CADJET 2 - Printertec

CADJET 2 - Printertec

CADJET 2

CADJET

®

2

Service Manual

Copyright

1995 ENCAD

®

, Inc. All rights reserved.

ENCAD is a registered trademark of ENCAD, Inc.

Trademark application for CADJET 2 is pending.

HP-GL, HP-GL/2, and HP RTL are registered trademarks of Hewlett-

Packard Company.

AutoCAD is a registered trademark of AutoDesk, Inc.

Other trademarks and registered trademarks are the property of their respective owners.

No part of this manual may be copied or distributed, transmitted, transcribed, stored in a retrieval system, or translated in any human or computing language, in any form or by any means, electronic, mechanical, 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. i

FCC Statement (U.S.A)

The United States Federal Communications Commission

(47 CFR 15.105 and 15.27) has specified that the following notice be brought to the attention of the users of the CADJET 2.

FEDERAL COMMUNICATIONS COMMISSION RADIO FREQUENCY

INTERFERENCE STATEMENT

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: l Reorient or relocate the receiving antenna. l Increase the separation between the equipment and receiver. l

Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. l 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.

Note: This product was FCC certified under test conditions that included the use of shielded I/O cables and connectors between system components. To be in compliance with FCC regulations, the user must use shielded cables and connectors and install them properly.

ii CADJET 2

VDE Statement

Hiermit wird bescheinigt, daß der CADJET 2 in Übereinstimmung mit den Bestimmungen der BMPT-AmstbIVfg 234/1991 funkentstört ist.

Der vorschriftsmäßige Betrieb mancher Geräte (z.B. Meßsender) kann allergings gewissen Einschränkungen unterliegen. Beachten Sie deshalb die Hinweise in der Bedienungsanleitung.

Dem Zentralamt für Zulassungen im Femmeldewesen wirde dan

Inverkehrbringen dieses Gerätes angezeigt und die Berechtigung zur

Überprüfung der Serie auf die Einhaltung der Bestimmungen eingeräumt.

ENCAD, Inc. U.S.A

CADJET 2 iii

Material Safety Data Sheet

CADJET 2 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. iv CADJET 2

PRINTING HISTORY

1st Edition September 18, 1995

CADJET 2 v

TABLE OF CONTENTS

QUICK OVERVIEW

CHAPTER 1 GENERAL INFORMATION ............................................................... 1-1

CHAPTER 2 THEORY OF OPERATION ............................................................... 2-1

CHAPTER 3 MAINTENANCE ................................................................................ 3-1

CHAPTER 4 TROUBLESHOOTING ...................................................................... 4-1

CHAPTER 5 DISASSEMBLY/ASSEMBLY ............................................................ 5-1

CHAPTER 6 CALIBRATION .................................................................................. 6-1

CHAPTER 7 REPLACEMENT PARTS LIST.......................................................... 7-1

APPENDIX A EMERGENCY FIRMWARE DOWNLOAD PROCEDURE ................ A-1

APPENDIX B PRINTER FIRMWARE UPGRADE PROCEDURE ........................... B-1

APPENDIX C FINAL ASSEMBLY DRAWINGS.......................................................C-1

APPENDIX D SCHEMATICS...................................................................................D-1

CADJET 2 vi

Table of Contents

CHAPTER 1 GENERAL INFORMATION

Overview, Technical Support, media sizes and plot areas, general product notes, plotter features and specifications, Line Length Accuracy and Skew information, acronyms and abbreviations, and glossary.

1.0 Introduction........................................................................................................ 1-1

2.0 Overview............................................................................................................ 1-2

2.1

2.2

Related Publications ............................................................................ 1-2

Features of this Service Manual........................................................... 1-3

2.2.1 Subject Headings ................................................................. 1-3

2.2.2

2.2.3

Figures and Tables .............................................................. 1-3

Manual Conventions ............................................................ 1-4

3.0 ENCAD Technical Support & Service ............................................................... 1-5

4.0 Media Sizes and Plotting Areas......................................................................... 1-6

5.0 General Product Notes ...................................................................................... 1-9

6.0 Plotter Features ............................................................................................... 1-10

7.0 Plotter Specifications ....................................................................................... 1-13

8.0 Line Length Accuracy ...................................................................................... 1-14

9.0 Skew................................................................................................................ 1-15

10.0 Acronyms and Abbreviations........................................................................... 1-17

11.0 Glossary .......................................................................................................... 1-18

CADJET 2 vii

Table of Contents

CHAPTER 2 THEORY OF OPERATION

Mechanical overview and electrical circuitry theory with block diagram visuals.

1.0 Introduction ....................................................................................................... 2-1

2.0 Mechanical Operation ....................................................................................... 2-2

2.1

2.2

Media Axis Drive .................................................................................. 2-2

Carriage Axis Drive .............................................................................. 2-2

3.0 Electrical Operation........................................................................................... 2-3

3.1 Circuit Assemblies ............................................................................... 2-3

3.1.1 Main Printed Circuit Board (MPCB) ..................................... 2-3

3.1.2

3.1.3

Front Panel Circuit ............................................................... 2-3

Carriage Printed Circuit Assembly (Carriage PCB).............. 2-4

3.2

3.3

3.4

3.5

3.6

3.7

Block Diagram ..................................................................................... 2-5

Power Supply....................................................................................... 2-6

Microprocessor .................................................................................... 2-7

Start-up Sequence............................................................................... 2-8

Memory................................................................................................ 2-9

Flash EPROM.................................................................................... 2-10

3.8

3.9

RAM................................................................................................... 2-11

EEPROM ........................................................................................... 2-11

3.10 Gate Array ......................................................................................... 2-12

3.11 Stepper Motor .................................................................................... 2-13

3.12 Servo Motor ....................................................................................... 2-15

3.13 Parallel and Serial Ports .................................................................... 2-16

3.14 Keypad/Display.................................................................................. 2-17

3.15 Carriage Circuits ................................................................................ 2-18

3.16 LED’s, Beeper, and Fan .................................................................... 2-19

3.17 Dot Firing Sequence .......................................................................... 2-19

3.18 Schematic Diagrams.......................................................................... 2-19 viii CADJET 2

Table of Contents

CHAPTER 3 MAINTENANCE

Maintenance of Unit, Slide Shaft, Service Station, Encoder Strip,

Cartridges, and Rollers.

1.0 Introduction........................................................................................................ 3-1

2.0 External Cleaning .............................................................................................. 3-2

3.0 Slide Shaft Maintenance ................................................................................... 3-3

4.0 Service Station Maintenance............................................................................. 3-5

5.0 Encoder Strip Maintenance ............................................................................... 3-6

6.0 Ink Cartridge Maintenance ................................................................................ 3-7

6.1 Initial Installation of Cartridges ............................................................. 3-7

6.2

6.3

Cleaning Cartridges ............................................................................. 3-9

Other Causes of Misfiring................................................................... 3-11

6.4

6.5

Storage of Cartridges During Extended Periods of Inoperation ......... 3-12

Refilled Cartridges.............................................................................. 3-12

7.0 Upper and Lower Rollers................................................................................. 3-13

CADJET 2 ix

Table of Contents

CHAPTER 4 TROUBLESHOOTING

Chart of problems and solutions with detailed action steps and cross reference information. Service Menu information. Keypad functions and messages. Plotter initialization sequence. Plotter error message descriptions. Operation problems.

1.0 Introduction ....................................................................................................... 4-1

2.0 Decision Logic Tables ....................................................................................... 4-2

2.1 Procedure for Using Decision Logic Tables......................................... 4-2

2.2 Decision Logic Tables.......................................................................... 4-3

3.0 Service Menu .................................................................................................... 4-8

4.0 Service Menu Description ................................................................................. 4-9

4.1 Service Information............................................................................ 4-10

4.1.1 Information Display Settings .............................................. 4-10

4.2

4.3

4.1.2 Information Print Settings .................................................. 4-13

Service Diagnostics ........................................................................... 4-14

Service Calibration............................................................................. 4-17

5.0 LED Keys ........................................................................................................ 4-18

6.0 LCD Keypad.................................................................................................... 4-19

7.0 Keypad Messages........................................................................................... 4-20

7.1 Plot Received..................................................................................... 4-20

7.2

7.3

7.4

Drying Plot ......................................................................................... 4-20

Insert Media ....................................................................................... 4-20

Memory Full ....................................................................................... 4-20

7.5

7.6

7.7

RAM OK............................................................................................. 4-21

Checksum Error................................................................................. 4-21

Plotter Error ....................................................................................... 4-21

7.8 Ready to Replot ................................................................................. 4-21

8.0 Initialization Sequence .................................................................................... 4-22

9.0 RS-422/RS-232 Error Messages..................................................................... 4-23

10.0 RAM Error ....................................................................................................... 4-24 x CADJET 2

Table of Contents

CHAPTER 4 TROUBLESHOOTING (continued)

11.0 Operation Problems ........................................................................................ 4-25

11.1 Plotter Does Not Turn On................................................................... 4-25

11.2 Plotter Slow to Initialize ...................................................................... 4-26

11.3 Plotter Will Not Plot ............................................................................ 4-27

11.3.1 Parallel Interface and Serial Interface Tests ...................... 4-29

11.4 No Movement in the Carriage Axis..................................................... 4-31

11.5 Media Problems ................................................................................. 4-34

11.5.1 Cut Sheet Media Won’t Load ............................................. 4-34

11.5.2 Media Feeds Out of Plotter When Plot is Completed ........ 4-36

11.5.3 Media Skews or Ripples..................................................... 4-36

11.5.4 Loaded Media Not Detected, Media Size Not Detected, or Plotter Has Incorrect Plot Area ...................................... 4-37

11.5.5 Keypad Display Shows LOAD MEDIA Message When

Rollfeed Media is Loaded .................................................. 4-38

11.5.6 Loud Grinding Noise When Media Loads .......................... 4-39

11.6 Media Cutting Problems..................................................................... 4-41

11.7 Ink Cartridge Problems ...................................................................... 4-42

11.7.1 Dried Up Cartridge ............................................................. 4-43

11.7.2 Determining Ink Level ........................................................ 4-44

11.8 PRIME Plot ........................................................................................ 4-45

11.9 Tri-Color Cartridge Failure Test Procedure ........................................ 4-46

11.10 Black Cartridge Failure Test Procedure ............................................. 4-47

11.10.1 Running the Cartridge Diagnostic Test .............................. 4-48

11.10.2 Interpreting the Cartridge Diagnostic Test ......................... 4-50

11.10.3 Black Cartridge Flex Test................................................... 4-51

11.11 Memory Full ....................................................................................... 4-55

11.12 Plotter Hesitates During Plotting ........................................................ 4-56

11.13 Plot Appearance is not as Expected .................................................. 4-56

11.14 Plots are Cut Off. ............................................................................... 4-57

CADJET 2 xi

Table of Contents

CHAPTER 4 TROUBLESHOOTING (continued)

11.15 Plotter is Noisy................................................................................... 4-58

11.16 User Parameters Not Saved When Power Is Cycled......................... 4-58

11.17 Plotter Carriage Moves Erratically...................................................... 4-59

11.18 Media Movement Erratic .................................................................... 4-61

11.19 LCD or LED Key(s) Inoperative ......................................................... 4-62

11.20 Front Keypad Display Inoperative...................................................... 4-64 xii CADJET 2

Table of Contents

CHAPTER 5 DISASSEMBLY/ASSEMBLY

Detailed procedures for removing and installing field replaceable parts and assemblies.

1.0 Introduction........................................................................................................ 5-1

2.0 Tools and Equipment Required ......................................................................... 5-4

3.0 Stand ................................................................................................................. 5-7

3.1 Removing the Plotter from the Stand ................................................... 5-7

3.2

3.3

Replacing the Plotter on the Stand ...................................................... 5-9

Alternate Method for Securing Carriage Assembly and Fixed

Blade.................................................................................................. 5-10

4.0 Right Cover Assembly, SIMMS, and MPCB .................................................... 5-11

4.1 Removing the Right Cover Assembly................................................. 5-11

4.2

4.3

Removing the MPCB Connectors ...................................................... 5-13

MPCB................................................................................................. 5-15

4.3.1 Removing the MPCB.......................................................... 5-15

4.4

4.5

4.3.2 Reinstalling the MPCB ....................................................... 5-16

Reinstalling the MPCB Connectors .................................................... 5-17

Extra Memory (SIMM) ........................................................................ 5-18

4.5.1

4.5.2

Extra Memory (SIMM) Removal ......................................... 5-18

Extra Memory (SIMM) Installation ...................................... 5-19

4.6 Reinstalling the Right Cover Assembly .............................................. 5-20

5.0 Servo Motor ..................................................................................................... 5-21

5.1

5.2

Removing the Servo Motor ................................................................ 5-21

Replacing the Servo Motor................................................................. 5-24

6.0 Display Assembly ............................................................................................ 5-25

6.1

6.2

Removing the Display Assembly........................................................ 5-25

Reinstalling the Display Assembly ..................................................... 5-26

7.0 Service Station Assembly................................................................................ 5-27

7.1

7.2

Removing the Service Station Assembly ........................................... 5-27

Reinstalling the Service Station Assembly ......................................... 5-29

CADJET 2 xiii

Table of Contents

CHAPTER 5 DISASSEMBLY/ASSEMBLY (continued)

8.0 Left Cover Assembly, Left Side Plate, Carriage Assembly, Trailing Cable, and Carriage Belt ............................................................................................ 5-30

8.1

8.2

8.3

Removing the Left Cover Assembly and Left Side Plate ................... 5-30

Removing the Carriage Assembly ..................................................... 5-32

Reinstalling the Carriage Assembly ................................................... 5-35

8.4

8.5

8.6

8.7

Reinstalling the Left Side Plate and Left Cover Assembly................. 5-40

Removing the Trailing Cable.............................................................. 5-41

Reinstalling the Trailing Cable ........................................................... 5-43

Removing the Carriage Belt from Carriage Assembly ....................... 5-46

8.8 Installing the Carriage Belt on Carriage Assembly............................. 5-47

9.0 Power Supply and ON/OFF Switch ................................................................. 5-48

9.1 Removing the Power Supply and ON/OFF Switch............................. 5-48

9.2 Installing the Power Supply and ON/OFF Switch............................... 5-49

10.0 Stabilizer Bracket and Encoder Strip............................................................... 5-50

10.1 Removing the Stabilizer Bracket........................................................ 5-51

10.2 Reinstalling the Stabilizer Bracket ..................................................... 5-52

11.0 Lower Drive Assembly, Fan Assembly, and Stepper Motor Assembly

(Inner Platen Parts) ......................................................................................... 5-54

11.1 Disassembly of Plotter Before Removing the Inner Platen Parts....... 5-55

11.2 Removing the Inner Platen Parts ....................................................... 5-57

11.3 Stepper Motor .................................................................................... 5-61

11.3.1 Removing the Stepper Motor............................................. 5-61

11.3.2 Reinstalling the Stepper Motor .......................................... 5-63

11.4 Reinstalling the Inner Platen Parts..................................................... 5-64

11.5 Reassembly of Plotter After Reinstalling the Inner Platen Parts........ 5-67

12.0 Fixed Blade ..................................................................................................... 5-70

12.1 Removing the Fixed Blade................................................................. 5-70

12.2 Reinstalling the Fixed Blade .............................................................. 5-71 xiv CADJET 2

Table of Contents

CHAPTER 5 DISASSEMBLY/ASSEMBLY (continued)

13.0 Cutter Wheel ................................................................................................... 5-72

13.1 Removing the Cutter Wheel ............................................................... 5-72

13.2 Replacement of Cutter Wheel............................................................ 5-74

14.0 Upper Roller Supports ..................................................................................... 5-75

14.1 Removing the Upper Roller Supports ................................................ 5-76

14.2 Installing the Upper Roller Supports .................................................. 5-81

CADJET 2 xv

Table of Contents

CHAPTER 6 CALIBRATION

Procedures to mechanically and electrically align the plotter following repairs, or when plotter performance has been affected.

