Manual
Initialization Troubleshooting
The sequence that the printer follows during initialization (power up) is
as follows:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Power supply turns on - LED D2 on carriage turns on
Reads the Flash ROM information.
Performs memory test with installed SIMMs.
Writes the Flash ROM data into RAM for quicker execution of the
code. Starts executing instructions from RAM.
Loads MPCB gate array with boot code data.
Checks for a valid ROM. If the ROM is not valid, waits for a ROM
image to be downloaded.
Steps 2 - 4 performed again.
Loads MPCB gate array with ROM code data.
Loads gate array on the carriage board. LED D2 goes out as soon
as the carriage board gate array is programmed.
Turns on power supply cooling fan.
Moves carriage.
Checks and measures media size if loaded.
Turn on display.
To troubleshoot using the D2 LED:
With the power off, move the carriage away from the service
station and snap the carriage cover off just enough to view the LED
located in Figure 4-1.
Turn on the unit. After a short delay, the LED D2 will light.
Ensure that the LED extinguishes after about 3-4 seconds.
Turn the unit off immediately after the LED extinguishes to
ensure no damage occurs to the carriage or carriage cover due to the
carriage movement as stated in step 11.
Snap the cover back onto the carriage.
4-14
Troubleshooting
NovaJet PRO 600e Service Manual
If the LED does not go out, setup the printer and download new
firmware as discussed in Chapter 3. Repeat these procedures.
If the LED still does not go out, possible areas to suspect is the MPCB,
carriage board, or the trailing cable.
TROUBLESHOOTING
Figure 4-1. Carriage Board LED D2 Location.
Troubleshooting
4-15
NovaJet PRO 600e Service Manual
This Page Intentionally Left Blank
4-16
Troubleshooting
Assembly\Disassembly
5
Introduction
Chapter 5 contains the procedures for removal and replacement of
the NovaJet PRO 600e printer assemblies and mechanisms. Illustrations are provided for clarity. Steps for each replaceable part may
depend on parts already removed in previous disassembly directions. It
is recommended that you read through each procedure before beginning
the removal and replacement of any assemblies or mechanisms.
The following is a list of tools which are recommended to disassemble and reassemble the printer:
#1 Phillips Torque Screwdriver
#2 Phillips Torque Screwdriver
#1 Slotted Torque Screwdriver
#2 Slotted Torque Screwdriver
#1 Phillips Screwdriver
#2 Phillips Screwdriver
#1 Slotted Screwdriver
#2 Slotted Screwdriver
Wrench, 1/4”
Screwdriver, Socket Head, 1/4”
Wire Cutters
Needle Nose Pliers
X-ACTO Knife
ESD Wrist Strap
ASSEMBLY/
DISASSEMBLY
•
•
•
•
•
•
•
•
•
•
•
•
•
•
The following materials are also required:
•
•
•
•
•
Isopropyl Alcohol
Cotton Swabs
Lint Free Cloth or Tissue
Double Sided Tape (1/16” thick, 3/4” wide)
Loctite Blackmax, P/N 200172
A Hardware Kit is available for the printers. See Chapter 6 of this
manual for the part number.
5-1
NovaJet PRO 600e Service Manual
Always turn the printer OFF, remove the power cord and
the interface cable before beginning any disassembly procedures. An electrical shock hazard may be present if
these precautions are not followed.
Remove the Left, Top, and Right Covers
Removing the Left Cover allows access to the left side of the Platen
for removal of the Carriage Assembly, Carriage Drive Belt, Tension
Assembly, and the Cutter Activator. Also located on this side is the
ink reservoirs and the Ink Delivery System portion that is connected to the reservoirs. Removal of the Left Cover is a requirement to remove the Lower Roller Assembly and the Vacuum Fan(s)
from inside the Platen.
Removing the Right Cover provides access to the Main Printed
Circuit Board (MPCB), Display and Keypad circuits, Servo Motor,
AC Entry Module and the Power Supply Cooling Fan.
The Top Cover needs to be removed before any of the other covers
can be removed. It also gives access to the Carriage Assembly and the
Service Station when in the open (up) position and the Carriage is at the
Carriage Access position.
To remove the Top Cover:
1. Put the Top Cover in the open position by lifting the front of the
Cover to the full upward position.
2. Depress and hold the retracting stop assembly located on the left
side of the Top Cover to disengage it from the Left Cover.
3. Lift up on the left side of the Top Cover until it clears the Left Cover
while still depressing the retracting stop assembly, then slide the
cover to the left to disengage it from the Right Cover.
5-2
Assembly\Disassembly
NovaJet PRO 600e Service Manual
To remove the Right Cover Assembly:
Figure 5-1. Right Cover Assembly Removal/Installation.
5. Reach under the Support Bracket and depress and hold the
retracting stop assembly that secures the Right Cover Assembly to
the Support Bracket.
6. Carefully lift up on the Right Cover Assembly until it clears the
printer enough to gain access to the Keypad, Display, and
Backlight connections going to the Main Printed Circuit Board
(MPCB).
7. Disconnect the Keypad flex cable connection at the J13 location on
the MPCB. See Figure 3-4 for jack locations on the MPCB.
Assembly\Disassembly
5-3
ASSEMBLY/
DISASSEMBLY
4. With a #2 Phillips screwdriver, remove the three screws securing
the Right Cover Assembly to the Right Baseplate and the two
screws securing it to the Right Sideplate. See Figure 5-1.
NovaJet PRO 600e Service Manual
8. Disconnect the Display data ribbon cable connector at the J12
location on the MPCB.
9. Disconnect the Display Power Converter connector at the J10
location on the MPCB. To disconnect, grasp the Display Power
Converter connector between thumb and forefinger and pull straight
out.
To remove the Left Cover Assembly:
10. Open the reservoir access Door. Disconnect and remove all ink
reservoirs.
Figure 5-2. Left Cover Assembly Removal/Installation.
11. With a #2 Phillips screwdriver, remove the two screws securing the
Left Cover Assembly to the Left Baseplate and the two screws
securing it to the Left Sideplate. See Figure 5-2.
12. Reach under the Support Bracket and depress and hold the
retracting stop assembly that secures the Left Cover Assembly to
the Support Bracket.
13. Carefully lift the Left Cover Assembly up and off the printer.
5-4
Assembly\Disassembly
NovaJet PRO 600e Service Manual
Install the Left, Top, and Right Covers
To install the Left Cover Assembly:
1. Position the Left Cover Assembly over the Left Baseplate and while
depressing the retracting stop assembly on the Support Bracket,
lower the Left Cover into position onto the Left Baseplate. Release
the retracting stop assembly.
Applying too much torque to the lower screws can cause
the mounts for the standoffs on the cover to break, requiring a replacement of the cover.
2. Using a #2 Phillips screwdriver, secure the Left Cover with two
screws located on the right side (torque to 15 in-lbs) and two
located under the baseplate (torque to 8 in-lbs).
3. Reinstall the ink reservoirs and reservoir door.
To install the Right Cover Assembly:
5. Reconnect the Display data ribbon cable to J12 on the MPCB.
6. Reconnect the Keypad flex cable to J13 on the MPCB. Orient the
side of the flex cable labeled ‘1’ to pin 1 on the MPCB.
7. While depressing the retracting stop assembly on the Support
Bracket, lower the Right Cover Assembly into position onto the
Right Baseplate. Release the retracting stop assembly.
Assembly\Disassembly
5-5
ASSEMBLY/
DISASSEMBLY
4. Position and hold the Right Cover Assembly over the Right
Baseplate and reconnect the Display Power Converter cable to J10
on the MPCB.
NovaJet PRO 600e Service Manual
Applying too much torque to the lower screws can cause
the mounts for the standoffs on the cover to break, requiring a replacement of the cover.
8. Using a #2 Phillips screwdriver, secure the Right Cover with two
screws located on the left side (torque to 15 in-lbs) and three located
under the baseplate (torque to 8 in-lbs.)
To install the Top Cover:
9. Insert the pin located on the right side of the Top Cover into the
corresponding hole on the Right Cover Assembly.
10. While depressing the retracting stop assembly on the left side of the
Top Cover, lower the left side of the Top Cover into position and
secure it to the Left Cover Assembly by releasing the retracting stop
assembly.
Remove the Keypad, Display, and Display Power
Converter
1. Perform steps 1 through 9 of the Remove the Left, Top, and Right
Covers procedure to remove the Top and Right Covers.
5-6
Assembly\Disassembly
NovaJet PRO 600e Service Manual
Figure 5-3. Keypad and Display Installation/Removal.