1.0 Introduction ....................................................................................................... 6-1

2.0 Required Supplies and Tools ............................................................................ 6-2

3.0 Required Documentation and Files ................................................................... 6-4

4.0 Downloading Files From the BBS ..................................................................... 6-5

5.0 Numbering Sequence of Upper Roller Supports ............................................... 6-7

6.0 Adjustments Prior to Calibration........................................................................ 6-8

6.1 Slide Shaft Profile Adjustment ............................................................. 6-9

6.2 Cartridge Head Height Adjustment .................................................... 6-12

6.2.1 Gauge Setup Procedure .................................................... 6-12

6.2.2

6.2.3

Cartridge Head Height Adjusting Procedure...................... 6-17

Verify Head Height Values................................................. 6-18

Encoder Strip Location/Visual Check................................................. 6-19 6.3

6.4

6.5

Idler Pulley and Belt Position Check .................................................. 6-20

Power Up and ROM Verification Test ................................................ 6-21

6.5.1 Functional Test .................................................................. 6-21

6.5.2 Adjustment of the Paper Sensor Potentiometer ................ 6-23

7.0 Paper Skew Setup .......................................................................................... 6-27

8.0 Paper Skew Adjustment.................................................................................. 6-28

8.1 Paper Skew Adjustment Sequence ................................................... 6-29

8.2

8.3

8.4

Mounting Screw Information .............................................................. 6-30

Other Functional Requirements ......................................................... 6-33

Adjustment of Upper Roller Supports ................................................ 6-34

8.4.1

8.4.2

8.4.3

8.4.4

Visual Verification .............................................................. 6-34

Observation of Paper Skew at Rear Media Alignment

Mark................................................................................... 6-35

Observation of Paper Skew at Front Media Alignment

Mark................................................................................... 6-37

Adjustment of the Mounting Screws .................................. 6-38 xvi CADJET 2

Table of Contents

CHAPTER 6 CALIBRATION (continued)

9.0 Plotting PRIME Pattern.................................................................................... 6-39

10.0 XY Calibration.................................................................................................. 6-43

10.1 Calibrating the Y-Axis (Carriage Axis or Horizontal Axis

Calibration)......................................................................................... 6-44

10.2 Calibrating the X-Axis (Paper Axis or Vertical Axis Calibration) ......... 6-46

11.0 Deadband Calibration...................................................................................... 6-47

11.1 Slow Deadband Calibration................................................................ 6-48

11.2 Fast Deadband (Height Calibration)................................................... 6-50

11.2.1 Adjusting Fast Deadband; Vertical Lines (All) and

Vertical Lines (One) ........................................................... 6-51

12.0 Cartridge Calibration - Horizontal and Vertical ................................................ 6-53

12.1 Adjusting the Horizontal Head-to-Head Calibration............................ 6-55

12.2 Adjusting the Vertical Head-to-Head Calibration................................ 6-56

13.0 Color Deadband Calibration ............................................................................ 6-57

13.1 Adjusting the Color Deadband Value ................................................. 6-58

14.0 Line Quality Plot (Computer) Test ................................................................... 6-60

CADJET 2 xvii

Table of Contents

CHAPTER 7 REPLACEMENT PARTS LIST

A complete listing (numerical, alphabetical, and illustrated alphabetical) of all field replaceable parts and assemblies for the CADJET 2 Color Inkjet

Plotters.

1.0 Introduction ....................................................................................................... 7-1

2.0 Numerical Listing............................................................................................... 7-2

2.1 Parts Used in both D-Size and E-Size (Numerical).............................. 7-2

2.2

2.3

D-Size Unique Parts (Numerical) ......................................................... 7-4

E-Size Unique Parts (Numerical) ......................................................... 7-5

3.0 Alphabetical Listing ........................................................................................... 7-6

3.1

3.2

Parts Used in both D-Size and E-Size (Alphabetical) .......................... 7-6

D-Size Unique Parts (Alphabetical) ..................................................... 7-8

3.3 E-Size Unique Parts (Alphabetical)...................................................... 7-9

4.0 Alphabetical Listing with Drawings .................................................................. 7-10

4.1

4.2

4.3

Drawings - Parts Used in both D-Size and E-Size ............................. 7-10

Drawings - D-Size Unique Parts ........................................................ 7-26

Drawings - E-Size Unique Parts......................................................... 7-30 xviii CADJET 2

Table of Contents

APPENDICES

APPENDIX A EMERGENCY FIRMWARE DOWNLOAD PROCEDURE

Procedure for downloading firmware to a CADJET 2 Color Inkjet Plotter which has a blank or corrupt Flash EPROM.

Emergency Firmware Download Procedure.................................................................A-1

APPENDIX B PRINTER FIRMWARE UPGRADE PROCEDURE

Procedure for upgrading a CADJET 2 Color Inkjet Plotter to the newest version of firmware (Flash EPROM is not blank or corrupt).

Printer Firmware Upgrade Procedure ..........................................................................B-1

APPENDIX C FINAL ASSEMBLY DRAWINGS

CADJET 2 Color Inkjet Plotters (D-Size and E-Size) Final Assembly

Drawings with Callouts.

CADJET 2 D-Size Final Assembly Callouts ................................................................ C-2

CADJET 2 E-Size Final Assembly Callouts ................................................................ C-4

APPENDIX D SCHEMATICS

Schematics for the CADJET 2 Color Inkjet Plotters Boards.

Main PCB Assembly ............................................................................................ 9 pages

Keypad PCB Assembly .......................................................................................... 1 page

Carriage PCB Assembly....................................................................................... 2 pages

Flex Circuit ............................................................................................................. 1 page

CADJET 2 xix

Table of Contents

F I G U R E S

CHAPTER 1 GENERAL INFORMATION

Number

Figure 1.1

Figure 1.2

Figure 1.3

Figure 1.4

Figure 1.5

Title

Page

Front View -- Cover Closed................................................................ 1-10

Front View -- Cover Open .................................................................. 1-11

Back View .......................................................................................... 1-12

Line Length Accuracy ........................................................................ 1-14

Skew .................................................................................................. 1-15

CHAPTER 2 THEORY OF OPERATION

Number Title

Page

Figure 2.1 Major Functional Areas of the Plotter .................................................. 2-5

Figure 2.2 Gate Array ......................................................................................... 2-12

Figure 2.3 Stepper Motor .................................................................................... 2-14

Figure 2.4 Servo Motor ....................................................................................... 2-15

Figure 2.5 Parallel and Serial Ports .................................................................... 2-16

Figure 2.6 Keypad Display.................................................................................. 2-17

Figure 2.7 Carriage Circuits ................................................................................ 2-18

CHAPTER 4 TROUBLESHOOTING

Number

Figure 4.1

Figure 4.2

Figure 4.3

Figure 4.4

Figure 4.5

Figure 4.6

Figure 4.7

Title

Page

LED Keys........................................................................................... 4-18

LCD Keypad ...................................................................................... 4-19

Parallel and Serial Loop Back Tests .................................................. 4-30

Tri-Color Cartridge Flex ..................................................................... 4-46

Sample of Black Cartridge Diagnostics Test...................................... 4-50

Black Cartridge Failure Test Setups .................................................. 4-51

Black Cartridge Flex Dimple Pattern .................................................. 4-53 xx CADJET 2

Table of Contents

CHAPTER 5 DISASSEMBLY/ASSEMBLY

Number Title

Page

Figure 5.1 CADJET 2 Hardware Kit Assembly...................................................... 5-5

Figure 5.2

Figure 5.3

Figure 5.4

Figure 5.5

CADJET 2 Final Assembly Tools......................................................... 5-6

Preparing the Plotter for Shipping ........................................................ 5-8

Preparing the Plotter for Shipping - Alternate Method ....................... 5-10

Inside View of Right Cover Assembly ................................................ 5-11

Figure 5.6

Figure 5.7

Figure 5.8

Figure 5.9

MPCB Connectors ............................................................................. 5-14

Location of SIMMS............................................................................. 5-18

Closeup View of Clip .......................................................................... 5-18

Side View of SIMMS Removal ........................................................... 5-18

Figure 5.10 Side View of SIMMS Installation ........................................................ 5-19

Figure 5.11 Servo Motor........................................................................................ 5-22

Figure 5.12 Compression of Frame Tensioner...................................................... 5-23

Figure 5.13 Display Assembly............................................................................... 5-25

Figure 5.14 Keypad PCB ...................................................................................... 5-26

Figure 5.15 Service Station Assembly .................................................................. 5-27

Figure 5.16 Inside View of Left Side Plate ............................................................ 5-31

Figure 5.17 Trailing Cable Connector Lock on Carriage PCB............................... 5-33

Figure 5.18 Left End of Y-Arm .............................................................................. 5-34

Figure 5.19 Reinstalling the Trailing Cable in J1 Connector ................................. 5-37

Figure 5.20 Positioning the Trailing Cable on the Stabilizer Bracket..................... 5-44

Figure 5.21 Removing the Carriage Belt ............................................................... 5-46

Figure 5.22 Placement of Carriage Belt on Carriage ............................................ 5-47

Figure 5.23 Encoder Strip ..................................................................................... 5-50

Figure 5.24 Inner Platen Parts .............................................................................. 5-54

Figure 5.25 Disassembly of Plotter Prior to Removing the Inner Platen Parts ...... 5-56

Figure 5.26 Removing the Lower Drive Shaft Screws........................................... 5-58

Figure 5.27 Removing the Foam Block ................................................................. 5-59

CADJET 2 xxi

Table of Contents

CHAPTER 5 DISASSEMBLY/ASSEMBLY (continued)

Number Title

Page

Figure 5.28 Lower Drive Assembly and Stepper Motor Assembly ........................ 5-62

Figure 5.29 Routing of Wires and Cables on Right Side Plate and MPCB ........... 5-68

Figure 5.30 Fixed Blade........................................................................................ 5-70

Figure 5.31 Cutter Assembly ................................................................................ 5-73

Figure 5.32 Upper Roller Support - Normal and Bent for Removal....................... 5-77

Figure 5.33 Removing the Old Upper Roller Support ........................................... 5-78

Figure 5.34 Inserting New Upper Roller Supports ................................................ 5-81

Figure 5.35 Positioning Upper Roller Supports..................................................... 5-82

CHAPTER 6 CALIBRATION

Number Title

Page

Figure 6.1 Upper Roller Supports Numbering Sequence...................................... 6-7

Figure 6.2 Inner Stand Off Screws and Turnbuckle ............................................ 6-10

Figure 6.3 Carriage Height Measurement Fixture ............................................... 6-14

Figure 6.4 Installation of Typical Black Cartridge................................................ 6-15

Figure 6.5 Top View of Carriage Board .............................................................. 6-23

Figure 6.6 Upper Roller Support and Mounting Screws...................................... 6-30

Figure 6.7 Correct Positioning of the Spring in the Upper Roller Support........... 6-32

Figure 6.8 Test for Minimum Acceptable Gap .................................................... 6-33

Figure 6.9 Visual Verification of Gap between Roller and Y-Arm ....................... 6-34

Figure 6.10 Paper Skew Acceptance Range for Rear Media Alignment Mark...... 6-36

Figure 6.11 Paper Skew Acceptance Range for Front Media Alignment Mark ..... 6-37

Figure 6.12 Motion of Rollers and Adjustment of Mounting Screws ..................... 6-38

Figure 6.13 Deadband Alignment ......................................................................... 6-47

Figure 6.14 Vertical Lines (All) .............................................................................. 6-51

Figure 6.15 Vertical Lines (One) ........................................................................... 6-52

Figure 6.16 CADJET 2 Calibration Worksheet ..................................................... 6-62 xxii CADJET 2

Table of Contents

CHAPTER 7 REPLACEMENT PARTS LIST

Number Title Part #

Page

Figure 7.1 Assy, Bracket, Drive Shaft

(left bracket w/bushing) ........................................P/N 204916 .......... 7-10

Figure 7.2 Assy, Carriage......................................................P/N 204854 .......... 7-10

Figure 7.3

Figure 7.4

Figure 7.5

Assy, Cover, Left..................................................P/N 203533 .......... 7-11

Assy, Cover, Right ...............................................P/N 203476 .......... 7-11

Assy, Cutter..........................................................P/N 203614 .......... 7-11

Figure 7.6

Figure 7.7

Figure 7.8

Figure 7.9

Assy, Exhaust ......................................................P/N 204384 .......... 7-12

Assy, Fan .............................................................P/N 203443 .......... 7-12

Assy, Hardware Kit CADJET 2, Service ..............P/N 205188 .......... 7-12

Assy, Idler ............................................................P/N 203345-1 ....... 7-12

Figure 7.10 Assy, Keypad Top ................................................P/N 203488 .......... 7-13

Figure 7.11 Assy, MPCB .........................................................P/N 205329 .......... 7-13

Figure 7.12 Assy, Pinch Roller ................................................P/N 203637-2 ....... 7-14

Figure 7.13 Assy, Rollguide, Left ............................................P/N 204969 .......... 7-14

Figure 7.14 Assy, Rollguide, Right ..........................................P/N 203477-2 ....... 7-14

Figure 7.15 Assy, Service Station ...........................................P/N 203233 .......... 7-15

Figure 7.16 Assy, Servo Motor................................................P/N 203265 .......... 7-15

Figure 7.17 Assy, Stepper Motor Bracket, Service

(right bracket w/bushing) ......................................P/N 205350 .......... 7-15

Figure 7.18 Assy, Stepper Motor Service (includes Gear) ......P/N 205128 .......... 7-16

Figure 7.19 Cable, Keypad .....................................................P/N 205111 .......... 7-16

Figure 7.20 Cable, RS422 Mini-DIN8......................................P/N 203977 .......... 7-17

Figure 7.21 Cam, Actuator (Left and Right) ............................P/N 203646 .......... 7-17

Figure 7.22 Caster, Locking, Twin...........................................P/N 202513 .......... 7-17

Figure 7.23 Caster, Non-Locking, Twin ...................................P/N 202512 .......... 7-18

Figure 7.24 Clip, Belt...............................................................P/N 203644-1 ....... 7-18

Figure 7.25 Cutter, Wheel .......................................................P/N 203622-1 ....... 7-18

Figure 7.26 Foam, Block .........................................................P/N 205079 .......... 7-19

CADJET 2 xxiii

Table of Contents

CHAPTER 7 REPLACEMENT PARTS LIST (continued)

Number Title Part #

Page

Figure 7.27 Foam, Bottom, Left .............................................. P/N 203480-1 ....... 7-19

Figure 7.28 Foam, Bottom, Right............................................ P/N 203481-1 ....... 7-19

Figure 7.29 Foam, Top, Left ................................................... P/N 203788-1 ....... 7-20

Figure 7.30 Foam, Top, Right ................................................. P/N 203789-1 ....... 7-20

Figure 7.31 Frame, Tensioner ................................................ P/N 203343-1 ....... 7-20

Figure 7.32 Keypad, Bottom ................................................... P/N 203440-1 ....... 7-21

Figure 7.33 ON/OFF Switch (Power Entry Module) ................ P/N 204599 .......... 7-21

Figure 7.34 Power Supply....................................................... P/N 204849 .......... 7-21

Figure 7.35 Roll Support ......................................................... P/N 203868-1 ....... 7-22

Figure 7.36 Screws, Stand...................................................... P/N 203485 .......... 7-22

Figure 7.37 Sideplate, Left...................................................... P/N 204968 .......... 7-23

Figure 7.38 Sideplate, Right ................................................... P/N 204973 .......... 7-23

Figure 7.39 Spring, Compression (Idler) ................................. P/N 203447 .......... 7-24

Figure 7.40 Spring, Compression (Top Cover) ....................... P/N 202010 .......... 7-24

Figure 7.41 Spring, Roll Holder............................................... P/N 203918-2 ....... 7-24

Figure 7.42 Stop, Retracting ................................................... P/N 204246 .......... 7-25

Figure 7.43 Support, Drive Shaft (middle support).................. P/N 203556-2 ....... 7-25

Figure 7.44 Angle, Trailing Cable ........................................... P/N 203800-32 ..... 7-26

Figure 7.45 Assy, Legs and Basket ........................................ P/N 205175 .......... 7-26

Figure 7.46 Assy, Lower Drive ................................................ P/N 204917-31 ..... 7-27

Figure 7.47 Assy, Stabilizer Bracket, Service ......................... P/N 204551 .......... 7-27

Figure 7.48 Assy, Top Cover .................................................. P/N 204367-5 ....... 7-27

Figure 7.49 Belt, Ribbed ......................................................... P/N 203903 .......... 7-28

Figure 7.50 Cable, Trailing...................................................... P/N 203778 .......... 7-28