3. With a 1/4” socket or wrench, remove the four standoffs that
secures the LCD Display Assembly to the Keypad. Remove the
Display Assembly.
4. Disconnect the grounding flex cable from the large standoff before
removing the Keypad Assembly. See Figure 5-4 for location.
Remove the Keypad Assembly.
Assembly\Disassembly
5-7
ASSEMBLY/
DISASSEMBLY
2. Turn the Right Cover Assembly over and disconnect the Display
power cable located at J13 from the Display Power Converter.
With a 1/4” socket or wrench, remove the four kepnuts securing
the Display Power Converter. See Figure 5-3. Remove the Display
Power Converter.
NovaJet PRO 600e Service Manual
Figure 5-4. Keypad Grounding Connection.
Install the Keypad, Display, and Display Power
Converter
1. Route the Keypad flex data and ground cables into the Right Cover
Assembly through the hole provided for the Keypad.
2. Place the Keypad into position and hold. Turn the Right Cover
Assembly over and position the Display Assembly onto the threaded
studs of the Keypad. Secure using four standoffs with a 1/4” socket
or wrench.
3. Attach the Keypad grounding flex cable to the cover standoff as
shown in Figure 5-4.
4. Secure the Display Power Converter onto the Display standoffs
using four kepnuts with a 1/4” socket or wrench. Torque to 6 in-lbs.
5-8
Assembly\Disassembly
NovaJet PRO 600e Service Manual
Remove Extra Memory (SIMM)
Integrated circuits may become weakened or damaged
by electrical discharge. Do not touch or work near integrated circuits without wearing an ESD wrist strap.
1. Perform steps 1 through 9 of the Remove the Left, Top, and Right
Covers procedure to remove the Top and Right Covers.
ASSEMBLY/
DISASSEMBLY
Figure 5-5. Extra Memory (SIMM) Installation/Removal.
2. The SIMM slots are at a 90° angle from the main circuit board.
Facing the top of the SIMM, push the side clips gently to the
outside (away from the SIMM) then push the top of the SIMM
module towards the left side of the printer until the SIMM becomes
free of the side clips. Lift up and pull the SIMM out, being careful
not to damage the fingers on the top. See Figure 5-5.
Assembly\Disassembly
5-9
NovaJet PRO 600e Service Manual
Install Extra Memory (SIMM)
NOTE
If you are installing two SIMM, you must install the one
located in J17 first. See Figure 3-4 for location.
1. The SIMM slots are at a 90° angle from the board. Place the SIMM
at a 45° into the connector as shown in Figure 5-5.
2. Slowly push the SIMM up to a 90° angle until the two side clips
snap into place. Make sure the SIMM is fully seated.
3. Perform steps 4 through 10 of the Install the Left, Top, and Right
Covers procedure to install the Right and Top Covers.
Remove the MPCB (Main Printed Circuit Board)
Integrated circuits may become weakened or damaged by
electrical discharge. Do not touch or work near integrated
circuits without wearing an ESD wrist strap.
1. Perform steps 1 through 9 of the Remove the Left, Top, and Right
Covers procedure to remove the Top and Right Covers.
2. Put on an ESD wrist strap.
3. Perform step 2 of the Remove Extra Memory (SIMM) procedure to
remove any memory that was added.
4. Disconnect the Power Supply connection at the J15 location by
grasping the Power Supply connector with thumb and forefinger
and pulling straight out. See Figure 3-4 for jack locations.
5-10
Assembly\Disassembly
NovaJet PRO 600e Service Manual
5. Disconnect the Stepper Motor connection at the J1 location by
grasping the Stepper Motor connector with thumb and forefinger
and pulling straight out.
6. Disconnect the Servo Motor connection (red and blue wires) at the
J2 location by grasping the Servo Motor connector with thumb
and forefinger and pulling straight out.
7. Disconnect the Leg Harness connection at the J3 location by
grasping the Leg Harness connector with thumb and forefinger
and pulling straight out.
8. Disconnect the Load Sensor connection at the J4 location by
grasping the Load Sensor connector with thumb and forefinger
and pulling straight out.
9. Disconnect the Vacuum Fan 1 connection at the J5 location by
grasping the Vacuum Fan 1 connector with thumb and forefinger
and pulling straight out.
10. Disconnect the Vacuum Fan 2 connection at the J6 location (60
inch model only) by grasping the Vacuum Fan 2 connector with
thumb and forefinger and pulling straight out.
11. Disconnect the Trailing cable connection at the J7 location. Use
the thumb and forefinger to pull up on the connector lock and
remove the Trailing Cable from the connector.
ASSEMBLY/
DISASSEMBLY
12. Disconnect the Power Supply Cooling Fan connection at the J8
location by grasping the Power Supply Cooling Fan connector
with the thumb and forefinger and pulling straight out.
13. With a #2 Phillips screwdriver, disconnect the ground straps
going to the side plate and baseplate by removing the screw
located near the parallel port on the MPCB.
14. Using care, remove the MPCB by unscrewing the remaining
screws securing the MPCB to the bracket using a #2 Phillips
screwdriver. See Figure 5-6.
Assembly\Disassembly
5-11
NovaJet PRO 600e Service Manual
Figure 5-6. MPCB Removal.
Failure to use an approved antistatic bag for storage or
shipment may cause damage to the MPCB and affect the
Warranty.
15. Place the MPCB in an ESD bag (antistatic bag) in preparation for
shipment to ENCAD for replacement or repair, or if it is to be
stored at your facility for repair.
5-12
Assembly\Disassembly
NovaJet PRO 600e Service Manual
Install the MPCB
Integrated circuits may become weakened or damaged by
electrical discharge. Do not touch or work near integrated
circuits without wearing an ESD wrist strap.
1. Put on an ESD wrist strap.
2. Remove the MPCB from the ESD bag.
3. Align the MPCB so that the serial and parallel connections protrude
out of the back of the printer and that the screw holes are aligned to
the holes on the power supply bracket.
4. Using a #2 Phillips Torque Screwdriver, fasten the MPCB to the
power supply bracket with 8 in-lb of torque. Ensure that the
ground straps from the side plate and baseplate are secured to the
MPCB by the screw located beside the side plate nearest to the
parallel port.
5. Connect the Power Supply Cooling Fan connector to J8 on the
MPCB.
6. Connect and lock the Trailing Cable connector to J7 on the MPCB.
8. Connect the Vacuum Fan 1 connector to J5 on the MPCB.
9. Connect the Load Sensor connector to J4 on the MPCB.
10. Connect the Leg Harness connector to J3 on the MPCB.
11. Connect the Servo Motor connector to J2 on the MPCB.
12. Connect the Stepper Motor connector to J1 on the MPCB.
Assembly\Disassembly
5-13
ASSEMBLY/
DISASSEMBLY
7. Connect the Vacuum Fan 2 (60 inch only) connector to J6 on the
MPCB.
NovaJet PRO 600e Service Manual
13. Connect the Power Supply connector to J15 on the MPCB.
14. Reinstall any additional memory into J17 by performing steps 1 and
2 of the Install Extra Memory (SIMM) procedure.
15. Perform steps 4 through 10 of the Install the Left, Top, and Right
Covers procedure to install the Right and Top Covers.
Remove Power Supply, Cooling Fan, and AC Entry
Module
1. Perform steps 1 through 9 of the Remove the Left, Top, and Right
Covers procedure to remove the Top and Right Covers.
2. Perform steps 3 through 15 of the Remove the MPCB (Main Printed
Circuit Board) procedure to remove and protect the MPCB.
3. Reach between the Power Supply Bracket and the AC Entry Module
and carefully pull out the quick disconnect assembly attaching the
Power Supply input to the AC Entry Module. Disconnect the Power
Supply input from the AC Entry Module.
4. Disconnect the clip securing the power supply wires to the top of the
support bracket.
5. While holding the Power Supply in place, remove the four screws
securing it to the Power Supply Bracket. See Figure 5-7.
6. Slide the Power Supply out of the Power Supply Bracket.
5-14
Assembly\Disassembly
NovaJet PRO 600e Service Manual
Figure 5-7. Power Supply Removal.
To remove the Cooling Fan and AC Entry Module:
8. Using a #1 Phillips screwdriver and a 1/4” wrench or socket,
remove the Fan from the Right Baseplate. See Figure 5-8.
Assembly\Disassembly
5-15
ASSEMBLY/
DISASSEMBLY
7. Using a #2 Phillips screwdriver, remove the four screws located
below the Right Baseplate securing the Power Supply Bracket to
the Right Baseplate. Remove the Power Supply Bracket.