Figure 7.51 Platen, Machined ................................................. P/N 204848 .......... 7-28

Figure 7.52 Slide Shaft ........................................................... P/N 204007-31 ..... 7-29

Figure 7.53 Angle, Trailing Cable ........................................... P/N 203800-3 ....... 7-30 xxiv CADJET 2

Table of Contents

CHAPTER 7 REPLACEMENT PARTS LIST (continued)

Number Title Part #

Page

Figure 7.54 Assy, Legs and Basket.........................................P/N 205174 .......... 7-30

Figure 7.55 Assy, Lower Drive ................................................P/N 204917-1 ....... 7-31

Figure 7.56 Assy, Stabilizer Bracket, Service..........................P/N 204550 .......... 7-31

Figure 7.57 Assy, Top Cover...................................................P/N 204367-7 ....... 7-31

Figure 7.58 Belt, 3 Rib ............................................................P/N 203230 .......... 7-32

Figure 7.59 Cable, Trailing ......................................................P/N 203448 .......... 7-32

Figure 7.60 Platen, Machined .................................................P/N 204847 .......... 7-32

Figure 7.61 Slide Shaft............................................................P/N 204007-2 ....... 7-33

APPENDIX A EMERGENCY FIRMWARE DOWNLOAD PROCEDURE

Number Title

Page

Figure A.1 Cable, RS422 Mini-DIN8......................................................................A-3

APPENDIX C FINAL ASSEMBLY DRAWINGS

Number Title

Page

Figure C.1 CADJET 2 D-Size Final Assembly...................................................... C-6

Figure C.2 CADJET 2 E-Size Final Assembly ...................................................... C-7

CADJET 2 xxv

Table of Contents

T A B L E S

CHAPTER 1 GENERAL INFORMATION

Number

Table 1.1

Table 1.2

Title

Page

Media Sizes and Maximum Plotting Areas for Rollfeed Media ............ 1-7

Media Sizes and Maximum Plotting Areas for Sheet Media ................ 1-8

CHAPTER 4 TROUBLESHOOTING

Number

Table 4.1

Table 4.2

Table 4.3

Table 4.4

Table 4.5

Table 4.6

Title

Page

Decision Logic Table One (DLT 1)....................................................... 4-4

Decision Logic Table Two (DLT 2)....................................................... 4-5

Decision Logic Table Three (DLT 3) .................................................... 4-6

Decision Logic Table Four (DLT 4) ...................................................... 4-7

Decision Logic Table Five (DLT 5)..................................................... 4-42

Black Cartridge Flex Test Matrix........................................................ 4-54

CHAPTER 6 CALIBRATION

Number

Table 6.1

Table 6.2

Title

Page

Carriage Height Settings Chart .......................................................... 6-16

Potentiometer Adjustment Flowchart ................................................. 6-25 xxvi CADJET 2

Chapter 1

GENERAL INFORMATION

1.0 Introduction

This manual provides service information for the ENCAD

®

, Inc.

CADJET 2 Color Inkjet Plotter. This manual is written for service personnel who are experienced in analog and digital circuitry.

Chapter 2, the Theory of Operation, should be read and thoroughly understood before attempting to troubleshoot or calibrate the plotter.

The CADJET 2 supports both pre-cut and roll media, automatically determining the media size and setting the hardclip limits accordingly.

The CADJET 2 uses both a serial interface and the Centronics parallel interface. It understands commands sent from the host computer in several forms, including HP-GL*, HP-GL/2*, and HP-RTL.

_______________

*

(Hewlett-Packard Graphics Language).

CADJET 2 1-1

General Information

2.0 Overview

Plotters draw according to instructions issued from a "host" computer.

Any plotter is engineered to understand a specific set of instructions and to execute each instruction in a precise manner. In addition, most plotters are designed to execute predetermined characters automatically without a specific line-by-line instruction from the program. These characters are part of the plotter's permanent memory.

2.1 Related Publications

The following publications contain additional information which may be useful in servicing the ENCAD, Inc. CADJET 2 Color Inkjet Plotter. l ENCAD, Inc. CADJET 2 User's Guide, P/N 205377 l ENCAD, Inc. CADJET 2 Troubleshooting Guide,

P/N 205368 l ENCAD, Inc. CADJET 2 Supplies Reference Guide,

P/N 205374 l

ENCAD, Inc. CADJET 2 Installation Guide, P/N 205367

(This is the instruction sheet for installing the floor stand.)

Additional copies of ENCAD, Inc. publications may be obtained by contacting your nearest authorized ENCAD, Inc. dealer or by contacting ENCAD’s Technical Support and Service Department.

1-2 CADJET 2

General Information

2.2 Features of this Service Manual

2.2.1 Subject Headings

All subject headings are numbered. Main subject headings are identified by a dark gray banner with large white type. First sublevel subject headings are in large bold type and are set in slightly from the left margin. Second sublevel subject headings are in bold, italicized type.

1.0 Main Subject Heading

1.1 First sublevel subject heading

Paragraph

1.1.1 Second sublevel subject heading

Paragraph

2.2.2 Figures and Tables

Figures are used to clarify procedures. They are for illustrative purposes only and may not necessarily be drawn to scale. Figures and Tables are easily located and cross-referenced, and are listed in the Table of Contents.

CADJET 2 1-3

General Information

CAUTION

NOTE

WARNING

2.2.3 Manual Conventions

CAUTION - Reminders of importance that must be addressed, but may or may not cause minor damage, are highlighted with the “Caution” symbol at the left and with a cautionary note in bold type and is enclosed in a box.

NOTE - Notes are placed before or after a procedure to inform the service person of specific details to improve quality, to give reminders of inter-related parts, and to provide other helpful information. They are indicated by the “Note” symbol at the left.

The text of the note is in italics and is enclosed in a box.

ORIENTATION - Instructions in this manual are based on the assumption that the service person is facing the front of the plotter.

References to top view, back view, and so forth are consistent with this engineering standard. References to the X Axis and Y Axis

(Paper Axis and Carriage Axis, respectively) follow the standard of

AutoCAD™ absolute coordinates: up and down for X, left to right for Y.

WARNING - Read all warning notes before proceeding with any action steps to eliminate possible serious damage to the plotter and/or possible personal injury to the service person. Warnings are indicated by the “Warning” symbol at the left. The warning text is in bold italics type and is enclosed in a box.

1-4 CADJET 2

General Information

3.0 ENCAD Technical Support & Service

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, contact 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:

(619) 452-4350

Help Desk FAX:

(619) 546-0659

Additional information is available on ENCAD’s bulletin board and through Internet:

ENCAD BBS:

(619) 452-2653 or (619) 452-3768

Internet WEB Page Address:

http://www.thegroup.net/encad/

CADJET 2 1-5

General Information

4.0 Media Sizes and Plotting Areas

NOTE

The CADJET 2 plotter is designed to recognize specific standard media sizes by checking the narrow dimension of the media as it is loaded. The Normal and Expanded Plot Areas depend upon

whether Rollfeed media or Sheet media has been loaded. The media sizes recognized by the plotter and the maximum plotting areas for Rollfeed media are listed in Table 1.1. The media sizes and maximum plotting areas for Sheet media are listed in Table 1.2.

Note: The Expanded setting for the Margins option expands the plot area and decreases the margins. The current maximum plotting area may be viewed in the CADJET 2 keypad display by performing the following steps:

1. Initialize unit and load paper.

2. Press the UP ARROW five times until you see the following display:

MAIN MENU

PAGE FORMAT

3. Press SELECT once to display:

PAGE FORMAT

MARGINS=NORMAL

4. Press the UP ARROW twice to display:

PAGE FORMAT

PLOT AREA

5. Press SELECT to view the current maximum plotting areas.

1-6 CADJET 2

General Information

Table Chapter 1 .1: Media Sizes and Maximum Plotting Areas for Rollfeed Media

Paper Size Normal Plot Area Expanded Plot Area

U.S. ENGINEERING

A 8.5” x 11.0” 7.3” x 9.8” 8.1” x 10.6”

B 11.0” x 17.0” 9.8” x 15.8” 10.6” x 16.6”

C 17.0” x 22.0” 15.8” x 20.8” 16.6” x 21.6”

D 22.0” x 34.0” 20.8” x 32.8” 21.6” x 33.6”

E 34.0” x 44.0” 32.8” x 42.8” 33.6” x 43.6”

U.S. ARCHITECTURAL

A 9.0” x 12.0” 7.8” x 10.8” 8.6” x 11.6”

B 12.0” x 18.0” 10.8” x 16.8” 11.6” x 17.6”

C 18.0” x 24.0” 16.8” x 22.8” 17.6” x 23.6”

D 24.0” x 36.0” 22.8” x 34.8” 23.6” x 35.6”

E 36.0” x 48.0” 34.8” x 46.8” 35.6” x 47.6”

ISO - A

A4 210 x 297 mm 180 x 267 mm 200 x 287 mm

A3 297 x 420 mm 267 x 390 mm 287 x 410 mm

A2 420 x 594 mm 390 x 564 mm 410 x 584 mm

A1 594 x 840 mm 564 x 810 mm 584 x 830 mm

A0 841 x 1189 mm 811 x 1159 mm 831 x 1179 mm

METRIC - DIN

A4 250 x 337 mm 220 x 307 mm 240 x 327 mm

A3 337 x 460 mm 307 x 430 mm 327 x 450 mm

A2 460 x 634 mm 430 x 604 mm 450 x 624 mm

A1 634 x 881 mm 604 x 851 mm 624 x 871 mm

A0 881 x 1229 mm 851 x 1199 mm 871 x 1219 mm

ISO - B

B3 353 x 500 mm 323 x 470 mm 343 x 490 mm

B2 500 x 707 mm 470 x 677 mm 490 x 697 mm

B1 707 x 1000 mm 677 x 970 mm 697 x 990 mm

SPECIAL

E1 30.0” x 42.0” 28.8” x 40.8” 29.6” x 41.6”

E2 26.0” x 38.0” 24.8” x 36.8” 25.6” x 37.6”

E3 27.0” x 39.0” 25.8” x 37.8” 26.6” x 38.6”

CADJET 2 1-7

General Information

Table Chapter 1 .2: Media Sizes and Maximum Plotting Areas for Sheet Media

Paper Size Normal Plot Area Expanded Plot Area

U.S. ENGINEERING

A 8.5” x 11.0” 7.3” x 9.0” 8.1” x 9.4”

B 11.0” x 17.0” 9.8” x 15.0” 10.6” x 15.4”

C 17.0” x 22.0” 15.8” x 20.0” 16.6” x 20.4”

D 22.0” x 34.0” 20.8” x 32.0” 21.6” x 32.4”

E 34.0” x 44.0” 32.8” x 42.0” 33.6” x 42.4”

U.S. ARCHITECTURAL

A 9.0” x 12.0” 7.8” x 10.0” 8.6” x 10.4”

B 12.0” x 18.0” 10.8” x 16.0” 11.6” x 16.4”

C 18.0” x 24.0” 16.8” x 22.0” 17.5” x 22.4”

D 24.0” x 36.0” 22.8” x 34.0” 23.6” x 34.4”

E 36.0” x 48.0” 34.8” x 46.0” 35.6” x 46.4”

ISO - A

A4 210 x 297 mm 180 x 247 mm 200 x 257 mm

A3 297 x 420 mm 267 x 370 mm 287 x 380 mm

A2 420 x 594 mm 390 x 544 mm 410 x 554 mm

A1 594 x 840 mm 564 x 791 mm 584 x 801 mm

A0 841 x 1189 mm 811 x 1139 mm 831 x 1149 mm

METRIC - DIN

A4 250 x 337 mm 220 x 287 mm 240 x 297 mm

A3 337 x 460 mm 307 x 410 mm 327 x 420 mm

A2 460 x 634 mm 430 x 580 mm 450 x 694 mm

A1 634 x 881 mm 604 x 831 mm 634 x 841 mm

A0 881 x 1229 mm 851 x 1179 mm 871 x 1189 mm

ISO - B

B3 353 x 500 mm 323 x 450 mm 343 x 460 mm

B2 500 x 707 mm 470 x 657 mm 490 x 667 mm

B1 707 x 1000 mm 677 x 950 mm 697 x 960 mm

SPECIAL

E1 30.0” x 42.0” 28.8” x 40.0” 29.6” x 40.4”

E2 26.0” x 38.0” 24.8” x 36.0” 25.6” x 36.4”

E3 27.0” x 39.0” 25.8” x 37.0” 26.6” x 37.4”

1-8 CADJET 2

General Information

5.0 General Product Notes

WARNING

The material below is very important for the proper and safe operation of the plotter and should be read before proceeding.

CLEANING - Alcohol contact with the Carriage Assembly bushings will cause damage. Wait until the Slide Shaft is completely dry before moving the Carriage Assembly.

CUTTER - Proper safety procedures should be used when handling the Cutter in order to avoid injury.

ENCODER STRIP - Water should NOT be used to clean the Encoder

Strip. See Chapter 3 of this manual for the cleaning procedure.

Be very careful when working near the Encoder Strip so that it is not damaged.

LUBRICANTS - Do not use any lubricants on this product. USE OF

LUBRICANTS WILL VOID THE WARRANTY.

SLIDE SHAFT - Dry the Slide Shaft completely after cleaning it with alcohol. Alcohol contact to the Carriage Assembly bushings will cause damage.

START UP - If the CADJET 2 doesn’t power-up, it must be turned off

immediately to eliminate any damage until the problem can be resolved.

CADJET 2 1-9

General Information

6.0 Plotter Features

NOTE

Note: The stand and basket assembly shown in Figure Chapter 1 .1 and Figure Chapter 1 .2 is changing. Drawings of the new stand and basket were not available at the time of publication.

The major features of the CADJET 2 plotter are illustrated and described in Figure Chapter 1 .1, Figure Chapter 1 .2, and

Figure Chapter 1 .3.

1-10 CADJET 2

Figure Chapter 1 .1: Front View -- Cover Closed

General Information

CADJET 2 1-11

General Information

1-12

Figure Chapter 1 .2: Front View -- Cover Open

CADJET 2

General Information

CADJET 2

Figure Chapter 1 .3: Back View

1. Centronics Parallel Port (J2)

2. RS-422/423 Serial Port/Apple Talk (J3)

3. Power Input Plug and ON/OFF Switch

4. ID Label

5. Left Rollguide

6. Right Rollguide

7. Rear Media Alignment Mark

1-13

General Information

7.0 Plotter Specifications

Standard Features:

Cut sheet or roll feed with cutter

Low ink level indicator

8 user-savable settings

Replot and multiple copies

Long plot up to 50 feet (15.4 m)

Merged vector/raster images

Ink reduction

Plot nesting

Auto rotation

Cut Sheet Maximum Plotting Area:

Normal = 0.59” (15 mm) margin on each of

3 sides and a 1.38” (35 mm) margin on the fourth side.

Expanded = 0.197” (5 mm) margin on each of 3 sides and a 1.38” (35 mm) margin on the fourth side.

Rollfeed Maximum Plotting Area:

Normal = 0.59” (15 mm) on all sides.

Expanded = 0.197” (5 mm) on all sides.

Line Length Accuracy:

±

0.015” (0.38mm) or

±

0.2% of the specified vector line length, whichever is greater

Long Plot:

Plot length: 50’ (15.24m)

Frame to Frame Registration: .01”

Distance Accuracy: .20% of total length

Buffer:

4 MB permanently installed

Two 72-pin 32-bit wide DRAM SIMM sockets.

User upgradable with 8, 16, 32, or 64 MB with

70 ns or faster SIMMS, conforming to JEDEC

Standard Number 21-C Release 4 or later.

Language Emulation:

HP-GL: HP 7440,7470,7475, 7550, 7570, 7575,

7576, 7580, 7585, 7586, 7596

HP-GL/2, HP-RTL, EN-RTL

Media Types:

Paper based: Presentation (5 mil) and

Premium Bond (7 mil)

Cotton based: Inkjet Vellum

Polyester based: Inkjet Transparency Film

(4 mil) and Inkjet Drafting

Matte Film (4 mil)

Rasterization:

Internal rasterizer

Resolution:

300 x 300 DPI monochrome, gray, and color

600 x 600 DPI monochrome and gray

Interfaces:

Centronics bi-directional parallel

RS-422 serial

RS-232 (requires adaptor cable)

Baud Rates:

300, 600, 1200, 2400, 4800, 9600, 19200,

38400

Power:

Universal Power Supply:

100-240 Vac, 50-60

±

2 Hz, AC Input, DC

Output

Consumption: 40 W Typical, 60 W Max.

Compliance:

Safety: UL, CSA, TUV

EMI: FCC Class B, VDE Class B

CISPR22

Physical Specifications:

E Size Model

Dimensions:

Height:

Width:

Depth:

48” (121 cm)

54” (140 cm)

28” (72 cm)

Weight:

Assembled:

Shipping - Plot-head:

69 lbs. (31 kg)

62 lbs. (28 kg)

D Size Model

Dimensions:

Height:

Width:

Depth:

42” (105 cm)

43” (112 cm)

28” (72 cm)

Weight:

Assembled:

Shipping - Plot-head:

57 lbs. (26 kg)

54 lbs. (25 kg)

Operating Environment:

41

°

to 104

°

F (5

°

to 40

°

C)

20 - 80% RH, Non-condensing

Storage Environment:

-40

°

to 140

°

F (-40

°

to 60

°

C)

10 - 80% RH, Non-condensing

1-14 CADJET 2

General Information

8.0 Line Length Accuracy

The following information for the CADJET 2 clarifies the amount of acceptable variation for plotting accurately. See Figure Chapter 1 .4.

CADJET 2

Figure Chapter 1 .4: Line Length Accuracy

1. The drawn line length L

w

is to be within

±

0.2% of the length specified. L

w

typically is constant on the top and bottom of the plot.

2. Line length L

L and

L

R

are to each be

± 0.2% of length L specified.

3. The total difference, or delta, between the longest line within specification and the shortest line within specification is:

L ( 1 + 0.2% ) - L ( 1 - 0.2% )

+ .2 - ( -.2 ) = .4%L

Example:

L

R

- L

L

=

∆L

∆L < 0.4% of L

If: L specified = 45”

Then:

∆L (left and right) must be .4% of 45

∆L < 0.18 inches

1-15

General Information

9.0 Skew

If the media loading instructions have been correctly implemented, these figures are conditions for variable paper movement during plotting. See Figure Chapter 1 .5.

1-16

Figure Chapter 1 .5: Skew

Given a specified rectangle L

W

wide and L high, the diagonal error

L

1

- L

2

defines the skew. The maximum acceptable skew is:

EQUAL TO: 0.2% of L

1

+ 0.2% of L

2

or

0.4% of (L

1

+ L

2

)

EXAMPLE: If:

L

W

= 60cm

L = 80cm

Then: L

1

should = L

2

= 100cm

Actual permissible skew ( L

1

- L

2

) = .4% x 100cm = .4cm or 0.157 inches.

CADJET 2

NOTE

General Information

Note: 1. This method is the only method used to specify skew. Other geometrical constructs may yield different results.

2. Actual output is a function of the combined line length and skew errors and typically is a straight polygon whose four sides are not necessarily equal.

CADJET 2 1-17

General Information

10.0 Acronyms and Abbreviations

ACK

A/D

ANSI

ARCH

AS

ASCII

AUTO

BTU

C

CAD

CHG cm cm/s

CPU

CTRL

CTS d or

∆ dB

DC

- Acknowledge

- Analog to Digital

- American National

Standards Institute

- Architectural

- Address Strobe KB

- American Standard Code for kHz

Information Interchange

- Automatic

- British Thermal Unit

- Celsius

- Computer Aided Drafting

- Change

- Centimeter

- Centimeter per second

- Central Processing Unit

- Control

- Clear to Send

- Differential

Hz

INIT

IP/s

ISO

LCD

LED

MANF

MAX

MB

MIN

PLL

- Hertz (cycles per second)

- Initialize

- Inches per second

- International Standards

Organization

- Kilobytes

- Kilo (One Thousand) Hertz

- Liquid Crystal Display

- Light Emitting Diode

- Manufacturer’s

- Maximum

- Megabyte

- Minimum mm - Millimeter

MPCB - Main Printed Circuit Board

PC

PD

- Personal Computer

- Pen Down

- Phase Locked Loop

PROM - Programmable Read Only

DPI

DRAM

DSR

DTE

DTR

EAS

ENQ

F

FCC g gm

GND

- Decibel

- Direct Current

- Dots Per Inch

- Dynamic Random Access

Memory

- Data Set Ready

- Data Terminal Equipment

- Data Terminal Ready

- Eavesdrop Enable Signal

- Enquire

- Fahrenheit

- Federal Communications

Commission

- Gravity (defined as

9.82 m/s

- grams

- Ground

2 or 32 ft/s 2 )

PU

Memory

- Pen Up

PWM - Pulse Width Modulation

RAM - Random Access Memory

ROM - Read Only Memory

RTS

RXD

- Ready to Send

- Receive

SG

TXD

TXDO

HP-GL - Hewlett-Packard Graphics

Language (older standard)

V

Vac

HP-GL/2 - Hewlett-Packard (standard) Vdc

Graphics Language W

- Signal Ground

SIMM - Single Inline Memory

Module

SRXD - Secondary Receive

STXD - Secondary Transmit

- Transmit

- Transmitter Signal Data

Output

UART - Universal Asynchronous

Receiver/Transmitter

- Volts

- Volts Alternating Current

- Volt Direct Current

- Watts

1-18 CADJET 2

General Information

11.0 Glossary

ASCII

ACCURACY

ASYNCHRONOUS

BASIC

BAUD

BIT

BI-DIRECTIONAL

BINARY

BITMAP

BYTE

BUFFER

BUS

CAD

CALIBRATION

CADJET 2

American Standard Code for Information Interchange. An information scheme used by computers to represent letters, numbers, and symbols.

The condition of being correct.

Data which is independent from a clock mechanism.

Beginner's All-Purpose Symbolic Instruction Code.

A common programmer's language for computer systems.

The rate of data transfer (number of bits per second that data is transmitted or received).

The smallest piece of digital information that can be handled by a processor. A unit of information equal to one binary decision.

Cartridges on the plotter fire ink on the media as the

Carriage moves in either direction, right to left and left to right.

The number system with a base of two used by the internal logic of all digital computers and controllers. It is a code that uses two distinct characters, usually the numbers 1 and 0.

A region of memory treated as a rectangular array of pixels.

A single group of 8 bits processed together in parallel.

Generally, eight bits which can be arranged in groups to represent 256 unique characters.

The part of the plotter’s memory used for receiving and temporarily holding plot files.

Computer circuits used to transmit data from one unit to another on a printed circuit board.

Computer Aided Drafting. A computer system or software designed to generate drawings on hardcopy media.

The procedures for adjusting the ink cartridge alignment, line length accuracy, and deadband.

1-19

General Information

CARRIAGE

CARRIAGE AXIS

CARTRIDGE

CENTRONICS

CONFIGURATION

CPU

DATA

DEADBAND

DEFAULT

DIAGNOSTICS

DISPLACEMENT

DISPLAY

DPI

DUTY CYCLE

EMULATE

1-20

The electromechanical assembly which carries the four ink

Cartridges across the media. The PCB on the Carriage contains the decoding circuits to fire the ink nozzles and determine carriage location.

The plot area measured parallel to the platen; that is, the

Y-Axis or Horizontal Axis.

The plastic housing containing the ink and the ink nozzles.

Two Cartridges are mounted on the plotter Carriage.

A parallel interface standard .

The way that the computer and plotter are interconnected and set up to operate as a system.

Central Processor Unit. The part of the computer system that contains the Arithmetic-Logic Unit and the Control Unit.

It forms the "brains" of the system, usually called the

"computer."

The term used to denote any or all facts, numbers, letters, and other characters used in information transfer.

The term when used in the physical or mechanical sense is

"lost motion." It results from a number of accumulated effects, such as friction, pulley and belt backlash, electrical losses, finite position errors from digital encoders, and low servo gain.

A value supplied by the internal firmware which is assumed to be the desired or common response for the plotter. This value may be changed by the user through the use of the front panel display buttons.

A set of firmware instructions for the detection and isolation of plotter malfunctions.

A change in position.

A device used to graphically show data.

Dots per inch, the number of dots the plotter lays down in an inch.

One complete cycle of time to complete a printing command.

To equal in quality or quantity.

CADJET 2

General Information

EPROM

FLASH EPROM

GRAVITY

Stores data and uses UV light to erase.

Electronically erasable and programmable. (Soldered on

MPCB and not replaceable.)

Used to indicate the force to which a body is subjected when accelerated.

HANDSHAKE

HARDCLIP LIMIT

HEIGHT ADJUSTMENT Height Adjustment refers to the adjustment of the gap between the Platen and the Cartridge head.

INITIALIZE The menu driven instruction set which brings the plotter to the factory default conditions.

INKJET

INK RECEPTIVITY

A method of controlling the speed that information flows between two computer devices to insure that the sender does not transmit data too quickly for the receiver to process.

A precise outer margin positioned around the plotting area.

The boundaries of the printing area beyond which the plotter cannot print.

INTERFACE CABLE

I/O ERROR

LAN

LINEAR ENCODER

MEDIA

MENU

The nozzle part of the ink cartridge.

The ability of the media to take various quantities of ink, thereby affecting the quality of the plot. This is determined by differences in sizing and media coating.

The cable used to connect the plotter to the computer.

CADJET 2 uses a serial or parallel interface cable.

A data transmission error between the computer and the plotter (for example, mismatched interfacing conditions such as baud rate and parity).

Local area network linking computers through cabling covering a 3K area.

Reads data through the optical sensor.

The surface on which the plotter prints the image. Media are available in a variety of types, including paper, polyester, canvas, and film.

A firmware created display allowing the user to select and execute various functions or features.

CADJET 2 1-21

General Information

MODE COMMAND

MODIFY

MONOCHROME

NESTING

OPACITY

ORIENTATION

P1

P2

PAPER AXIS

This command sets the protocol parameters used to initialize the Asynchronous Communications Adapter

(Com Port).

The user may change a plotting parameter previously set by the default values.

Printing done in only one color, usually black.

Placing two or more plots horizontally on the media.

The ability of media to prevent ink from showing through.

The direction of the plotted image on the media; that is, portrait or landscape.

A scaling point used by the plotter that specifies the location of the plot's lower left corner. On the CADJET 2, this point will either be NORMAL or MAX.

A scaling point used by the plotter that specifies the location of the plot's upper right corner. On the CADJET 2, this point will either be NORMAL or MAX.

The long side of the plot area measured at right angles to the platen; that is, the X-Axis or Vertical Axis.

PARALLEL INTERFACE An interface type in which a separate line is used for each data bit in a byte or word and all bits are transferred simultaneously, making it faster than a serial interface.

PARITY A method for checking for errors in the transfer of information between computing devices. Parity checks the accuracy of the binary data on a serial connection.

PLATEN

PLOT AREA

PLOTTER

The surface on which the media moves.

The area in which the plotter prints the image, determined by the width of the media.

An electromechanical device that produces hardcopies of computer data. Typically, this is done by moving the drawing device and/or the media to create lines or filled areas.

POROSITY

PRIME

A measure of the flow of ink or air through the media.

To clear the ink cartridges by forcing them to fire rapidly.

1-22 CADJET 2

General Information

RAM

RASTER IMAGE

REPEATABILITY

RESET

RESOLUTION

ROLLFEED

ROM

RS-422

RS-423

QUADRANTS

SCALING

SCALING POINTS

SERIAL INTERFACE

SERVO

Random Access Memory. Usually temporary electronic storage for data. Data will be lost when power is removed.

A graphic image created by dots called bitmaps. The plot is defined in terms of pixels (dots) rather than as vectors.

Each pixel is defined by a bit. A bit that is “on” will print a dot on the media. A bit that is “off” will leave the area blank.

The act of repeating. In plotting, the ability of a plotter to return to a predetermined location on the plot with a given amount of accuracy.

The plotter’s menu-driven instruction to return the plotter to a predetermined status.

The sharpness of a printed image as measured by dots per inch. The number of dots per unit of area to which the plotter may be addressed.

Media that is packaged on a roll and is loaded and fed through the back of the plotter.

Read Only Memory. Permanent electronic storage for data.

Used to store the plotter's internal instructions. There is no data loss when power is removed.

Differential communication serial port with a mini-Din connector compatible to Apple/Mac.

Single-Ended Communication that requires conversion of the mini-Din to a DB-9 or a DB-25.

Blocks that count data to sequence the ink jet firing.

Dividing of the plotting area into units convenient for the plotting application.

Points which have been assigned user unit values in the

(SC) instruction. These points define the user coordinate system mapped into the area defined by P1 and P2.

An interface type which uses a single data line to transfer all data bits sequentially between devices. Slower than a parallel interface.

A self-correcting closed loop electromechanical system that compares an output signal to an input or feedback signal.

CADJET 2 1-23

General Information

SHEET MEDIA

SKEW

STEPPER

STOP BIT

TRANSDUCER

UART

UNI-DIRECTIONAL

VECTOR

VELOCITY

Media that is packaged in individual sheets and is loaded and fed through the front of the plotter.

The rotation of the media from the initial inserted position

(not the rotational inaccuracy of the initial media loading).

Affects line length accuracy, especially in the paper axis.

May be measured, in the demo plot or any plot, by how far the line on the left margin is different from the line on the right margin. Sometimes referred to as “SLEW.” See

Section 9.0 of this chapter for information about determining the Skew and Chapter 6 for the adjustment procedures.

The media drive motor. The motor rotates one step for each pulse generated by the drive circuit. Position is controlled by the number of pulses generated.

In the RS-422/432 configuration, one or two bits following a transmitted data byte which notify the receiver that the information is complete.

Converts dynamic quantity into voltage.

Universal Asynchronous Receiver/Transmitter. An interface device used between bit serial and bit parallel communications devices.

Cartridges on the plotter fire ink on the media during right to left movement only.

A graphic created by geometric lines. HP-GL and HP-GL/2 files are vector files.

The time-rate of linear motion in a given direction.

Commonly referred to as speed.

1-24 CADJET 2

General Information

Chapter 1 GENERAL INFORMATION 1-1

1.0 Introduction......................................................................................................... 1-1

2.0 Overview............................................................................................................. 1-2

2.1 Related Publications ....................................................................................... 1-2

2.2 Features of this Service Manual...................................................................... 1-3

2.2.1 Subject Headings ..................................................................................... 1-3

2.2.2 Figures and Tables................................................................................... 1-3

2.2.3 Manual Conventions................................................................................. 1-4

3.0 ENCAD Technical Support & Service................................................................. 1-5

4.0 Media Sizes and Plotting Areas.......................................................................... 1-6

5.0 General Product Notes ....................................................................................... 1-9

6.0 Plotter Features ................................................................................................ 1-10

7.0 Plotter Specifications ........................................................................................ 1-14

8.0 Line Length Accuracy ....................................................................................... 1-15

9.0 Skew................................................................................................................. 1-16

10.0 Acronyms and Abbreviations.......................................................................... 1-18

11.0 Glossary ......................................................................................................... 1-19

TABLES

Table 1.1: Media Sizes and Maximum Plotting Areas for Rollfeed Media................... 1-7

Table 1.2: Media Sizes and Maximum Plotting Areas for Sheet Media ...................... 1-8

FIGURES

Figure 1.1: Front View -- Cover Closed ..................................................................... 1-11

Figure 1.2: Front View -- Cover Open ....................................................................... 1-12

Figure 1.3: Back View ............................................................................................... 1-13

Figure 1.4: Line Length Accuracy.............................................................................. 1-15

Figure 1.5: Skew ....................................................................................................... 1-16

CADJET 2 1-25

Chapter 2

THEORY OF OPERATION

1.0 Introduction

This chapter explains the mechanical and electrical theory of the operation of the CADJET 2 Color Inkjet plotter.

The CADJET 2 is a 68340 microprocessor-based digital plotter that receives plotting instructions from a host computer through the

RS-422/423 serial interface or the Centronics parallel interface.

CADJET 2 2-1

Theory of Operation

2.0 Mechanical Operation

2.1 Media Axis Drive

The Media Axis Drive moves the plotting media in a direction perpendicular to the length of the plotter. This friction drive consists of the Stepper Motor, reduction gears, and the Pinch Wheels.

2.2 Carriage Axis Drive

The Carriage Axis Drive moves the plotter Carriage Assembly along the length of the plotter. The drive consists of a Servo Motor, Drive

Belt, and Tensioning Assembly.