NovaJet PRO 600e Service Manual
Figure 5-8. Cooling Fan/AC Entry Module Removal.
8. Using a 1/4” wrench or socket, disconnect the AC Entry Module
ground from the ground stud on the Right Baseplate.
9. Remove the AC Entry Module by pressing in on the securing tabs
until the module is released.
Install the Power Supply, Cooling Fan, and AC
Entry Module
To install the Cooling Fan and AC Entry Module:
1. Insert the AC Entry Module into the AC Entry Module hole on the
Right Baseplate from the back of the printer. Press in until it snaps
securely into place.
2. Attach the AC Entry Module ground connection to the grounding
stud on the Right Baseplate.
3. Hold the Cooling Fan into place while inserting the four bolts into
the assembly. Attach the four 1/4” nuts to the bolts to secure Fan
assembly. Torque to 4 in-lbs.
4. Reinstall the Power Supply Bracket using four screws.
5-16
Assembly\Disassembly
NovaJet PRO 600e Service Manual
5. Insert and hold the Power Supply into place while securing it with
four screws. Torque to 15 in-lbs.
6. Reconnect the Power Supply to the AC Entry Module by reattaching
the quick disconnect connection. Push the quick disconnect
assembly behind the Power Supply Bracket and out of sight.
7. Perform steps 1 through 14 of the Install the MPCB procedure to
install the MPCB.
8. Perform steps 4 through 10 of the Install the Left, Top, and Right
Covers procedure to install the Right and Top Covers.
Remove Servo Motor
1. Perform steps 1 through 9 of the Remove the Left, Top, and Right
Covers procedure to remove the Top and Right Covers.
2. Perform steps 3 through 13 of the Remove the MPCB (Main Printed
Circuit Board) procedure to disconnect all connectors from the
MPCB.
3. Reach between the Power Supply Bracket and the AC Entry Module
and carefully pull out the quick disconnect assembly attaching the
Power Supply input to the AC Entry Module. Disconnect the Power
Supply input from the AC Entry Module.
NOTE
ASSEMBLY/
DISASSEMBLY
The following procedure will leave the MPCB and
Power Supply still attached to the Power Supply
Bracket. For this procedure there is no reason to remove these assemblies from the Power Supply Bracket.
4. Using a #2 Phillips screwdriver, remove the screw securing the
ground strap from the MPCB to the side plate.
5. Using a #2 Phillips screwdriver, remove the four screws securing
the Power Supply Bracket to the Right Baseplate. Remove the
Power Supply Bracket.
Assembly\Disassembly
5-17
NovaJet PRO 600e Service Manual
Figure 5-9. Slacken Carriage Belt.
6. Remove the Right Sideplate to gain access to the Servo Motor by
unscrewing the four screws securing it to the Platen.
7. Depress the back of the Frame Tensioner (see Figure 5-9) to create
slack in the Carriage Belt and slip it off of the Servo Motor pulley.
8. Move the Carriage Belt to the left so it is out of the way of the Servo
Motor pulley.
9. Move the Carriage Assembly to the left end of the Slide Shaft.
10. Lift up gently and hold the right end of the Trailing Cable.
11. Using a #2 Phillips screwdriver, remove the back screw on the
Servo Motor. The screwdriver will be at a slight angle.
Be careful not to strip the head of the screw or to cause
damage to the Encoder Strip.
12. Lower the Trailing Cable back into place.
13. While holding the Servo Motor, remove the front screw on the Servo
Motor.
5-18
Assembly\Disassembly
NovaJet PRO 600e Service Manual
14. Lower the motor to clear the pulley assembly from the platen and
carefully bring the motor out of the printer.
Install Servo Motor
1. Reinsert the Servo Motor under the Platen with the connector
facing the FRONT side of the Platen. Guide the pulley up
through the opening in the Platen.
2. Once the Servo Motor pulley is through the Platen, push up on
the Servo Motor and align the screw holes with the screw hole
openings.
3. Insert the front screw into the Servo Motor and tighten it almost
all the way.
4. Lift up gently and hold the right end of the Trailing Cable.
Make sure the screw does not go into the motor at an
angle, and be careful not to strip the head of the screw
or to cause damage to the Encoder Strip.
5. Insert the back screw into the Servo Motor and tighten it.
7. Depress the back of the Frame Tensioner and wrap the Carriage
Belt over the Servo Motor pulley. Make sure that the guides on
the inside of the belt are inserted in the pulley grooves and that
the belt is not twisted.
8. Move the Carriage Assembly back and forth to check the Carriage
Belt tension.
9. Reinstall the Right Sideplate with four screws and a #2 Phillips
screwdriver. Press the side plate down and towards the back of
the printer before tightening. Torque to 15 in-lb.
Assembly\Disassembly
5-19
ASSEMBLY/
DISASSEMBLY
6. Tighten both screws on the Servo Motor to 15 in-lb of torque.
NovaJet PRO 600e Service Manual
10. Ensure that all cable endings are protruding through the cable
access hole in the Right Sideplate.
11. Reinstall the Power Supply Bracket (with assemblies) using four
screws.
12. Reconnect the grounding strap from the MPCB to the side plate.
13. Reconnect the Power Supply to the AC Entry Module by reattaching
the quick disconnect connection. Push the quick disconnect
assembly behind the Power Supply Bracket and out of sight.
14. Perform steps 5 through 13 of the Install the MPCB procedure to
reinsert the removed connections from the MPCB.
15. Perform steps 4 through 10 of the Install the Left, Top, and Right
Covers procedure to install the Right and Top Covers.
Remove the Ink Delivery System
1. Perform steps 1 through 3 and 10 through 13 of the Remove the
Left, Top, and Right Covers procedures to remove the Top and Left
Covers.
NOTE
The Foam Chain Shelf being removed in step 2 is only on
the 60 inch printers.
2. Remove the Foam Chain Shelf located inside the rear support
bracket.
3. Move the Carriage to the center of the Slide Shaft.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
4. With a flathead screwdriver, press the Electronics Cover (p/o the
Ink Delivery System) tab located in the upper slot on the left side of
the Carriage Assembly. See Figure 5-10. Lift up on the front left
side of the Electronics Cover until it comes part way off of the
Carriage Assembly. Then lift up on the front right side of the
Electronics Cover and move the Electronics Cover slightly to the left
so that the back of it clears the Back Support Bracket.
Assembly\Disassembly
5-21
ASSEMBLY/
DISASSEMBLY
Figure 5-10. Electronics Cover Removal.
NovaJet PRO 600e Service Manual
Figure 5-11. Disconnect Ink Delivery System Link.
NOTE
The last link of the Ink Delivery System linkage is a special link and is to remain as part of the Left Sideplate
Assembly. It is mounted to the Sideplate Assembly and
will not be delivered as part of the Ink Delivery System.
5. Disconnect the last link of the Ink delivery System from the rest of
the link assembly by pressing in on the two small posts from the
next to last link that are located in the holes of the last link. See
Figure 5-11. Releasing one post at a time may be easier to
accomplish than trying both at once.
6. Disconnect the Ink Delivery System Bracket from the Left Sideplate
using a #2 Phillips screwdriver.
7. Carefully slide the Ink Delivery System out of the printer.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
Install the Ink Delivery System
1. Secure the Ink Delivery System Bracket to the Left Sideplate using
two screws.
2. Reattach the rest of the Ink Delivery System linkage train to the
last link (located on the Left Sideplate).
3. Position the Ink Delivery System into the Support Bracket so that it
is easier to orient the Electronics Cover portion of the system over
the Carriage for reinstallation.
4. Position the Electronics Cover over the Carriage with the back of
the Electronics Cover under the Support Bracket. Depress the two
tabs on each side of the Cover and lower the Assembly onto the
Carriage until it snaps into place.
5. Place the Foam Chain Shelf in the Support Bracket (PRO 60e only.)
Align the left side of the Shelf to the center of the leftmost pinch
roller.
6. Perform steps 1 through 3 and 9 and 10 of the Install the Left, Top,
and Right Covers procedure to install the Left and Top Covers.
Remove the Carriage Assembly, Carriage Belt, and
the Frame Tensioner
2. Perform steps 2 through 7 of the Remove the Ink Delivery System
procedures to remove the Ink Delivery System.
3. Using a #2 Phillips screwdriver, remove the four screws that
secures the Left Sideplate Assembly to the Platen. Remove the Left
Sideplate Assembly.
4. Lift up on the connector lock to unlock the Trailing Cable connector
(J1) on the Carriage PCB and remove the end of the Trailing Cable.