The Stepper and Servo Motors are controlled from the main printed circuit assembly by the microprocessor, which also supplies to the

Carriage the signals necessary to cause the ink cartridge nozzles to fire the desired colors of ink onto the media.

2-2 CADJET 2

Theory of Operation

3.0 Electrical Operation

3.1 Circuit Assemblies

Four circuit assemblies are contained in the CADJET 2 plotter: the

Main Printed Circuit Board (in the right cover assembly), the front panel circuits (in the Keypad Assembly), and the Carriage Flex

Assembly and the Carriage Rigid Board (in the moveable Carriage

Assembly).

3.1.1 Main Printed Circuit Board (MPCB)

The Main Printed Circuit Board (MPCB) contains six features:

1. Microprocessor (CPU)

2. Gate Array

3. Memory Circuits

4. Stepper Motor driver

5. Servo Motor driver

6. Interface Circuits: Serial & Centronics Parallel

Front Panel

3.1.2 Front Panel Circuit

The Front Panel Circuit contains two features:

1. Supertwist Display (Liquid Crystal Display, or LCD)

2. Keypad

CADJET 2 2-3

Theory of Operation

3.1.3 Carriage Printed Circuit Assembly

(Carriage PCB)

The Carriage Printed Circuit Assembly (Carriage PCB) contains five features:

1. Registers

2. Demultiplexers

3. Ink Nozzle Drivers (Inkjet Driver Circuit)

4. Linear Encoder

5. Paper Sensor (separate board)

2-4 CADJET 2

Theory of Operation

3.2 Block Diagram

Figure Chapter 2 .1 illustrates the major functional areas of the plotter.

Major control and data paths are shown.

CADJET 2

Figure Chapter 2 .1: Major Functional Areas of the Plotter

2-5

Theory of Operation

3.3 Power Supply

An internal UL recognized switching power module supplies power for the CADJET 2. It provides a constant 5Vdc and 24Vdc output from input voltage in the range of 100~240 Vac. A power switch mounted on the back left end of the platen turns the power on and off. The 24V supply is used for the stepper controller which advances the paper, the servo controller which moves the Carriage and provides power to fire the inkjets. The 5V supply powers the logic circuits.

The DS1233D reset generator IC monitors the 5V power supply and holds

RESET

low for 350ms after the 5V supply reaches 4.375V. When

RESET

goes high, the microprocessor itself will drive it low for an additional 512 clock cycles. If the microprocessor’s 32KHz crystal oscillator is not working, it will hold

RESET

low.

2-6 CADJET 2

Theory of Operation

3.4 Microprocessor

The microprocessor (a Motorola MC68340) is a central processor unit which supervises system functions, executes the plotter firmware, manipulates data, and controls input/output data busses. It has two built-in serial ports, a two channel DMA controller, a timer module, a 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 Keypad/Display module. 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 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.

The phase-locked-loop (PLL) frequency synthesizer generates the

16.777MHz system clock from a 32768Hz crystal reference.

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.

CADJET 2 2-7

Theory of Operation

3.5 Start-up Sequence

Immediately after power-up, the following sequence of events takes place:

1. System registers in the microprocessor are initialized. This includes initializing the clock generator. Prior to this, the clock runs at about half its normal speed.

2. All LEDs are turned on and off. The fan is turned off.

3. The display is initialized and the copyright message is displayed.

4. A checksum of the EPROM is performed.

5. The first four kilobytes of RAM are tested to make sure enough

RAM is working to run the compiled C code.

6. Execution of the compiled C code begins.

7. RAM size is determined, and all RAM is tested. Status information is shown on the display during the test. “Memory OK” is displayed at the end of the test.

8. The code in the EPROM is copied to RAM, and the program begins executing out of RAM.

2-8 CADJET 2

Theory of Operation

3.6 Memory

Memory is used to retain large amounts of information. This information is stored in the device memory in the form of binary bits.

Plotter memory consists of Flash EPROM, RAM, and EEPROM. Flash

EPROM is 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.

RAM is Random Access Memory which provides temporary storage of the microprocessor calculation and input/output data. The plotter control program is also copied from the Flash EPROM to RAM where it can be executed faster.

EEPROM is an Electrically Erasable, Programmable, Read Only

Memory which provides storage for calibration constants and user configuration data entered from the front panel keys.

Maximum usable memory is as follows:

RAM = 68 MB

Flash EPROM = 1 MB

EEPROM = 1KB

CADJET 2 2-9

Theory of Operation

3.7 Flash EPROM

The system firmware is stored in a Flash EPROM. The Flash EPROM allows the firmware to be upgraded by simply downloading a file containing the new firmware. It can be erased and reprogrammed more than 10,000 times. The term “Flash” means that bytes cannot be individually erased. A block or the whole device is erased at the same time and the block or whole device is then reprogrammed.

The plotter is designed to support Flash devices. The 29F040 is a

512Kx8 5V only device. There is an extra socket for another

512Kx8 available.

The normal method of downloading new firmware is to send the plotter a file of the new code. This requires using an appropriate host

utility. This can be done through either the serial or parallel port. This method requires code to be running in the plotter to interpret the file.

If, for some reason, the EPROM is blank or corrupt, there is an alternate method to download firmware to the plotter. This alternate method takes advantage of a feature of the MC68340 processor known as Background Debug Mode (BDM). Background Debug

Mode only works through the serial port and requires a special

host utility. It is a mode that allows some registers and RAM to be written to, based upon commands sent through the serial port. The special host utility provides user instructions as it runs.

2-10 CADJET 2

Theory of Operation

3.8 RAM

The plotter also has two 72-pin 32-bit wide SIMM sockets for RAM.

The plotter is supplied with 4 Megabytes of RAM permanently installed on the Main Board. The following SIMM sizes are supported: 4MB

(1Mx32), 8MB (2Mx32), 16MB (4Mx32), and 32MB (8Mx32). The

SIMMS must have an access time of 70ns or less, and conform to

JEDEC Standard Number 21-C Release 4 or later. Remove the Right

Cover Assembly to install additional memory (see Chapter 5,

Section 4.5 for installation procedures). Refer to the User’s Guide for specifications and requirements.

3.9 EEPROM

An 8K bit serial non-volatile EEPROM stores calibration and configuration information. It retains data while the unit is off.

CADJET 2 2-11

Theory of Operation

3.10 Gate Array

Figure Chapter 2 .2: Gate Array

The gate array contains the hardware logic for dot firing, monitoring changes in the Carriage position, controlling DMA (Direct Memory

Access) through the parallel port, and generating the PWM (Pulse

Width Modulation) waveforms for the servo.

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 upgrading the system software.

The

XDONE

signal is held low by the gate array and all its outputs are in a high impedance state until its programming is complete.

2-12 CADJET 2

Theory of Operation

3.11 Stepper Motor

The media is driven by a Stepper Motor which drives the media in a direction perpendicular to the length of the plotter. The media in the plotter can advance forward and backward, depending upon the commands which the Stepper Motor receives from the microprocessor.

The Stepper Motor drive 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.

The first is a switching power supply, but in this case the current rather than the voltage is regulated. Instead of output capacitors to filter voltage ripple, output inductance in the form of the motor winding filters current ripple. The other type of circuit is a bipolar chopper drive which is commonly used for driving stepper and servo motors.

In both cases, the circuit has the additional feature that the reference varies with time so that a waveform is generated rather than a steady state signal.

CADJET 2 2-13

Theory of Operation

Each circuit contains four main blocks (see Figure Chapter 2 .3):

1. Reference waveform generator

The microprocessor uses a D/A (digital to analog) converter to set the desired level for the current in the stepper motor winding. The output of the D/A converter varies in time to create a reference waveform. This reference waveform is centered around 10V.

2. Motor current sense

The voltage across a series current sense resistor is measured and level shifted so that it is centered around 5V.

3. Compare and control

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.

Figure Chapter 2 .3: Stepper Motor

2-14 CADJET 2

Theory of Operation

3.12 Servo Motor

CADJET 2

Figure Chapter 2 .4: Servo Motor

The Carriage is driven by the Servo Motor. The speed of the Carriage is controlled by varying the duty cycle of the power applied to the controller. The microprocessor checks the position of the Carriage 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 speed. A linear optical encoder (Encoder Strip) is used to monitor the

Carriage position.

The optical codestrip runs the length of the Carriage and contains 150 lines and spaces per inch. Thus there are 300 edges per inch. The detector actually consists of two detectors. They are separated from each other such that one detects edges halfway between where the other detects edges. This is known as a quadrature decoder. It gives an effective resolution of 600 lines per inch. The direction the Carriage 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 moves left and decrements as the Carriage moves right. The hardware counter is only eight bits wide, so it cannot store a value large enough to represent an absolute carriage 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.

2-15

Theory of Operation

3.13 Parallel and Serial Ports

Figure Chapter 2 .5: Parallel and Serial Ports

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.

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 RS422 electrical specifications, and the control signal

(DTRCLK) meets the RS423 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 RS232 devices when an appropriate adapter cable is used. This cable is available from ENCAD. Please refer to Chapter 7 of this Service Manual for the part number.

2-16 CADJET 2

Theory of Operation

3.14 Keypad/Display

Figure Chapter 2 .6: Keypad Display

In addition to the seven dedicated function keys on the plotter Right

Cover Assembly as part of the main board, the front keypad uses four keys to access the menu: main, select, forward (up arrow), and backward (down arrow). The data from the four keys and to the display is encoded on the second serial port of the microprocessor.

The display provides information to the user on plotter status.

CADJET 2 2-17

Theory of Operation

3.15 Carriage Circuits

Figure Chapter 2 .7: Carriage Circuits

The Carriage contains the optical encoder for horizontal position sensing, a Paper Sensor, and the logic and drive circuitry for firing the ink jets.

2-18 CADJET 2

Theory of Operation

3.16 LEDs, Beeper, and Fan

Five LEDs indicate the following conditions: READY, MEDIA OUT,

INK LOW, MONOCHROME, and COLOR MODE. The beeper contains built-in driver circuitry so that it beeps whenever power is applied to it. The beeper alerts the user to error conditions in these categories. The Fan provides suction on the platen bed and holds the paper flat during the plot process.

3.17 Dot Firing Sequence

The following sequence of events occurs for every strip printed:

1. A buffer in RAM is filled with all the firing data for the whole strip.

2. The DMA controller is initialized.

3.

INIT

_

DMA

is set in the gate array. This causes the gate array to initiate the DMA transfer of the 24 bytes of firing data for the first position into the buffer RAM. The last byte of data is the quadrature counter value at which to fire the jets.

4.

ENEQ

is set in the gate array to enable the hardware position comparator.

5. When the Carriage reaches the firing position, the gate array sequences through the thirteen jet positions in the cartridge quadrants. The data in the buffer ram transfers to the Carriage electronics and the appropriate jets fire. The gate array initiates the DMA transfer of the data for the next firing position. This step repeats until the entire strip is printed, then the process repeats, starting at the first step.

3.18 Schematic Diagrams

Engineering schematic diagrams for the Main PCB Assembly, Keypad

PCB Assembly, Carriage PCB Assembly, and the Flex Circuit are located in Appendix D.

CADJET 2 2-19

Theory of Operation

Chapter 2 THEORY OF OPERATION 2-1

1.0 Introduction ........................................................................................................ 2-1

2.0 Mechanical Operation ........................................................................................ 2-2

2.1 Media Axis Drive ............................................................................................. 2-2

2.2 Carriage Axis Drive ......................................................................................... 2-2

3.0 Electrical Operation ............................................................................................ 2-3

3.1 Circuit Assemblies .......................................................................................... 2-3

3.1.1 Main Printed Circuit Board (MPCB).......................................................... 2-3

3.1.2 Front Panel Circuit ................................................................................... 2-3

3.1.3 Carriage Printed Circuit Assembly (Carriage PCB) .................................. 2-4

3.2 Block Diagram ................................................................................................ 2-5

3.3 Power Supply.................................................................................................. 2-6

3.4 Microprocessor ............................................................................................... 2-7

3.5 Start-up Sequence.......................................................................................... 2-8

3.6 Memory........................................................................................................... 2-9

3.7 Flash EPROM............................................................................................... 2-10

3.8 RAM.............................................................................................................. 2-11

3.9 EEPROM ...................................................................................................... 2-11

3.10 Gate Array .................................................................................................. 2-12

3.11 Stepper Motor ............................................................................................. 2-13

3.12 Servo Motor ................................................................................................ 2-15

3.13 Parallel and Serial Ports ............................................................................. 2-16

3.14 Keypad/Display........................................................................................... 2-17

3.15 Carriage Circuits ......................................................................................... 2-18

3.16 LEDs, Beeper, and Fan .............................................................................. 2-19

3.17 Dot Firing Sequence ................................................................................... 2-19

3.18 Schematic Diagrams................................................................................... 2-19

2-20 CADJET 2

Theory of Operation

FIGURES

FIGURE 2.1: MAJOR FUNCTIONAL AREAS OF THE PLOTTER ............................. 2-5

FIGURE 2.2: GATE ARRAY ..................................................................................... 2-12

FIGURE 2.3: STEPPER MOTOR ............................................................................. 2-14

FIGURE 2.4: SERVO MOTOR.................................................................................. 2-15

FIGURE 2.5: PARALLEL AND SERIAL PORTS....................................................... 2-16

FIGURE 2.6: KEYPAD DISPLAY .............................................................................. 2-17

FIGURE 2.7: CARRIAGE CIRCUITS ........................................................................ 2-18

CADJET 2 2-21

Chapter 3

MAINTENANCE

1.0 Introduction

WARNING

This chapter contains general maintenance and cleaning instructions for the CADJET 2 plotter. Refer to Chapter 4 for troubleshooting information.

1. Always disconnect the power cord and the interface cables before cleaning the plotter. An electrical shock hazard may result if these procedures are not followed.

2. Never allow liquids to come in contact with the plotter’s electrical circuitry. Failure to follow this procedure may result in an electrical shock hazard and damage to the plotter.

CADJET 2 3-1

Maintenance

2.0 External Cleaning

CAUTION

Do not use abrasive cleansers of any sort on any area of the plotter. Damage to the surface texture may result.

Clean the exterior surface of the plotter with a soft, damp cloth. For more persistent stains, a small amount of liquid cleaner may be used.

Cleaning intervals are determined by the environment in which the plotter is used.

3-2 CADJET 2

Maintenance

3.0 Slide Shaft Maintenance

CAUTION

Lubrication should not be used on the Slide Shaft. It may damage the Carriage Assembly, the Servo Motor, and/or the Carriage Belt.

USE OF LUBRICATION WILL VOID THE WARRANTY!

An accumulation of dirt or other contamination on the Slide Shaft may result in excessive drag on the Carriage, which will affect the plot quality. It is therefore necesssary to clean the Slide Shaft at regular intervals, as determined by the environmental conditions.

To clean the Slide Shaft:

1. Park the Carriage Assembly in the Service Station.

2. Disconnect the power cord and interface cables from the plotter.

3. Raise the plotter top cover.

4. Moisten a clean cloth or paper wipe with isopropyl alcohol.

5. Wipe the length of the Slide Shaft with the moistened cloth.

CADJET 2 3-3

Maintenance

CAUTION

To prevent damage to the plotter, do not slide the Carriage on the shaft until the alcohol is completely dry.

6. Manually move the Carriage from end to end.

7. Wipe the Slide Shaft with a dry cloth to remove any deposits left by the Carriage.

8. Reconnect the power cord and interface cables and run the

PRIME plot. (See Chapter 4, Section 11.8 for information concerning the appearance of the PRIME plot.) During plotting, make sure that: a. the Carriage Assembly slides freely on the Slide Shaft, and b. there is no Carriage vibration or any noise.

If the Carriage Assembly does not move freely, or if there is

Carriage vibration and/or any noise, clean the Slide Shaft again and repeat the PRIME plot. If the problem is not resolved, refer to

Chapter 4, Section 11.17 “Plotter Carriage Moves Erratically” for additional troubleshooting steps.

3-4 CADJET 2

Maintenance

4.0 Service Station Maintenance

Ink and dust accumulation on the Service Station may affect the print quality. To clean the Service Station:

1. Disconnect the power cord.

2. Raise the Top Cover.

3. Carefully move the Carriage Assembly to the center of the Slide

Shaft.