Assembly\Disassembly
5-23
ASSEMBLY/
DISASSEMBLY
1. Perform steps 1 through 13 of the Remove the Left, Top, and Right
Covers procedures to remove the Left, Top and Right Covers.
NovaJet PRO 600e Service Manual
Figure 5-12. Strain Relief Removal/Installation.
5. Remove the Trailing Cable and Strain Relief from the Carriage
Assembly by releasing the latch on the left lower side of the Strain
Relief and lifting it off of the Carriage Assembly. See Figure 5-12.
6. Compress the back of the Frame Tensioner and use the end of a
screwdriver to remove the Carriage Belt from the Servo Motor
pulley. See Figure 5-9.
7. Remove the Compression Spring from the Frame Tensioner and set
it aside.
8. Push the Carriage Belt through the Frame Tensioner enough to
remove the Idler Pulley Assembly from the Frame Tensioner, and
then set aside the Idler Pulley Assembly and the Frame Tensioner.
See Figure 5-13.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
Figure 5-13. Frame Tensioner.
9. Slide the Carriage Assembly and Drive Belt off the left side of the
Slide Shaft.
10. Once the Carriage Assembly is removed from the Slide Shaft, turn
it over so that you can see the Belt Clamp. See Figure 5-14.
ASSEMBLY/
DISASSEMBLY
Figure 5-14. Carriage Belt Clamp.
Assembly\Disassembly
5-25
NovaJet PRO 600e Service Manual
11. To disengage the Carriage Belt from the Belt Clamp, push the
Carriage Belt away from the left post of the Belt Clamp and gently
lift up until the bottom edge of the Carriage Belt clears the top of
the left post.
12. Push the Carriage Belt away from the right post of the Belt Clamp
and gently lift up to finish removing the Carriage Belt from the Belt
Clamp.
Failure to use an approved antistatic bag for storage or
shipment may cause damage to the MPCB and affect the
Warranty.
13. Place the Carriage Assembly in an ESD (antistatic) bag in
preparation for shipment to ENCAD for replacement or repair, or if
it is to be stored for repair at your facility.
Install the Carriage Assembly, Carriage Belt, and
the Frame Tensioner
1. To install the Belt onto the Carriage Assembly, the “bumps” on the
belt (where the ends of the belt are joined together to make the belt
continuous) must be positioned between the left and right posts of
the Belt Clamp. See Figure 5-14.
2. Slide the Carriage Belt between the right post and the middle post
and guide it down into the Belt Clamp. Then slide the Carriage Belt
between the left post and the middle post and finish placing the
Carriage Belt into the Belt Clamp.
3. Check the position of the Carriage Belt to make sure it matches
Figure 5-14.
4. Make sure the left end of the Trailing Cable extends out beyond the
left end of the Trailing Cable Support Assembly.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
5. Slide the Carriage Assembly onto the left end of the Slide Shaft,
making sure that the Encoder Strip fits into the slot in the Slider
and the Encoder on the Carriage PCB. Guide the belt while
sliding the Carriage Assembly from left to right on the Slide
Shaft.
6. Move the Carriage Assembly to the left end of the Slide Shaft and
align the left bushing on the Carriage Assembly with the left end
of the Slide Shaft.
7. Insert the Strain Relief (with Trailing Cable) onto the Carriage
Assembly by sliding it onto the Strain Relief Support until it
snaps firmly into place. See Figure 5-13.
8. Place the Trailing Cable into the J1 connector lock on the
Carriage PCB. Make sure the silver fingers on the Trailing Cable
are fully inserted into the lock and slide both sides of the
connector lock shut at the same time.
9. Place the right side of the back of the Electronics Cover under the
Trailing Cable Support Assembly and gently press down on the
ends of the Electronics Cover until the latches snap into the
Carriage Assembly.
10. Slide the Carriage Assembly to about the middle of the Slide Shaft
and stretch out the Carriage Belt.
11. Insert the Carriage Belt into the Frame Tensioner so that the belt
extends about an inch past the Frame Tensioner.
13. Once the Idler Pulley Assembly is in position, pinch the belt to
hold the Idler Pulley Assembly in place and pull it into the Frame
Tensioner so that the axle rests in the V-shaped groove in the
Frame Tensioner.
14. Insert the Compression Spring into the opening in the back of the
Frame Tensioner so that the end of the spring fits over the post
inside the opening.
Assembly\Disassembly
5-27
ASSEMBLY/
DISASSEMBLY
12. Holding the Carriage Belt and Frame Tensioner, insert the Idler
Pulley Assembly into the loop of the belt. Make sure that the side
of the Idler Pulley Assembly with the thicker outer ring of plastic
is facing up. See Figure 5-13.
NovaJet PRO 600e Service Manual
15. Fit the Compression Spring over the post at the back of the Y-Arm
Assembly.
16. Fit the notch in the front end of the Frame Tensioner over the notch
in the front of the Y-Arm Assembly.
17. Depress the back of the Frame Tensioner and slip the Carriage Belt
over the Servo Motor pulley. Make sure that the guides in the
Carriage Belt are properly fitted over the Servo Motor pulley.
18. Gently move the Carriage Assembly from end to end and make sure
that the Carriage Belt is not rubbing against any other parts.
Remove the Carriage PCB
Integrated circuits may become weakened or damaged by
electrical discharge. Do not touch or work near integrated
circuits without wearing an ESD wrist strap.
1. Perform the Carriage Assembly, Carriage Belt, and the Frame
Tensioner Removal procedures to remove the Carriage Assembly
from the Slide Shaft.
2. Put on an ESD wrist strap.
3. Unlock the connectors and remove all flex cables on the Carriage
PCB.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
4. Unlock the latch on the right end of the Carriage Assembly and
lift up the right end of the Carriage PCB. See Figure 5-15.
5. Slide the Carriage PCB to the right to remove the tab on the left
end of the Carriage PCB from the slot in the Carriage Assembly.
Assembly\Disassembly
5-29
ASSEMBLY/
DISASSEMBLY
Figure 5-15. Carriage PCB Removal/Installation.
NovaJet PRO 600e Service Manual
Failure to use an approved antistatic bag for storage or
shipment may cause damage to the Carriage PCB and
affect the Warranty.
6. Place the Carriage PCB in an ESD bag (antistatic bag) in
preparation for shipment to ENCAD for replacement or repair, or if
it is to be stored at your facility for repair.
Install the Carriage PCB
1. Put the tab on the left end of the Carriage PCB into the slot in the
left side of the Carriage Assembly. See Figure 5-15.
2. Ensure that no flex cables are underneath the Carriage PCB.
3. Push down the right end of the Carriage PCB until the latch snaps
into place.
4. Reattach all flex cables on the Carriage PCB.
5. Perform the Install the Carriage Assembly, Carriage Belt, and the
Frame Tensioner procedures to reinstall the Carriage Assembly.
Remove the Paper Sensor or the Encoder Sensor
1. Perform the Remove the Carriage Assembly, Carriage Belt, and the
Frame Tensioner procedures to remove the Carriage Assembly from
the Slide Shaft.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
Figure 5-16. Paper and Encoder Sensor Removal.
2. To remove the Paper Sensor:
b. Turn the Carriage Assembly over and hold it while firmly
grasping the Paper Sensor between thumb and index finger. See
Figure 5-16.
c. Pull straight up on the Paper Sensor and remove it from the
Carriage Assembly.
3. To remove the Encoder Sensor:
a. Unlock the connector at J2 and remove the flex cable.
b. Turn the Carriage Assembly over and lay it with the top side
facing down.
Assembly\Disassembly
5-31
ASSEMBLY/
DISASSEMBLY
a. Unlock the connector at J3 and remove the flex cable.
NovaJet PRO 600e Service Manual
c. Push down on the plastic clip and at the same time push down
on the Encoder until the plastic pieces on each side of the Encoder
clear the ridges which hold it in place. Then pull it straight out.
See Figure 5-8.
Install the Paper Sensor or the Encoder Sensor
Figure 5-17. Paper and Encoder Sensor Installation.
1. To install the Paper Sensor:
a. Turn the Carriage Assembly so that the bottom side of it is
facing up.
b. Route the flex on the Paper Sensor through the slot in the
Carriage Assembly. Make sure the flex cable goes all the way
through and does not curl under the Carriage PCB.
c. Grasp the Paper Sensor between thumb and index finger and
guide the sides of the board into the grooves on each side of the
opening. See Figure 5-17.
d. Push the Paper Sensor board down into the Carriage Assembly
until it snaps firmly into place.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
e. Turn the Carriage Assembly over and insert the Paper Sensor
flex cable into the connector at J3.
f.
Push both sides of the connector lock shut at the same time.
2. To install the Encoder Sensor:
a. Turn the Carriage Assembly so that the bottom side of it is
facing up.
b. Push down on the plastic clip and slide the back of the
Encoder Sensor over it.
c. Push the Encoder Sensor in past the ridges until the Encoder
Sensor snaps into place.
d. Turn the Carriage Assembly over and insert the Encoder flex
cable into the connector at J2.
e.
Push both sides of the connector lock shut at the same time.
3. Perform the Carriage Assembly, Carriage Belt, and the Frame
Tensioner Reinstallation procedures to reinstall the Carriage
Assembly.
Replacing the Carriage Bushings
Assembly\Disassembly
5-33
ASSEMBLY/
DISASSEMBLY
1. If there is not enough space on both sides of the Slide Shaft to
remove the Carriage bushings, perform the Carriage Assembly,
Carriage Belt, and the Frame Tensioner Removal procedures to
remove the Carriage Assembly from the Slide Shaft.
NovaJet PRO 600e Service Manual
Figure 5-18. Carriage Bushing Removal.
2. Use a flat tip screwdriver to push up on the latch which holds the
Carriage Bushing in place. See Figure 5-18.
3. Pull the Carriage Bushing out of the Carriage Assembly.
4. Repeat Steps 2 and 3 for the other Carriage Bushing.
Figure 5-19. Carriage Bushing Installation.
5. Orient the new Bushing as shown in Figure 5-19 so that the metal
tab on top of the Bushing goes into the Carriage Assembly first.
6. Push the Bushings in until they snap into place.
7. Perform the Reinstall the Carriage Assembly, Carriage Belt, and
the Frame Tensioner procedures to reinstall the Carriage Assembly
if Carriage was removed.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
Remove the Service Station
Figure 5-20. Service Station Removal.
1. Place the Top Cover in the open position.
2. Move the Carriage Assembly to the left side of the Slide Shaft.
3. Reach into the Right Cover and pull back on the Service Station
release tab located on the far side of the Service Station. See
Figure 5-20.
4. Raise the right side of the Service Station out of the Platen.
Install the Service Station
1. To install the Service Station, position the Service Station inside
the Right Cover and place the left side of the Service Station into
the Platen.
2. Push down on the right side of the Service Station until the
Service Station snaps into place.
3. Slide the Carriage Assembly to the right and back into the home
position. Lower the Top Cover.
Assembly\Disassembly
5-35
ASSEMBLY/
DISASSEMBLY
5. Lift out the left side of the Service Station from the Platen and
remove the Service Station. Moving the Service Station farther to
the right might be required to release the left side of the Service
Station.
NovaJet PRO 600e Service Manual
Remove the Trailing Cable Assembly
1. Perform steps 1 through 13 of the Remove the Left, Top, and Right
Covers procedures to remove the Left, Top and Right Covers.
2. If you have not already removed the Carriage Assembly from the
Slide Shaft, you will need to perform Steps 3 through 7 of the
Removing the Carriage Assembly, Carriage Belt, and the Frame
Tensioner procedures in order to remove the Electronics Cover and
release the left end of the Trailing Cable from the Carriage PCB.
3. Disconnect the Trailing Cable Assembly connector at the J6 location
on the MPCB. Use the thumb and forefinger to pull forward on the
connector lock and remove the Trailing Cable from the connector.
See Figure 3-6 if necessary.
4. The Trailing Cable Assembly is secured to the Stabilizer Bracket by
two pieces of double sided tape. Remove the Trailing Cable
Assembly from the Stabilizer Bracket.
5. Remove the ferrite and the tape securing it to the Trailing Cable.
Install the Trailing Cable Assembly
1. Apply two new pieces of double sided tape to the Stabilizer Bracket.
Ensure that the tape is in the same location as the original tape
was.
The right side of the Trailing Cable (the side connected to
the MPCB) must extend beyond the Stabilizer Bracket by
5” (4 7/8” - 5 1/8”) or 128mm (125mm - 131mm.)
2. Slip the ferrite around the Trailing Cable and insert the right side
of the Trailing Cable Assembly through the access hole provided in
the Right Side plate.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
3. Slide the Carriage Assembly (if installed) to the far left side of the
Slide Shaft. While ensuring a 5” (125mm) overhang on the right
side, position the Trailing Cable over the Stabilizer Bracket and
slowly lower it onto the bracket. Ensure that the Trailing Cable
goes on straight and that there are no buckles in the cable. Firmly
press the Trailing Cable Assembly onto the tape to secure it into
position.
4. Connect the right end to the MPCB at the J6 location.
5. Tape the ferrite to the Trailing Cable approximately 1/4” (6mm)
from the left side of the side plate.
6. If the Carriage Assembly is not installed, perform steps 5 through
18 of the Install the Carriage Assembly, Carriage Belt, and the
Frame Tensioner procedures.
7. If the Carriage Assembly is installed, insert the Trailing Cable
Assembly into the Strain Relief Assembly. Insert the Strain Relief
(with Trailing Cable) onto the Carriage Assembly by sliding it onto
the Strain Relief Support until it snaps firmly into place. See
Figure 5-4.
Remove the Stabilizer Bracket and Encoder Strip
1. Perform steps 1 through 13 of the Remove the Left, Top, and Right
Covers procedures to remove the Left, Top and Right Covers.
3. Perform the Remove the Carriage Assembly, Carriage Belt, and
the Frame Tensioner procedures to remove the Carriage Assembly
from the Slide Shaft.
4. Perform steps 3 and 4 of the Remove the Trailing Cable Assembly
procedures to remove the Trailing Cable Assembly.
5. Remove the Support Bracket by slightly tilting the top of the
Support Bracket towards the front of the printer and lifting it
straight up. See Figure 5-21.
Assembly\Disassembly
5-37
ASSEMBLY/
DISASSEMBLY
2. Perform steps 2 through 6 of the Remove the Ink Delivery System
procedures to remove the Ink Delivery System.
NovaJet PRO 600e Service Manual
Figure 5-21. Stabilizer Bracket Installation/Removal.
6. Remove the Stabilizer Bracket from the Y-Arm Assembly by
removing the four alignment Allen screws and washers located on
the back of the Y-Arm Assembly.
The Encoder Strip is not a field removable item. The
entire Stabilizer Bracket Assembly with the Encoder Strip
and Trailing Cable installed is to be replaced if the Encoder Strip is damaged.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
Install the Stabilizer Bracket and Encoder Strip
1. Install the Stabilizer Bracket Assembly (with Encoder Strip and
Trailing Cable) onto the Y-Arm Assembly using the four
alignment Allen screws and washers. Hand tighten only.
2. Install the Support Bracket onto the Stabilizer Bracket Assembly
by placing the Support Bracket onto the Stabilizer Bracket with
a slight forward tilt.
3. Perform the Install the Carriage Assembly, Carriage Belt, and
the Frame Tensioner Procedures to install the Carriage
Assembly, Carriage Belt, and the Frame Tensioner.
4. Perform steps 2 through 7 of the Install the Trailing Cable
Assembly procedures to finish installing the Trailing Cable
Assembly.
5. Perform the Install the Ink Delivery System procedures to install
the Ink Delivery System.
6. Perform the Install the Left, Top, and Right Covers procedures to
install the Left, Top and Right Covers.
7. Perform the Head Height Adjustment procedures found in
Chapter 3 of this service manual.
ASSEMBLY/
DISASSEMBLY
Remove the Y-Arm Assembly, Pinch Rollers,
Slide Shaft, and Auto-Load Sensor
1. Perform steps 1 through 13 of the Remove the Left, Top, and
Right Covers procedures to remove the Left, Top and Right
Covers.
2. Perform steps 2 through 6 of the Remove the Ink Delivery
System procedures to remove the Ink Delivery System.
3. Perform the Remove the Carriage Assembly, Carriage Belt, and
the Frame Tensioner procedures to remove the Carriage
Assembly from the Slide Shaft.
Assembly\Disassembly
5-39
NovaJet PRO 600e Service Manual
4. Perform steps 3 and 4 of the Remove the Trailing Cable Assembly
procedures to remove the Trailing Cable Assembly.
5. Perform steps 5 and 6 of the Remove the Stabilizer Bracket and
Encoder Strip procedures to remove the Stabilizer Bracket
Assembly.
6. Disconnect the Load Sensor connector at the J4 location on the
MPCB. Grasp the Load Sensor connector with the thumb and
forefinger and pull straight out.
7. Remove the seven screws that secures the Y-Arm Assembly to the
Platen. See Figure 5-22.