4. Dampen a cotton swab with warm water and wipe the seals and the rubber wiper to completely remove ink residue and dust accumulation. Also clean all the excess ink out of the reservoirs and out of the bottom of the Service Station.

5. Remove all moisture from the seals and the wiper with a dry swab.

6. Reconnect the power cord.

CADJET 2 3-5

Maintenance

5.0 Encoder Strip Maintenance

Clean the Encoder Strip only as necessary to remove any buildup of debris. Isopropyl alcohol may be used. You may notice that it tends to fog the Encoder Strip; however, no detrimental effect has been observed as of the publication date of this manual. To clean the

Encoder Strip, use a Q-Tip which has been slightly dampened with isopropyl alcohol and wipe along the length of the Encoder Strip on both sides of the Encoder Strip.

3-6 CADJET 2

Maintenance

6.0 Ink Cartridge Maintenance

CAUTION

1. Hold the Cartridges by the green or black area only. Do not let the copper or gold areas come in contact with any surface.

2. When installing the Cartridges, lower them straight down into the Cartridge Covers. Tilting the Cartridges at an angle may cause damage to the Carriage Flex Cable.

3. Tapping Cartridges on any hard surface may jar Cartridge components and cause extreme damage.

6.1 Initial Installation of Cartridges

1. Cartridges can dry out quickly, so keep them in the original containers until ready for installation.

2. After removing the Cartridge from the container, carefully remove the tape from the nozzle area (do not touch nozzle or jet area).

Save the tape and the original container so that they are available in case the Cartridge is removed from the plotter for a prolonged period of time.

3. Lower the Cartridge straight down into the Cartridge Cover and firmly press down and forward so that the Cartridge moves forward slightly. Push the lever up until it stops. When installing the

Tri-Color Cartridge, press firmly on its top as you close the lever.

CADJET 2 3-7

Maintenance

4. Run the PRIME plot and verify that all the jets are firing. The bands should be smooth without dark streaks or white lines. The sloping (diagonal) lines should not look fuzzy or contain gaps. You may need to run the PRIME plot several times. If a satisfactory plot is not obtained, follow the instructions below in Section 6.2.

You may also need to refer to Chapter 4, Section 11.7 “Ink

Cartridge Problems.”

5. After a satisfactory PRIME plot is obtained, perform the Cartridge

Calibration. See Chapter 6, Section 12.0 of this service manual.

3-8 CADJET 2

Maintenance

6.2 Cleaning Cartridges

CAUTION

Do not use alcohol in the nozzle plate area. Alcohol in this area will cause damage to the ink Cartridge.

1. Remove the Cartridge from the Cartridge Holder.

2. Press lightly against the jets with a moistened (with water), lint-free, non-paper cloth (do not use tissues) until ink is released from the Cartridge.

Blot, do not wipe, the jet area. Wiping may damage the jet area.

CAUTION

CAUTION

Gently blot any excess ink, reinstall Cartridge, and run PRIME. It may be necessary to run the PRIME plot several times in order to obtain a satisfactory plot. See Chapter 4, Section 11.8 for information concerning the appearance of the PRIME plot.

3. If the Cartridge continues to misfire, remove the Cartridge again.

Use an ultrasonic cleaner (the type used to clean technical pens or jewelry, typically found in drafting supply stores or department stores) with water (distilled water preferred but not necessary).

Hold the bottom end (nozzle plate end) of the Cartridge in the water.

1. The green end of the Tri-Color Cartridge should never be inserted in the ultrasonic cleaner.

2. Do not allow the Cartridge nozzle plate to rest on the bottom of the ultrasonic cleaner.

CADJET 2 3-9

Maintenance

NOTE

Set the timer for 10-20 seconds, then remove. Dry the Cartridge body (avoid touching the jet area). Reinstall Cartridge and run

PRIME again. Repeat steps as often as necessary to improve

PRIME. After a satisfactory PRIME plot is obtained, perform the

Cartridge Calibration. See Chapter 6, Section 12.0 of this service manual.

4. If priming and the above maintenance procedures fail to unclog a

Cartridge, the Cartridge may be out of ink.

Note: Also see Chapter 4, Section 11.7 “Ink Cartridge Problems”.

3-10 CADJET 2

Maintenance

6.3 Other Causes of Misfiring

Cause

1. Cartridge is not seated properly in the Cartridge Holder.

2. Ink spills (buildup) or other debris on the Cartridge or the

Flex Cable.

Solution

Reinstall Cartridge into the Cartridge Holder.

Lower the Cartridge straight down into the

Cartridge Holder and gently press down and forward so that the Cartridge moves forward slightly. Push the lever up until it stops.

Clean the Flex Cable in the Cartridge Holder and the electrical contact and jet areas on the

Cartridge gently with a Q-Tip moistened with distilled water (tap water is OK if distilled water is unavailable). Do not use Acetone or any other harsh cleaner because these may cause damage to the Flex Cable. If ink buildup continues, replace the Cartridge.

Clean the Service Station. See Section 4.0. 3. Buildup of ink in the Service

Station.

4. Cartridge damage (due to dropping, improper storage, or tapping Cartridge on a hard surface).

If damaged, replace with a new Cartridge.

CADJET 2 3-11

Maintenance

6.4 Storage of Cartridges During Extended Periods of

Inoperation

If the Cartridges are left in the plotter:

1. If the plotter is not used for an extended period of time, it is preferred that the Cartridges remain in the plotter with the Carriage parked at the Service Station. Make sure that the Cartridges are properly capped in the Service Station.

2. When you are ready to use the plotter again, you may need to run the PRIME plot several times. You may need to refer to the procedures above in Section 6.1 “Initial Installation of Cartridge” and in Section 6.2 “Cleaning Cartridges” if the PRIME plot is unsatisfactory.

If the Cartridges are removed for an extended period of time:

1. Blot the ink off the nozzle plate area (the nozzle plate area must be completely dry or the protective tape will not stick).

2. Put the protective tape back on the Cartridge and return the

Cartridge to the original container.

3. Place the container in a plastic bag with the jets facing up so that ink won't drain or leak out, causing clogging.

4. Store the Cartridge in a closed area (desk or storage cabinet) at room temperature for best results. Keep the Cartridge out of direct sunlight and away from heating or air conditioning vents.

They can also be stored in a refrigerator.

5. After stored Cartridges are reinstalled, follow the procedures above in Section 6.1 “Initial Installation of Cartridge.”

6.5 Refilled Cartridges

ENCAD does not recommend or support the use of refilled Cartridges.

3-12 CADJET 2

Maintenance

7.0 Upper and Lower Rollers

WARNING

1. Do not use alcohol or any other cleansers to clean the

Upper and Lower Rollers. Use only distilled water and a lintfree cloth.

2. NEVER attempt to clean the Upper and Lower Rollers by using the plotter’s FEED MEDIA key and the UP or DOWN

ARROWS on the Display Keypad. The cloth could become jammed in the plotter and cause severe damage. ALWAYS disconnect the power cord and manually turn the 96 Teeth

Gear on the Lower Drive Assembly.

In order to prevent erratic media movement during plotting, it is necessary to periodically clean the Upper and Lower Rollers.

To clean the Upper and Lower Rollers:

1. Park the Carriage Assembly in the Service Station.

2. Disconnect the power cord from the plotter.

3. Raise the plotter top cover.

4. Manually turn the 96 Teeth Gear on the Lower Drive Assembly

(the gear is near the Service Station) as you hold a lint-free cloth that has been moistened with distilled water against the rollers.

Do not allow the cloth to slip between the Upper and Lower

Rollers.

CADJET 2 3-13

Maintenance

Chapter 3 MAINTENANCE 3-1

1.0 Introduction ........................................................................................................ 3-1

2.0 External Cleaning ............................................................................................... 3-2

3.0 Slide Shaft Maintenance .................................................................................... 3-3

4.0 Service Station Maintenance.............................................................................. 3-5

5.0 Encoder Strip Maintenance ................................................................................ 3-6

6.0 Ink Cartridge Maintenance ................................................................................. 3-7

6.1 Initial Installation of Cartridges .................................................................... 3-7

6.2 Cleaning Cartridges .................................................................................... 3-9

6.3 Other Causes of Misfiring.......................................................................... 3-11

6.4 Storage of Cartridges During Extended Periods of Inoperation ................ 3-12

6.5 Refilled Cartridges..................................................................................... 3-12

7.0 Upper and Lower Rollers.................................................................................. 3-13

3-14 CADJET 2

Chapter 4

TROUBLESHOOTING

1.0

Introduction

1.

2.

3.

These repair and replacement procedures are intended for trained personnel.

Disconnect the power cord and remove the interface cables before fixing the plotter.

An electrical shock hazard may result if these procedures are not followed.

Never allow liquids to come in contact with the plotter electrical circuitry.

Failure to follow this procedure may result in an electrical shock hazard and damage to the plotter.

This chapter contains the CADJET 2 Decision Logic Tables (DLT’s),

Service Menu information, instructions for using the Front Keypad and

Side Panel keys, and the actions to take when the operation of the plotter does not appear to be normal.

The Decision Logic Tables list possible remedies to various conditions of the plotter.

Information on using the DLT’s is given below in

Section 2.1.

Other information in this chapter covers situations that could not be adequately addressed in a DLT. The Service Menu and the Front and

Side Panel figures aid in the understanding of the plotter tests and how to scroll through the menu.

CADJET 2

4-1

Troubleshooting

2.0

Decision Logic Tables

2.1

Procedure for Using Decision Logic Tables

NOTE

Note: Always check the information at the top of the DLT carefully so that you are aware of any warnings, references to other manuals, any “Begin with” or “Exit to” information, and the assumptions upon which the particular DLT is constructed.

After this information has been reviewed, locate the condition with which you are dealing.

The section of the DLT labeled “CONDITIONS” asks questions concerning various conditions which can be answered “Yes” or “No” (Y or N).

The section of the DLT labeled “ACTIONS” provides actions which can be performed. The actions are listed progressively from simple to complex, with the lowest cost/time factor first. The information is listed in this order: Hardware, Software, Mechanical, and Electrical.

Use the following hypothetical condition to familiarize yourself with the

DLTs.

CONDITION

The media does not load. The plotter is a CADJET 2 and is receiving power.

PROCEDURE

1.

After reviewing all information at the top of Table Chapter 4 .1,

DLT 1, it has been determined that DLT 1 is the proper table to use.

4-2

CADJET 2

Troubleshooting

NOTE

NOTE

2.

Read the conditions listed in the DLT and answer each question.

For this DLT 1, if the answer to the question is “YES” (Y), proceed to the next condition.

Note: In some of the DLT’s, you proceed to the next condition if the answer to the condition is “NO.”

3.

When a question (condition) is answered “NO” (N), look across the row for the letter “N.” Look down the column containing the letter

“N” for the actions to be taken. For our example, “media does not load,” the condition on DLT 1 reads “DOES PAPER LOAD?” and column 7 contains the “NO” answer for this condition.

Note: In some of the DLT’s, if the answer to the condition is “YES,” you look for the letter “Y” in that row and then look down the column containing the “Y” for the actions to be taken.

4.

Look down column 7 for the number 1. The ACTION for the row containing the number 1 in column 7 is “CHECK STEPPER

MOTOR CONNECTOR (JP5).” This is the first action which should be performed to correct the condition of the media not loading.

5.

If the first action does not correct the condition, proceed to the number 2 in column 7. If, after performing the listed action, the condition is not corrected, proceed to the next number in column 7 until one of the actions corrects the condition.

6.

If none of the actions corrects the condition, the last action that will be provided is “CALL ENCAD TECHNICAL SUPPORT.” This does not necessarily mean that you have performed an action incorrectly or that you have misdiagnosed the problem; not every situation can be covered in a DLT.

2.2

Decision Logic Tables

The Decision Logic Tables begin on the next page.

CADJET 2

4-3

Troubleshooting

Table Chapter 4 .1: Decision Logic Table One (DLT 1)

WARNING: OBSERVE ALL STANDARD STATIC AND SAFETY PRECAUTIONS

REFERENCES: CALIBRATION PROCEDURES (USER’S GUIDE & SERVICE MANUAL)

BEGIN WITH:

EXIT TO:

ASSUMPTIONS LISTED BELOW

THE DECISION LOGIC TABLE INDICATED AT THE END OF THIS TABLE

ASSUMPTIONS: 1.

CADJET 2 SERIES PLOTTER

2.

INPUT POWER

CONDITIONS

DOES DISPLAY COME ON?

DOES MEMORY COUNT UP?

DOES EPROM REVISION DISPLAY?

IS CARRIAGE SEQUENCE COMPLETE?

DOES THE KEYPAD FUNCTION?

DOES PAPER LOAD?

DOES FAN POWER UP?

DOES SELF TEST RUN?

Y

Y

Y

Y

Y

Y N

Y

Y

COLUMN NUMBERS

1 2 3 4 5 6 7 8 9

N

N

N

N

N

N

N

ACTIONS

VERIFY INPUT POWER

VERIFY INPUT POWER ON MPCB

RESEAT DISPLAY CONNECTOR (J1)

REPLACE MPCB

CLEAN SIMMS CONTACTS

TEST ANY EXTRA SIMMS AND REPLACE IF DEFECTIVE

REPLACE MPCB

VERIFY MPCB POWER

REPLACE MPCB

INSURE CARRIAGE MOVES FREELY

CLEAN AND INSPECT ENCODER STRIP

VERIFY BELT POSITION

VERIFY TENSIONER SPRING POSITION

RESEAT SERVO MOTOR POWER CONNECTOR (J6)

REPLACE SERVO MOTOR ASSEMBLY

REPLACE MPCB

RESEAT KEYPAD CONNECTOR (J1)

EVALUATE KEYPAD ACTION

VERIFY INSTALLATION OF LATEST EPROM REVISION

REPLACE MPCB

CHECK STEPPER MOTOR CONNECTOR (JP5)

REPLACE STEPPER MOTOR

REPLACE MPCB

RESEAT FAN CONNECTOR (J5)

REPLACE FAN ASSEMBLY

REPLACE MPCB

CALL ENCAD TECHNICAL SUPPORT (see Chapter 1, Section 3.0)

GO TO DECISION LOGIC TABLE 2 (DLT 2) X

3

4

1

2

1

2

3

1

2

5

6

7

3

4

1

2

3

4

1

2

1

2

3

1

2

3

5 4 3 8 5 4 4

X

4-4

CADJET 2

Troubleshooting

Table Chapter 4 .2: Decision Logic Table Two (DLT 2)

WARNING: OBSERVE ALL STANDARD STATIC AND SAFETY PRECAUTIONS

REFERENCES: CALIBRATION PROCEDURES (USER’S GUIDE & SERVICE MANUAL)

BEGIN WITH:

EXIT TO:

DECISION LOGIC TABLE ONE (DLT 1)

DECISION LOGIC TABLE THREE (DLT 3)

ASSUMPTIONS: 1.

CADJET 2 SERIES PLOTTER

2.

POWER ON SEQUENCE OK COLUMN NUMBERS

CONDITIONS

PLOTTER INTERMITTENTLY REBOOTS

INTERNAL FUSE (THERMAL) BLOWS

TRANSIENT INTERMITTENT MPCB FAILURES

SMOKE

1 2 3 4 5

N Y

N

N

N

Y

Y

Y

ACTIONS

CLEAN AND RESEAT ANY EXTRA SIMMS

TEST AND REPLACE ANY EXTRA SIMMS

REPLACE SERVO MOTOR

REPLACE MPCB

VERIFY INPUT POWER QUALITY

CHECK AND REPLACE INPUT XFORMER AS REQUIRED

REPLACE MPCB

POWER OFF AND CALL ENCAD TECHNICAL SUPPORT (see Chapter 1, Section 3.0)

1

2

1

2

1

2

3

3 3 4 1

CADJET 2

4-5

Troubleshooting

Table Chapter 4 .3: Decision Logic Table Three (DLT 3)

WARNING: OBSERVE ALL STANDARD STATIC AND SAFETY PRECAUTIONS

REFERENCES: CALIBRATION PROCEDURES (USER’S GUIDE & SERVICE MANUAL)

BEGIN WITH: DECISION LOGIC TABLE TWO (DLT 2) OR PLOTTING ERRORS

ASSUMPTIONS: 1.

CADJET 2 SERIES PLOTTER

2.