Figure 5-22. Y-Arm Installation/Removal.
8. The pinch rollers are held on by a small C clamp located on the
back of the Y-Arm Assembly. See Figure 5-23. While holding the
pinch roller, remove the C clamp and move the pinch roller towards
the front of the Y-Arm Assembly until it clears the back of the YArm Bracket.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
Figure 5-23. Pinch Roller.
9. Spin the back of the pinch roller to either side and remove the
back spring.
10. Carefully tilt the back of the pinch roller upwards. This brings
the front of the pinch roller down, away from the Slide Shaft.
Carefully remove the spring that is going into the Slide Shaft
from the top of the pinch roller.
11. Remove the pinch roller.
13. Using a #1 Phillips screwdriver, remove the two screws that
secure the Auto-Load Sensor to the Y-Arm. Remove the AutoLoad Sensor wires from the four wire clamps on the back part of
the Y-Arm Bracket.
Install the Y-Arm Assembly, Pinch Rollers, Slide
Shaft, and Auto-Load Sensor
1. Install the Auto-Load Sensor Assembly into the back part of the
Y-Arm Bracket using a #1 Phillips screwdriver. Torque to 6 inlbs.
Assembly\Disassembly
5-41
ASSEMBLY/
DISASSEMBLY
12. From the bottom of the Y-Arm Assembly, remove the four screws
that secure the Slide Shaft and its two supports from the Y-Arm
Assembly.
NovaJet PRO 600e Service Manual
2. Route the Load Sensor wires through the four wire clamps on the
back part of the Y-Arm Bracket.
3. Install the Slide Shaft and two supports to the Y-Arm Assembly
using four screws. Torque to 8 in-lbs.
4. Insert the back compression spring onto the shaft of the pinch roller
and push the back of the shaft through the back of the Y-Arm
Assembly. Install the C clamp around the shaft of the pinch roller.
5. While compressing the forward pinch roller spring with a
screwdriver (or other flat object), position the pinch roller onto the
Y-Arm Assembly until the forward spring is located under the hole
in the Slide Shaft. Release the spring and verify that the spring
enters the hole in the Slide Shaft and that no kinks are present in
the spring.
6. Perform steps 4 and 5 for all pinch rollers.
7. Using a #2 Phillips screwdriver, secure the Y-Arm Assembly to the
Platen using seven screws. Torque to 15 in-lbs.
8. Perform the Install the Stabilizer Bracket and Encoder Strip
procedures to install the Stabilizer Bracket and Encoder Strip.
9. Perform the Install the Carriage Assembly, Carriage Belt, and the
Frame Tensioner Procedures to install the Carriage Assembly,
Carriage Belt, and the Frame Tensioner.
10. Perform the Install the Trailing Cable Assembly procedures to
install the Trailing Cable Assembly.
11. Perform the Install the Ink Delivery System procedures to install
the Ink Delivery System.
12. Perform the Install the Left, Top, and Right Covers procedures to
install the Left, Top and Right Covers.
13. Perform the Head Height Adjustment procedures found in Chapter
3 of this service manual.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
Remove the Lower Roller Assembly, Stepper
Motor and Vacuum Fan
The Inner Platen contains the Lower Drive Roller Assembly, the
Vacuum Fan Assembly, the Stepper Motor Assembly, Drive Shaft
Supports, and the Foam Block. These parts are collectively referred to
as the Inner Platen Parts.
NOTE
The removal of the Lower Drive Roller Assembly and
Vacuum Fan(s) is easier if extracted out of the left side of
the Platen.
1. Perform steps 1 through 13 of the Remove the Left, Top, and Right
Covers procedures to remove the Left, Top and Right Covers.
2. Perform steps 2 through 4 of the Remove Servo Motor procedures to
remove the Right Sideplate Assembly.
3. Perform steps 2 through 5 of the Remove Service Station procedures
to remove the Service Station.
ASSEMBLY/
DISASSEMBLY
Be careful when removing the Foam Block so that it does
not tear. It is very important to have an intact Foam
Block to produce sufficient vacuum inside the Platen to
properly hold down the media.
4. Using the accesses gained by removing the Right Sideplate and the
Service Station, remove the foam block from between the Lower
Drive Roller Assembly and the Servo Motor.
5. Perform steps 2 through 6 of the Remove the Ink Delivery System
procedures to remove the Ink Delivery System.
Assembly\Disassembly
5-43
NovaJet PRO 600e Service Manual
6. Using a #2 Phillips screwdriver, remove the two screws that secure
the Left Sideplate Assembly to the Platen. See Figure 5-24.
NOTE
The Novajet PRO 600e 42 inch model has one Vacuum
Fan and Exhaust assembly while the 60 inch has two
sets of Vacuum Fans and Exhausts.
7. Using a #1 Phillips screwdriver, remove the four screws on the
bottom of the Platen which holds the Fan Exhaust(s) in place.
8. While holding the Vacuum Fan through the hole left when the
Exhaust assembly was removed, remove the 3 screws on the bottom
of the Platen that holds the Vacuum Fan in place using a #2
Phillips screwdriver. Do not allow the screws to come out at an
angle.
Figure 5-24. Inner Platen Assembly/Disassembly.
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Assembly\Disassembly
NovaJet PRO 600e Service Manual
9. Using a #1 Phillips screwdriver, remove the black flat-head
screws from the top of the Platen that holds the left and right
Drive Shaft Supports in place.
It may be necessary to loosen (do not remove) the screws
that secure the Y-Arm Assembly to the Platen so that
the Lower Drive Roller Assembly clears the ends of the
screws that protrude inside of the Platen when removing the Lower Drive Roller Assembly.
It may be necessary to loosen (do not remove) the screws
that secure the left Leg Assembly to the Platen so that
the Lower Drive Roller Assembly clears the ends of the
screws that protrude inside of the Platen when removing the Lower Drive Roller Assembly.
ASSEMBLY/
DISASSEMBLY
The Fan Assemblies will be removed at the same time
that the Lower Drive Roller Assembly is removed. Exercise extreme care that the fan assemblies do not drop
out of the Platen when removing the Lower Drive Roller
Assembly.
10. Carefully slide the Lower Drive Roller Assembly (and the Fan
Assemblies) out of the left side of the Platen.
Assembly\Disassembly
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NovaJet PRO 600e Service Manual
11. Remove the Stepper Motor Extension Spring from the Stepper Motor
and the post on the Left Lower Drive Shaft Bracket. See Figure 525.
Figure 5-25. Stepper Motor Removal/Installation.
12. Remove the hardware securing the Stepper Motor to the Left Lower
Drive Shaft Bracket and remove the Stepper Motor.
Install the Lower Roller Assembly, Stepper Motor
and Vacuum Fan
1. Loosely attach the Stepper Motor to the Lower Roller bracket using
Stepper Motor hardware as shown in Figure 5-19.
2. Attach the Stepper Motor tension spring to the Stepper Motor and
the Lower Roller Bracket. Tighten the Stepper Motor hardware to 8
in-lb of torque.
5-46
Assembly\Disassembly
NovaJet PRO 600e Service Manual
It may be necessary to loosen (do not remove) the screws
that secure the Y-Arm Assembly to the Platen so that
the Lower Drive Roller Assembly clears the ends of the
screws that protrude inside of the Platen while installing the Lower Drive Roller Assembly.
It may be necessary to loosen (do not remove) the screws
that secure the left Leg Assembly to the Platen so that
the Lower Drive Roller Assembly clears the ends of the
screws that protrude inside of the Platen when removing the Lower Drive Roller Assembly.
NOTE
3. Slide the right side of the Lower Drive Roller Assembly inside of
the left side of the Platen until the first roller is inserted.
4. Position and hold one of the Fan Assemblies under the Lower Drive
Roller Assembly and between the first and second rollers. Continue
to insert the Lower Drive Roller Assembly into the Platen.
5. Position and hold the other Fan Assembly (for 60 inch model only)
under the Lower Drive Roller Assembly and between the seventh
and last rollers. Continue to insert the Lower Drive Roller
Assembly completely into the Platen.
Assembly\Disassembly
5-47
ASSEMBLY/
DISASSEMBLY
Ensure that the Lower Drive Supports and Fan Assemblies are oriented in the correct position before inserting
into the Platen. See Figure 5-24 for visual indication of
correct orientation.
NovaJet PRO 600e Service Manual
6. Reaching inside the Fan Exhaust hole under the Platen, position
and secure the Fan Assembly(ies) using a #2 Phillips screwdriver.
7. Reinstall the Fan Exhaust Assembly(ies) using a #2 Phillips
screwdriver.
8. Install the Lower Drive Roller Assembly support brackets using a
#2 Phillips screwdriver.
9. Reinsert the Foam Block. Make sure that the Stepper Motor and
Fan(s) cables are exiting out of the back corner of the Foam Block.
See Figure 5-26. The Foam Block is positioned between the Stepper
Motor and the Servo Motor. Make sure it is not tilted at an angle.
Figure 5-26. Inside Platen, Right Side.
5-48
Assembly\Disassembly
NovaJet PRO 600e Service Manual
11. Reinsert the Service Station.
12. Reinstall the Right Sideplate using a #2 Phillips screwdriver.
Ensure that all cables from inside the Platen are exiting out of the
large hole in the Sideplate.
13. Reinstall the Power Supply Bracket using four screws and a #2
Phillips screwdriver.
14. Perform steps 5 through 14 of the procedures to reconnect the
MPCB.
15. Reinstall the Left Baseplate using a #2 Phillips screwdriver.
16. Reinstall the Left Sideplate using a #2 Phillips screwdriver.
17. Perform steps 1 through 4 of the Install the Ink Delivery System
procedures to reinstall the Ink Delivery System.
18. Perform the Install Left, Top, and Right Covers procedures to
install the Left, Top, and Right Covers.
Remove the Media Take-Up and Feed Sensor
Brackets and Sensors
NOTE
ASSEMBLY/
DISASSEMBLY
The sensors for the media Take-Up and Feed Assembly
are identical, but the brackets that they mount to have
distinct differences. The top bracket has an additional
extended arm attached to help in directing the media from
blocking the sensor’s beam path. Ensure that the bracket
is being replaced with the correct bracket.
1. Remove all media and media rollers from the printer.
2. Disconnect the sensor leads from the printers leg assembly by
squeezing the sides of the connector to release the quick disconnect
latches.
3. With a pair of wire cutters, cut the wire tie wraps (see Figure 5-27)
that is securing the sensor leads to the sensor bracket.
Assembly\Disassembly
5-49
NovaJet PRO 600e Service Manual
4. Remove the sensor by unscrewing the plastic nut off of the front of
the sensor. Pull the sensor out of the bracket.
5. Using a #2 Phillips screwdriver, remove the two screws securing
the bracket to the leg assembly.
Figure 5-27. Media Take-Up and Feed Sensor Removal.
5-50
Assembly\Disassembly
NovaJet PRO 600e Service Manual
Install the Media Take-Up and Feed Sensor
Brackets and Sensors
1. Using a #2 Phillips screwdriver, install the two screws securing the
bracket to the leg assembly.
2. Insert the sensor into the hole on the sensor bracket, secure by
screwing on the plastic nut onto the front of the sensor.
3. Route the sensor wires to the back of the bracket and secure the
wires using two wire tie wraps.
4. Bringing the wire from under the bracket, attach the wire
connector to the leg harness plug. Push connector in until firmly
seated.
Remove the Media Take-Up and Feed Motors
1. Remove all media and media rollers from the printer.
2. Remove the four screws holding the Cradle Idler to the leg
assembly. See Figure 5-28.
3. Carefully slide the Cradle Idler assembly out of the leg assembly
until the wires going to the motor can be removed.
5. From the back of the Cradle Idler, disconnect the tension spring
from the post located on the Cradle Idler.
6. Using a #2 Phillips screwdriver, remove the screw and washer
holding the motor mount to the Cradle Idler. Carefully remove the
motor, motor mount, and motor gear subassembly from the Cradle
Idler.
7. Remove the C clamp that is securing the motor gear to the motor.
8. Using a #1 Phillips screwdriver, remove the three screws, washers,
and lock washers from the motor mount to remove the motor.
Assembly\Disassembly
5-51
ASSEMBLY/
DISASSEMBLY
4. Remove the wires from the motor.
NovaJet PRO 600e Service Manual
Install the Media Take-Up and Feed Motors
1. Using a #1 Phillips screwdriver, install the three screws, washers,
and lock washers that secures the motor to the motor mount.
2. Install the motor gear to the motor. Secure with a C clamp.
3. Insert the motor, motor mount, and motor gear subassembly into
the back of the Cradle Idler. Tilt the subassembly slightly while
installing to align the motor gear with the opening on the top of the
Cradle Idler.
4. Screw in the screw and washer that secures the motor mount to the
Cradle Idler.
5. Attach the tension spring to the post on the Cradle Idler.
6. Position the Cradle Idler assembly in front of the hole in the leg
assembly. Attach the wire connectors to the motor (red to the
positive terminal, black to the negative terminal.)
7. Insert the Cradle Idler Assembly into the leg and secure with four
screws.
5-52
Assembly\Disassembly
NovaJet PRO 600e Service Manual
ASSEMBLY/
DISASSEMBLY
Figure 5-28. Media Take-Up and Feed Motor Removal.
Assembly\Disassembly
5-53
NovaJet PRO 600e Service Manual
Remove the Media Drying Fans
1. On the left side of the drying fan assembly is a black wingnut used
to adjust the position of the fan assembly. Remove the black
wingnut.
2. Disconnect the drying fan assembly leads from the printers leg
assembly by squeezing the sides of the connector to release the
quick disconnect latches.
3. Lift the entire drying fan assembly off of the printer.
4. Remove the air filter from the fan to be removed by squeezing the
tabs on the filter housing to release the housing off the fan.
5. Remove the four bolts securing the back bracket (the one with the
positioning bolts on the bottom) to both of the side plates.
6. Pull the back bracket away from the fans to gain access to the
faulty fan. Carefully pull the fan away from the front bracket until
access is gained to reach the electrical connector.
7. Disconnect the connector to the fan.
Install the Media Drying Fans
1. Reconnect the electrical connection to the fan. Push the connector
and wires into the bracket so the fan can be seated correctly on the
bracket.
2. Carefully orient all the fans so that the back bracket can be
installed correctly. Secure the back bracket to the side plates.
3. Install the air filter and air filter housing.
4. Lay the entire assembly onto the support brackets on the printer.
Ensure that the cable connector is on the right side of the printer as
it is installed.
5. Reattach the positioning wingnut on the left side of the assembly.
6. Attach the wire connector to the leg harness plug. Push connector
in until firmly seated.
5-54
Assembly\Disassembly
Parts List
6
This chapter lists the items and their associated numbers for the parts
and assemblies of the NovaJet PRO 600e printers that are field
replaceable. The list is in order of part name as identified in the
assembly/disassembly chapter.
This list is to be used in conjunction with the assembly/disassembly
procedures to aquire the necessary parts and properly install them
into the printer.
The parts and asssemblies may be ordered through your local authorized dealer or ENCAD, Inc.’s Technical Support and Service department.
PARTS LIST
6-1
FIGURE ITEM
PART NAME
PART #
6-1
1
COVER W/DOOR, LEFT ......................... 209220-7
6-1
2
RESERVIOR ASSEMBLY, BLUE ............ 207616-3
RESERVIOR ASSEMBLY, GRAY ......... 207616-4
6-1
3
CAP, RESERVIOR ................................... 207562
6-1
4
TUBE ASSY, RESERVIOR, BLUE .......... 209580
TUBE ASSY, RESERVIOR, GRAY ....... 209581
6-1
5
INK DELIVERY SYSTEM, 60” ................ 207613-1
INK DELIVERY SYSTEM, 42” ............. 207613-2
6-1
6
FITTING, FEMALE, GRAY .................... 207552-1
FITTING, FEMALE, BLUE ................. 207553-1
6-1
7
C-RING ..................................................... 207789
6-1
8
SIDE PLATE, LEFT ................................ 207554-3
6-1
9
BASE PLATE, LEFT ............................... 209565
HARDWARE KIT ..................................... 208810
ASSEMBLY, AUTOPRIME...................... 207660-1
SIMM, 32MB, 72 PIN .............................. 210610
ASSY, HEIGHT GAGE KIT ..................... 209996-1
LOOPBACK TEST CABLE ...................... 205462
NovaJet PRO 600e System Service Manual
PARTS LIST
Figure 6-1. Left Side Parts Breakdown.