POWER ON SEQUENCE OK

CONDITIONS

CARRIAGE AXIS FAILURE

INTERNAL ERROR # 1

MEMORY HIGH / LOW

MEMORY FULL

CHECKSUM ERROR

PROCESSES BUT DOES NOT PLOT

OVER INK OF MEDIA

POOR VERTICAL LINE QUALITY

POOR HORIZONTAL LINE QUALITY

BANDING

INK SMEARING

COLUMN NUMBERS

1 2 3 4 5 6 7 8 9 10 11 12

N

N

N

N

N

N Y

N Y

N

N

N

N

Y

Y

Y

Y

Y

Y

Y

Y

Y

ACTIONS

VERIFY BELT TENSION

RESEAT SERVO MOTOR POWER CONNECTOR (J6)

CLEAN & INSPECT ENCODER STRIP FOR DAMAGE

REPLACE SERVO MOTOR

REPLACE MPCB

CLEAN & INSPECT ANY EXTRA SIMMS

VERIFY PROPER SIMMS SIZE & SPEED

TEST ANY EXTRA SIMMS & REPLACE IF DEFECTIVE

REPLACE MPCB OR SIMMS SOCKET

SET RASTER MEMORY TO MAX & RESEND PLOT

ADD MEMORY SIMMS

CHECK INPUT POWER CONDITIONING

REPLACE EPROMS

REPLACE MPCB

USE ROLL FEED SOFTWARE DRIVER

SET WAIT TIME TO 5 SECONDS

RUN DEMO PLOT. IF OKAY, CHECK SOFTWARE

RETEST WITH ENCAD SUPPORTED QUALITY MEDIA

RUN VERTICAL CALIBRATION

VERIFY DEAD BAND ADJUSTMENT

SEE CARRIAGE AXIS FAILURE

RUN HORIZONTAL CALIBRATION

VERIFY POSITION & CONDITION OF SLIDER & PATH

VERIFY ENHANCED MODE

VERIFY CARRIAGE HORIZONTAL CALIBRATION

VERIFY PRIME & REPLACE CARTRIDGE AS REQUIRED

VERIFY X/Y CALIBRATION

REPLACE MPCB

CARRIAGE HEIGHT ADJUSTMENT

VERIFY FAN OPERABLE & REPLACE IF REQUIRED

CALL ENCAD TECHNICAL SUPPORT (see Chapter 1,

Section 3.0)

3

4

1

2

5

6

3

4

1

2

1

2

1

2

3

1

2

1

2

1

2

3

1

2

3

4

1

2

5

1

2

5 3 4 3 3 4 3 6 3

4-6

CADJET 2

Troubleshooting

Table Chapter 4 .4: Decision Logic Table Four (DLT 4)

WARNING: OBSERVE ALL STANDARD STATIC AND SAFETY PRECAUTIONS

BEGIN WITH: CONDITIONS

ASSUMPTIONS: 1.

RS422/232 ERROR STATUS

2.

ON LINE SYSTEM CONNECTION

CONDITIONS

I/O ERROR # 0 (NO I/O ERROR HAS OCCURRED.)

I/O ERROR # 10

I/O ERROR # 11

I/O ERROR # 12

I/O ERROR # 13

I/O ERROR # 14

I/O ERROR # 15

I/O ERROR # 16

I/O ERROR # 17

I/O ERROR # 18

I/O ERROR # 19

I/O ERROR # 20

I/O ERROR # 21

1 2

N

N

N

N

N

N

N

N

N

N Y

N

N

3

Y

4

Y

COLUMN NUMBERS

5

Y

6

Y

7

Y

8

Y

9

Y

10

Y

11

Y

12

Y

13

Y

ACTIONS

OUTPUT INSTRUCTION RECEIVED WHILE ANOTHER

OUTPUT INSTRUCTION IS BEING EXECUTED. THE

FIRST IS EXECUTED WHILE THE NEXT

INSTRUCTIONS ARE IGNORED.

CHECK FOR PROPER SYNTAX IN ESCAPE

SEQUENCES.

CHECK FOR VALID CONTROL INSTRUCTION DATA.

VERIFY PARAMETERS DO NOT EXCEED S.C. LIMITS.

TOO MANY PARAMETERS RECEIVED. ADDITIONAL

PARAMETERS AFTER THE CORRECT NUMBER ARE

IGNORED.

CONFIRM MATCHING PARITY AND DATA BITS.

WRONG HANDSHAKE. CHECK DTR

NORM/HARDWIRE.

INPUT BUFFER OVERFLOW. THIS WILL RESULT IN

THE LOSS OF DATA AND PROBABLY AN HP-GL

EMULATION ERROR.

VERIFY CABLE CONFIGURATION.

MATCH BAUD RATE ON PLOTTER AND COMPUTER.

TRY LOWER BAUD RATE.

CHECK FOR EXCESSIVE CABLE LENGTH.

LINE DRIVER/LINE RECEIVER DEFECTIVE.

1

1

1

1

1

1

2

1

2

1

1

2

1

RS422/232 SERIAL XTDA/XRDA FAILURE. (OCCURS

ONLY WITH A LOOP BACK CONNECTOR IN TEST.)

RS422/232 DTR OR CTS TEST FAILURE. (OCCURS

ONLY WITH A LOOP BACK CONNECTOR IN TEST.)

1

1

CADJET 2

4-7

Troubleshooting

3.0

Service Menu

A Service Menu has been built into the plotter firmware to aid in troubleshooting the plotter. You should have received a copy of the

Service Menu chart with this Service Manual. (If you did not receive the chart, please call the ENCAD Help Desk at the number given in

Chapter 1, Section 3.0.) It contains all the necessary instructions for navigating the Service Menu.

At the present time, one Service Menu structure is currently in use, based upon the firmware revision level of the plotter.

Information about the revision level is found by scrolling to the following display, which is located in the SERVICE INFORMATION level of the Service

Menu:

ROM REVISION

CADJet V1.5xx

From time to time, revisions of the firmware may be released by the

Company. These revisions will be available on new releases of the

Utilities Disk and on ENCAD 's Technical Support BBS, which is listed in Chapter 1 of this manual.

The Service Menu has three levels or submenus.

Detailed descriptions of these three levels are given in Section 4.0 below.

4-8

CADJET 2

Troubleshooting

4.0

Service Menu Description

NOTE

Note: Consult your copy of the Service Menu chart for instructions for navigating the Service Menu. If you did not receive the chart, please call the ENCAD Help Desk at the number given in Chapter 1, Section 3.0.

The Service Menu begins at the following display:

UTILITIES

SERVICE

This option has three levels or submenus: z z z

SERVICE INFORMATION,

SERVICE DIAGNOSTICS, and

SERVICE CALIBRATION.

CADJET 2

4-9

Troubleshooting

4.1

Service Information

SERVICE

INFORMATION

This level provides information about the User

Settings. There are two sub-levels: z z

INFORMATION DISPLAY SETTINGS and

INFORMATION PRINT SETTINGS.

4.1.1

Information Display Settings

INFORMATION

DISPLAY SETTINGS

DATE:

TIME:

XX-XX-XX

XX:XX:XX

This option displays only the current user’s User

Settings.

(No changes can be made to the User

Settings from the Service Menu. Changes must be made in the USER SETTINGS level of the Main

Menu.)

Current time and date settings in use.

ROM REVISION

CADJet V1.5xx

Shows current CADJET 2 Revision Level.

RELEASE INFO

REV 1.5xx ROM

TOTAL MEMORY

XXXXXXXX BYTES

Shows the release date of the current firmware.

Shows the number of bytes available.

MEMORY CONFIG

I / O =128K RAS=3M

Shows buffer memory bank and raster memory available.

EMULATE LANGUAGE

HPGL2

Shows the Emulation Language in use.

The

CADJET 2 is programmed for HP-GL and HP-GL/2.

4-10

CADJET 2

BAUD RATE

9600

PARITY

EVEN,7BITS

HANDSHAKE

HARDWIRE

Troubleshooting

Shows the number of bits per second that are transmitted or received.

Reports voltage fluctuations or memory chip failure.

Allows time for processing hardwire communication.

DTR

NORMAL

FIRING RATE

5000

If DTR=NORMAL, Data Terminal Ready for information; if DTR=BYPASS, data transfer start or stop is sent to the buffer via the transmit receive lines.

PRINT MODE

NORMAL

Shows draft, normal, quality, or enhanced line resolution.

PRINT DIRECTION

BI

Shows choice of bi-directional or uni-directional jet firing.

PRINT COLOR

COLOR

Shows the method of printing, including dots per inch.

Options are: MONO 300X300, GRAY 300X300,

COLOR 300X300, MONO 600X600, and GRAY

600X600.

Shows the current speed at which the ink is fired onto the media in 100 Hz increments from 3000 Hz to

10,000 kHz.

CADJET 2

4-11

Troubleshooting

4-12

MAX PWM/POSITION

14 84 0

PWM/SATURATION

0 245 0 -1

STOP/MAX/DISABLE

0 50 0

The first number shows the currently recorded maximum PWM (Pulse Width Modulator) value, which is a value between zero and 255.

The second number refers to the Encoder position where the error occurred.

(There are 600 Encoder units per inch.)

The third number is the maximum duration of time (in milliseconds) that the threshold PWM has been reached.

Shows the current PWM as last viewed. You can go into this display while the plotter is running to view the power being applied to the Servo Motor.

The first number is a signed value (positive or negative, depending upon which direction the motor is going).

The second number is the threshold PWM, which is always 245 in the current firmware version.

The third number tells the current state of the

Carriage: 0 = stopped, 1 = accelerating, 2 = moving at constant speed, and 4 = decelerating.

The fourth number is the filtered velocity in Encoder units per millisecond.

A negative number indicates left to right movement and a positive number indicates right to left movement.

(If you multiply

Encoder units per millisecond by 1,000 and divide by

600, the result is inches per second.)

The first number shows the current stopped time.

This will usually be zero unless there has been a failure (Carriage Axis Failure).

The second number is the maximum amount of time in milliseconds that an error will be allowed to continue past the time at which the threshold PWM was reached before the unit shuts down.

The third number is usually at zero unless a function is being performed (such as cutting the paper) during which the shutdown criteria are disabled.

CADJET 2

ERROR/CMD/POS

0 0 0

Troubleshooting

If an error occurs, this display provides information which shows the type of error.

It also shows the command and Encoder position where the error occurred. If you have an unexplained error and need to call ENCAD’s Technical Support department, this display can give the technician more information to enable the error to be diagnosed.

Displays how long the plotter has been turned on.

ON TIME

XX:XX:XX

PLOT TIME

XX:XX:XX

Records the time used on plotter.

4.1.2

Information Print Settings

INFORMATION

PRINT SETTINGS

This option prints all eight stored User Settings.

Media must be loaded in order to print them.

CADJET 2

4-13

Troubleshooting

4.2

Service Diagnostics

SERVICE

DIAGNOSTICS

This level contains the following firmware tests to detect and isolate plotter malfunctions:

Paper Sensor

Serial Port

Parallel Port

Cartridge

Carriage Vibration

Color Test

Key Pad

LCD

LED

ROM

RAM

Speaker

Servo Motor

Paper Motor

Fan

DIAGNOSTICS

PAPER SENSOR

This option tests the Paper Sensor and reports the available plotting area in inches and millimeters.

DIAGNOSTICS

SERIAL PORT

This option tests the serial port and reports any errors. You must have the Loopback plug in place

to perform this test.

DIAGNOSTICS

PARALLEL PORT

DIAGNOSTICS

CARTRIDGE

DIAGNOSTICS

CARRIAGE VIBRATE

This option tests the parallel port and reports any errors. You must have the Loopback plug in place

to perform this test.

This option tests the Cartridges by printing a test pattern (PRIME).

This option tests the Carriage vibration by printing a test pattern which consists of five sets of three parallel lines.

4-14

CADJET 2

DIAGNOSTICS

KEYPAD

DIAGNOSTICS

LCD

DIAGNOSTICS

LED

DIAGNOSTICS

ROM

DIAGNOSTICS

RAM

DIAGNOSTICS

SPEAKER

DIAGNOSTICS

SERVO MOTOR

Æ

DIAGNOSTICS

COLOR TEST=XX%

Troubleshooting

Four 1” bands of each color in various saturations can be printed.

This allows you to try different percentages of ink with different media, and tests for the accuracy of the saturation level. This test is also useful in determining whether the Carriage height is tilted.

This option causes any one of the four keys on the

LCD keypad to beep if the key tests OK.

This option causes the LCD to briefly display two rows of 16 eights if the LCD tests OK.

This option causes all the lights on the plotter to light for two seconds (note that the lights for READY and either MONO or COLOR are always lit).

This test returns a value of OK or ERROR.

This test returns a value of OK or ERROR.

This option causes the speaker to sound for one second.

This test gives the option of testing the Servo Motor at either slow or fast speed. You can enter the number of cycles for the Servo Motor test (500 is recommended).

CADJET 2

4-15

Troubleshooting

DIAGNOSTICS

PAPER MOTOR

Æ

DIAGNOSTICS

FAN

This test feeds the paper (media) forward a specific number of inches (do not exceed 5 inches) in either slow or fast speed.

This option will start the Fan. The Fan will run until the SELECT key is pressed.

4-16

CADJET 2

Troubleshooting

4.3

Service Calibration

SERVICE

CALIBRATION

This level contains firmware instructions for performing the electrical calibration of the plotter.

See Chapter 6, Sections 9.0 through 14.0 of this manual for the procedures for performing the electrical calibration.

CALIBRATION

DEADBAND=XX

CALIBRATION

VERT LINES(ONE)

CALIBRATION

VERT LINES(ALL)

This option prints the deadband test and allows the value to be changed.

This option prints two 1-1/2” vertical lines within each of the 16 regions in uni-directional mode.

This option prints two 1-1/2” vertical lines within each of the 16 regions in bi-directional mode.

CALIBRATION

SLOW DEADBAND

This option prints 1 line of deadband across all 16 regions.

CADJET 2

4-17

Troubleshooting

5.0

LED Keys

Ready

Media Out

Indicates that the plotter is on-line.

Blinks when processing data or printing.

Indicates that the plotter is out of media.

Ink Low

Mono/Color

Offline/Reset

Load

Indicates that an ink cartridge has reached the Ink Low level set by user.

Indicates whether the plotter is set for monochrome or color printing.

Pressing Offline/Reset once takes the plotter offline and allows you to load media, replace cartridges, clear paper jams, or perform other maintenance. All plotter keypad and menu functions are available while plotter is offline.

The current plot continues when Offline/Reset is pressed again. To reset the plotter and clear the print buffer, you press

Offline/Reset once, use the UP

ARROW to choose RESET=YES, and then press SELECT.

Access Cartridges

Moves the Carriage out of the

Service Station.

Prime

Fires the Cartridges to help clear the inkjets.

Cut

Feed Media

Cuts roll media.

Interacts with display and arrow keys to move media forward or backward.

Loads and positions the media for printing.

4-18

Figure Chapter 4

.1: LED Keys

CADJET 2

Troubleshooting

6.0

LCD Keypad

z

The plotter goes into sleep mode after 7 minutes of inactivity.

Pressing any key puts it into ready mode.

z

Press the MENU key to return to a previous menu level.

z Use the ARROW keys to scroll through the menus and options.

z Press SELECT to choose a menu, or to change and save a setting in displays with an equals sign (=).

To change a setting, press SELECT once (equals sign blinks) and use the

ARROW KEYS to scroll through the choices. Press SELECT to save your choice (blinking stops).

z

Submenu items with an arrow (

Æ

) have additional submenus.

MENU

SELECT

MAIN MENU

PRINT MODE

Figure Chapter 4 .2: LCD Keypad

CADJET 2

4-19

Troubleshooting

7.0

Keypad Messages

The Keypad and LCD display messages will be of considerable help in determining the status of the plotter and possible corrective action when operation does not appear to be normal. See Sections 5.0 and

6.0 to understand how the keys function.

7.1

Plot Received

PLOT RECEIVED

UNABLE TO CHANGE

This indicates that the user has attempted to make a change to the plotter parameters after the plot data has been received. Plotting parameters must be set prior to the data transmission. When you set each of the parameters, be sure to press SELECT to save the settings.

7.2

Drying Plot

x MIN

DRYING PLOT x SEC

With Roll-Feed enabled, the plotter waits a specified amount of time before cutting the media and allowing the plot to fall. If cut sheet media is being used, there will be no plotter action after the dry-time elapses.