Parts List
6-3
FIGURE ITEM
6-2
1
PART NAME
PART #
COVER ASSY, TOP, 60” .......................... 207787-1
COVER ASSY, TOP, 42” ....................... 207787-2
6-2
2
SPRING, COMPESSION ......................... 209052
6-2
3
RETRACTING STOP, ASSEMBLY ......... 208838
6-2
4
TRAILING CABLE ASSY, 60” ................. 207573-2
TRAILING CABLE ASSY, 42” .............. 207584-2
6-2
5
STABILIZER ASSY WITH TRAILING
CABLE AND ENCODER STRIP
60”
..................................................... 209070
42”
..................................................... 209069
6-2
6
AUTOLOAD SENSOR ASSY ................... 207715
6-2
7
SLIDE SHAFT, 60” .................................. 207492
SLIDE SHAFT, 42” ............................... 207493
6-2
8
BELT, 60” ................................................. 207475
BELT, 42” ............................................. 207476
6-2
9
FRAME, TENSIONER ............................. 203870-1
6-2
10
SPRING, COMPRESSION (IDLER) ........ 203999
6-2
11
IDLER ASSEMBLY .................................. 203405-1
6-2
12
FOAM, CHAIN SUPPORT ...................... 209657-1
6-2
13
PINCH ROLLER ASSEMBLY ................. 207486
6-2
14
SERVICE STATION ASSY ...................... 207611-2
6-2
15
PLATEN ASSY, 60” ................................. 207496
PLATEN ASSY, 42” .............................. 207509
6-2
16
KNIFE DAMPER ASSY ........................... 202000
NovaJet PRO 600e System Service Manual
PARTS LIST
Figure 6-2. Platen and Above Parts Breakdown.
Parts List
6-5
FIGURE ITEM
PART NAME
PART #
6-3
1
COVER, RIGHT ....................................... 208230-7
6-3
2
KEYPAD ASSEMBLY .............................. 209096-3
6-3
3
DISPLAY ASSY ........................................ 210043
6-3
4
POWER ENTRY MODULE ..................... 207508
6-3
5
FAN COOLING, POWER SUPPLY ........ 207593
6-3
6
MAIN PRINTED CIRCUIT BOARD ........ 210111-101
6-3
7
POWER SUPPLY ASSEMBLY ................ 210010
6-3
8
SIDE PLATE, RIGHT .............................. 207591-3
6-3
9
BASE PLATE ASSY, RIGHT ................... 210089
NovaJet PRO 600e System Service Manual
PARTS LIST
Figure 6-3. Right Side Parts Breakdown.
Parts List
6-7
FIGURE ITEM
6-4
1
PART NAME
PART #
MOTOR ASSY, SERVO,
W/FERRITE AND CAPACITOR ........... 209667
6-4
2
BLOCK, RIGHT FOAM ........................... 207559
6-4
3
STEPPER MOTOR ASSY ........................ 209071
6-4
4
BRACKET, LOWER ROLLER ASSY ....... 208987
6-4
5
FAN ASSEMBLY, VACUUM ................... 203443
6-4
6
EXHAUST, GRILL .................................. 204976
6-4
7
LOWER ROLLER ASSY, 60” ................... 207023
LOWER ROLLER ASSY, 42” ................ 207506
6-4
8
FAN ASSY, VACUUM, 60” ONLY .......... 208981
6-4
9
BLOCK, LEFT FOAM ............................. 209177
NovaJet PRO 600e System Service Manual
PARTS LIST
Figure 6-4. Inner Platen Parts Breakdown.
Parts List
6-9
FIGURE ITEM
6-5
1
PART NAME
PART #
INK DELIVERY SYSTEM, 60” ................ 207613-1
INK DELIVERY SYSTEM, 42” ............. 207613-2
6-5
2
CARTRIDGE TUBE ASSY, BLUE (4) ..... 208996-1
CARTRIDGE TUBE ASSY, GRAY (4) ... 208997-1
6-5
3
CARRIAGE PCB ....................................... 209567-104
6-5
4
C-RING ..................................................... 207789
6-5
5
FITTING, FEMALE, GRAY .................... 207552-1
FITTING, FEMALE, BLUE ................. 207553-1
6-5
6
STRAIN RELIEF ..................................... 208276
6-5
7
ENCODER SENSOR W/FLEX ................ 209578-101
6-5
8
PAPER SENSOR W/FLEX ...................... 207180
6-5
9
CARRIAGE BUSHING SET (2) ............... 209568
6-5
10
CARRIAGE FRAME ASSY ....................... 209176
CARRIAGE, COMPLETE ASSEMBLY .... 209774-01
NovaJet PRO 600e System Service Manual
PARTS LIST
Figure 6-5. Carriage Assembly Parts Breakdown.
Parts List
6-11
FIGURE ITEM
PART NAME
PART #
6-6
1
GUIDE, PAPER ADJUSTABLE .............. 207644
6-6
2
SHAFT W/FIXED RIGHT ROLLER
60”
..................................................... 207657-1
42”
..................................................... 207657-2
6-6
3
CLAMP, GUIDE PAPER ......................... 207659
6-6
4
CRADLE, IDLER ..................................... 207667
6-6
5
GEAR, MOTOR, DRIVE ........................... 207666
6-6
6
MOTOR, DRIVE ....................................... 207767
6-6
7
BRACKET ASSY, SENSOR, TOP ............ 207656
6-6
8
BRACKET ASSY, SENSOR, BTM ........... 207752
6-6
9
SENSOR ASSEMBLY .............................. 207727
6-6
10
HARNESS, WIRING, LEG DRIVE .......... 207731
6-6
11
FAN ASSEMBLY, DRYER ....................... 207725
6-6
12
FILTER, DRYER, FAN ............................ 207729
NovaJet PRO 600e System Service Manual
PARTS LIST
Figure 6-6. Power Feed and Take-Up Parts Breakdown.
Parts List
6-13
This Page Intentionally Left Blank
Index
F
alignments
head height . . 3-20
slide shaft . . 3-17
axis drive
carrier . . 2-4
paper (media) . . 2-3
fan, cooling . . 5-14
firmware
downloading . . 2-9, 3-36, 3-37
B
I
banding . . 3-14
bushings, carrier
replacing . . 5-33
ink delivery system . . 5-20
C
jack
connections
carrier . . 3-9
MPCB . . 3-9
cabling . . 3-38
calibration
color . . 3-24
deadband . . 3-27
X-axis . . 3-30
carrier . . 5-23
cartridges . . 3-6, 3-24
cautions . . 1-4
control panel . . 2-16
D
download
firmware . . 3-36
E
encoder strip . . 5-37
ESD . . 1-3
G
general block diagram . . 2-1
J
L
linear encoder strip . . 3-4
M
main printed circuit board . . 2-6, 3-7
media
feed and take-up system . . 2-5
memory
SIMMs . . 2-9
installation . . 5-9
menu
accessory . . 3-33
calibration . . 3-31
calibration (deadband) . . 3-29
color calib . . 3-26
diagnostics . . 3-32
main . . 2-16
service . . 3-28
utility . . 3-26
Index-1
INDEX
A
NovaJet PRO 600e Service Manual
M (cont)
motor
media feed/take-up
resistance check . . 3-13
servo
controller . . 2-12
removal/installation . . 5-17
resistance check . . 3-11
stepper (media)
controller . . 2-10
removal/installation . . 5-43
resistance check . . 3-12
MPCB . . 5-10
N
notes . . 1-4
O
optical encoder strip . . 2-4, 2-12
P
pinch rollers . . 5-39
power supply . . 2-17, 5-14
R
related publications . . 1-3
S
scheduled maintenance . . 3-1
service station . . 3-3, 5-35
signal flow . . 3-38
specifications . . 1-5
T
technical support
ENCAD BBS . . 1-8
ENCAD website . . 1-8
help desk
FAX # . . 1-8
telephone # . . 1-8
Index-2
test
carriage . . 3-33
color . . 3-33
continuous . . 3-34
fan . . 3-34
legs . . 3-34
loopback . . 3-34
parallel port . . 3-34
serial port . . 3-34
servo cycle . . 3-33
servo PWM . . 3-33
tools, required . . 5-1
trailing cable . . 5-36
troubleshooting . . 4-1
banding . . 4-7
degraded line quality . . 4-10
does not print . . 4-5
fan not operating . . 4-11
faulty keypad . . 4-8
ink cartridge failure . . 4-5
internal error
auto-sensor failure . . 4-4
carriage axis failure . . 4-3
encoder sensor failure . . 4-4
MPCB failure . . 4-5
paper sensor failure . . 4-4
trailing cable failure . . 4-5
media
both motors inoperative . . 4-12
feed motor inoperative . . 4-12
sensor inoperative . . 4-13
take-up motor inoperative . . 4-11
media does not move . . 4-2
no power . . 4-1
noisy operation . . 4-9
paper skewing . . 4-7
V
vacuum fan . . 5-43
W
warnings . . 1-4

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