The user may release the media at any time.

7.3

Insert Media

INSERT MEDIA

USE LOAD KEY

Data has been received, but no media has been loaded. Load media for plotting.

7.4

Memory Full

MEMORY FULL

PRESS ANY KEY

The I/O buffer has overflowed. The plot being sent will probably not be complete.

Buffer allocation should be reset. If this does not resolve the problem, increase the buffer memory by upgrading the SIMMS module to a larger size (maximum of 64MB). Refer to the CADJET 2 User's Guide for the acceptable sizes, manufacturers, and installation procedures.

4-20

CADJET 2

Troubleshooting

7.5

RAM OK

RAM OK:

REV X

4MB

The plotter stops at this point in the initialization sequence and does not display the LOAD message on the display. This may indicate a RAM error (see

Section 10.0 of this chapter), even though the RAM test has indicated RESULT=OK.

Check the RAM installation on the Main Printed Circuit Board. Make sure that the RAM is fully seated.

Incompatible

SIMMS may also cause this problem.

See the

CADJET 2 User’s Guide for acceptable SIMMS sizes and the replacement procedure.

7.6

Checksum Error

CHECKSUM ERROR

A Checksum error during the initialization sequence is an indication of a probable ROM error.

The Main

Printed Circuit Board must be replaced.

Refer to

Chapter 5, Sections 4.3 of this manual for the replacement procedures.

7.7

Plotter Error

PLOTTER ERROR

CARRIAGE AXIS

The Carriage has stopped moving in its normal direction due to an obstruction such as a paper jam or a hand in the way. Turn the plotter OFF and remove any obvious obstruction and the media.

Turn the plotter ON, load new media, and resend the plot. If this same message appears, call ENCAD's Technical

Support and Service department at the number listed in Chapter 1, Section 3.0 for further instructions.

7.8

Ready to Replot

READY TO REPLOT

XXXXX

For cut sheet only. This display indicates the plotter is ready to generate another copy of the same image which has already been transmitted to the plotter and printed. This display will remain until a piece of cut sheet media is loaded.

Line two of the display indicates the quantity of replots remaining.

CADJET 2

4-21

Troubleshooting

8.0

Initialization Sequence

A variety of checks are automatically performed by the plotter. When power is connected, the initialization process begins. The plotter will briefly display a copyright message and then start the internal initialization. The Fan will turn on and the Carriage will move from right to left and back to the Service Station. The first message reads:

ROLL=OFF CUT=ON

SAVE MEDIA=ON

The Carriage will then move across the plotter, engage the Cutter and move back to the Service Station, cutting the media if a roll of media is installed.

At this point the initialization sequence is complete, and the plotter will wait for user input or action. If the sequence is interrupted and is not completed, or if any error messages are displayed, refer to the

Decision Logic Tables in Section 2.2 of this chapter for corrective action.

When the plotter is not used for seven minutes, it will go into “sleep” mode. Pressing any key or sending data to the plotter will wake it up.

4-22

CADJET 2

Troubleshooting

9.0

RS-422/RS-232 Error Messages

The following error messages can appear as a result of communication problems.

Reference Section 11.3.1 for the Parallel

Interface and Serial Interface Loop Back Tests.

ERR 0

ERR 10

ERR 11

ERR 12

ERR 13

ERR 14

ERR 15

ERR 16

ERR 17

ERR 18

ERR 20

ERR 21

No I/O error has occurred.

Output instruction received while another output instruction is being executed. The first is executed while the next instructions are ignored.

Invalid byte received after the first three characters,

ESC., in a device control instruction.

Invalid byte received while parsing a device control instruction.

The parameter containing the invalid byte and all following parameters are defaulted.

Parameter out of range.

Too many parameters received. Additional parameters after the correct number are ignored.

A framing error, parity error, or overrun error has occurred.

Input buffer overflow. This will result in the loss of data and probably an HP-GL emulation error.

Baud rate mismatch.

I/O error indeterminate.

RS-422/RS-232 serial xtda/xrda failure.

(Occurs only with a loop back connector in test.)

RS-422/RS-232 DTR or CTS test failure. (Occurs only with a loop back connector in test.)

CADJET 2

4-23

Troubleshooting

10.0 RAM Error

At Initialization, a message of RAM HIGH or RAM LOW may appear for one of the following reasons:

1.

The most common cause of this message is the incorrect installation of any extra RAM (SIMMS). Refer to the removal and replacement procedures in Chapter 5, Section 4.5 and check the

SIMMS installation if any extra RAM was installed on the plotter.

2.

The SIMM may be defective or not compatible with the plotter circuits. The SIMM type needs to meet parity by 8 or 9 bits and the speed needs to be 70 nanoseconds or faster.

See the

CADJET 2 User’s Guide for information concerning the acceptable

SIMMS sizes and the replacement procedure in Chapter 5,

Section 4.5 of this service manual.

3.

The socket on the MPCB may be defective. In this case, replace the MPCB according to the procedure in Chapter 5, Section 4.3.

4-24

CADJET 2

Troubleshooting

11.0 Operation Problems

The information in this section will help to solve a variety of operational problems which may occur with the CADJET 2 plotter.

Follow the procedures carefully. Establish a logical procedure for troubleshooting by referencing the Troubleshooting Chart in Section 2.0 of this chapter.

11.1

Plotter Does Not Turn On

1.

Make sure the AC power cord is securely connected to the plotter and to a functioning AC outlet.

2.

Disconnect the Power Cable from the JP1 connector on the MPCB

(see Chapter 5, Sections 4.1 and 4.2.) and check for voltage coming out of the Power Cable. If there is voltage, the fuse on the

Power Supply is good. If there is not voltage, you need to check the fuse (Step 3 below).

3.

Turn off power and disconnect the power cord. Make sure the fuse on the Power Supply is good. See Chapter 5, Section 9.0.

Use only a 250 Volt 2 Amp Fast Blow fuse, 5mm x 20mm. (Be

careful not to mistakenly use a 32 Volt fuse.)

CADJET 2

4-25

Troubleshooting

11.2

Plotter Slow to Initialize

If the plotter takes an excessive amount of time (30 seconds or more) to complete the initialization sequence:

1.

If any extra SIMMS has been installed: a.

The SIMMS contacts may need to be cleaned.

Clean the

SIMMS contacts.

b.

The SIMMS may be defective. Replace the extra SIMMS if cleaning the contacts does not improve the performance.

See Chapter 5, Section 4.5 for the procedures for replacing the SIMMS.

c.

If performance is not improved after replacing the extra

SIMMS, the SIMMS socket may be defective. In this case, you must replace the MPCB. See Chapter 5, Section 4.3.

2.

there may be a defective Flash EPROM on the Main Printed

Circuit Board.

Because the Flash EPROM is soldered to the

MPCB, it is necessary to replace the MPCB. Refer to Chapter 5,

Section 4.3 of this manual for the removal and replacement procedures for the MPCB.

4-26

CADJET 2

Troubleshooting

11.3

Plotter Will Not Plot

1.

CAUTION

2.

Do not press the Cartridge downward too hard. This could damage the Cartridge Covers.

When installing the Cartridges, lower them straight down into the Cartridge Covers. Tilting the Cartridges at an angle may cause damage to the Carriage Flex Cable.

1.

Make sure the ink cartridges are properly seated.

The most common cause of plot failure is that the ink cartridges are not fully seated in the Cartridge Covers.

The copper area on the

Cartridges must be in contact with the flex cables at the back of the Carriage Assembly.

Pull the levers downward to open the

Cartridge Covers and remove the Cartridges. When reinstalling them, lower them straight down into the Cartridge Covers and gently push down and forward so that the Cartridges slide forward slightly. Push the levers up until they stop (do not use excessive

force).

2.

Check for a loose interface Trailing Cable at the Carriage

Assembly or at the Main PCB.

See Chapter 5, Section 8.6 for correct installation procedures.

3.

Make sure the system is properly initialized. See Section 8.0 in this chapter.

You may need to perform the interface test described in Section 11.3.1 of this chapter.

CADJET 2

4-27

Troubleshooting

4.

Verify communication between the plotter and the computer by transmitting the following BASIC program to the plotter (character codes are enclosed in [ ] ):

[ESC]%-1BBPIN;SP1;PA500,500;

LBPLOTTER/INTERFACE TEST OK[CHR$(3)]

SP0;PA0,0;PG;

The plotter should print out “Interface Test OK.” Did the plot run correctly?

If YES: the plotter and the computer are properly communicating.

If NO: check the settings of the plotter interface. Correct any settings, cycle the power to the plotter, and run the test again. If the plot fails again, have the interface cable and computer’s interface card tested.

5.

Run the Demo Plot from MAIN MENU DEMO PLOT on the plotter.

If the plot runs correctly, the problem is not in the plotter.

4-28

CADJET 2

CADJET 2

Troubleshooting

11.3.1

Parallel Interface and Serial Interface Tests

If communications problems exist with the parallel interface or serial interface, a test of the plotter's internal parallel or serial interface circuits may be performed. This "Loop Back Test" will verify that the parallel or serial communications circuits of the plotter are functioning correctly. See Figure Chapter 4 .3. This test requires the use of a

Centronics plug (for the parallel test) or an 8-PIN plug (for the serial test), both made according to the directions in Figure Chapter 4 .3. To perform the test, proceed as follows:

1.

Remove the interface cable from the rear of the plotter.

2.

Insert the plug into the interface connector.

3.

Advance the menu on the plotter to the SERVICE DIAGNOSTICS display. Press SELECT. Press the DOWN ARROW once to go to

DIAGNOSTICS SERIAL PORT display, or press the DOWN

ARROW twice to go to the DIAGNOSTICS PARALLEL PORT display.

(Refer to the CADJET 2 Service Menu chart if necessary.)

4.

At either the DIAGNOSTICS SERIAL PORT display or the

DIAGNOSTICS PARALLEL PORT display, press SELECT and observe the display on the keypad.

If it displays

RESULT=ERROR, the communications circuits are not communicating correctly and the Main PCB must be replaced.

5.

If it displays RESULT=OK, then the communications circuits of the plotter are functioning correctly. The interface problem is in the configuration of the plotter, or in the parallel or serial interface cable, or in the external circuits.

4-29

Troubleshooting

4-30

Figure Chapter 4 .3: Parallel and Serial Loop Back Tests

CADJET 2

Troubleshooting

11.4

No Movement in the Carriage Axis

1.

Is power applied to the plotter?

2.

Is the front panel display ON?

If NO: a.

Check the Keypad cable’s connection (J1) to the

Main Printed Circuit Board. Be certain that it is fully seated. See Chapter 5, Section 6.2.

b.

Disconnect the Power Cable from the JP1 connector on the MPCB (see Chapter 5,

Sections 4.1 and 4.2.) and check for voltage coming out of the Power Cable. If there is voltage, the fuse on the Power Supply is good. If there is not voltage, you need to check the fuse (Step d below).

c.

Check for voltages at the Main Printed Circuit

Board.

d.

Turn power off and disconnect the power cord.

Check the fuse on the Power Supply.

See

Chapter 5, Section 9.0. Use only a 250 Volt 2 Amp

Fast Blow fuse, 5mm x 20mm. (Be careful not to

mistakenly use a 32 Volt fuse.)

If YES: Is the CARRIAGE AXIS FAILURE message displayed?

a.

Turn off the plotter and then turn it on again to see if the same message appears.

If YES: Make sure that nothing is blocking the movement of the Carriage Assembly. Turn off the plotter and move the Carriage

Assembly from left to right to make sure it moves freely.

CADJET 2

4-31

Troubleshooting

4-32

If the Carriage Assembly does move freely, but the CARRIAGE AXIS FAILURE message is still displayed after powerup:

1) The Servo Motor needs to be replaced.

See Chapter 5, Section 5.0

for the removal and reinstallation procedures.

2) The MPCB Servo Driver may be defective.

Replace the MPCB.

See

Chapter 5, Section 4.3.

If the Carriage Assembly does not move freely, check the following:

1) The Cutter Wheel may be engaged

(down) and is interfering with Carriage

Assembly movement.

2) The Carriage Belt tension may be incorrect. See Chapter 5, Section 8.8.

3) The Slide Shaft may be dirty.

See

Chapter 3, Section 3.0

for cleaning procedures.

4) There may be debris on the Encoder

Strip.

See Chapter 3, Section 5.0 for cleaning procedure.

5) The Upper Roller Supports may be at an angle and are hitting the Carriage

Assembly. See Chapter 5, Section 14.0

if they need to be replaced.

6) There may be a loose bushing on the

Carriage Assembly.

See Chapter 5,

Section 8.0 for instructions on removing the Carriage Assembly so this can be checked.

7) The Carriage Height may not be correct.

See Chapter 6, Section 6.2.

CADJET 2

Troubleshooting

If NO: the problem is most likely in the Servo

Motor, the Main PCB, or the Encoder strip.

1) Check the Trailing Cable connections.

See Chapter 5, Section 8.6.

2) Replace the Servo Motor.

Chapter 5, Section 5.0.

See

3) If replacing the Servo Motor doesn’t correct the problem, replace the MPCB.

See Chapter 5, Section 4.0.

4) If the problem is not solved after both the Servo Motor and the MPCB are replaced, replace the Stabilizer Bracket

Assembly, which contains the Encoder

Strip. See Chapter 5, Section 10.0.

CADJET 2

4-33

Troubleshooting

11.5

Media Problems

11.5.1

Cut Sheet Media Won’t Load

If cut sheet media won’t load:

1.

Check to see if the plotter is set for roll-feed media.

From the Main Menu, press one of the arrow keys to advance to the display shown below:

MAIN MENU

PRINTER SETUP

Press SELECT and press the DOWN ARROW three times. If the following display appears,

PRINTER SETUP

ROLL=ON

the plotter is set for roll-feed media and needs to be changed for cut sheet. To change the setup, press SELECT (the equals sign

(=) will blink) and one of the arrow keys so that the display reads as follows:

PRINTER SETUP

ROLL=OFF

Press SELECT to save the change (the equals sign (=) will stop blinking).

Align a sheet of media on the Platen and press the

LOAD button. The media will be sized and pulled to the back of the plotter until it reaches the starting position on the Platen.

4-34

CADJET 2

Troubleshooting

2.

In media with a preprinted border, the optical sensor on the

Carriage Assembly may sense the preprinted border as the edge of the media if the preprinted border is too wide. Use the Manual

Load function (see Chapter 2 in the CADJET 2 User’s Guide for instructions).

3.

Certain media types may cause difficulty in loading.

Use the

Manual Load function (see Chapter 2 in the CADJET 2 User’s

Guide for instructions).

4.

The paper sensor may be defective. As an intermediate measure, use the Manual Load function. See Chapter 2 in the CADJET 2

User’s Guide for instructions. In order to test the paper sensor, see Chapter 6, Section 6.5 for the Paper Sensor Potentiometer

Adjustment.

If it fails this adjustment, replace the Carriage

Assembly.

See Chapter 5, Section 8.0 for the removal and installation procedures.

CADJET 2

4-35

Troubleshooting

11.5.2

Media Feeds Out of Plotter When Plot is

Completed

If the plotter feeds the media out of the plotter after the plot is completed, there are three possible causes: a.

The media has been loaded incorrectly. The narrower edge of the media must be placed under the rollers when the media is loaded.

The plotter determines media size by checking the narrow edge of the media. Rotate the media and load again.

b.

Non-standard media has been loaded.

The plotter determines media size by measuring the width and makes a determination of the length based upon standard media sizes. Refer to Tables 1.1

or 1.2 in Chapter 1 for acceptable sizes.

Example: Set the plotter to MEDIA=ARCH if you use “C” size

Architectural media.

c.

Paper Axis Calibration is out. Perform the Paper Axis Calibration in Chapter 6, Section 10.2.

d.

Image is too small for paper size selected in application.

Set

SAVE MEDIA=ON on the plotter.

11.5.3

Media Skews or Ripples

If the media skews or ripples as it moves through the plotter, there are two possible causes: a.

The media was not loaded properly.

Remove the media and carefully load it again.

b.

The Upper Roller Supports which hold the media have become dirty, misaligned or excessively worn.

Refer to the alignment procedures in Chapter 6, Sections 7.0 and 8.0 and/or to the removal and replacement procedures in Chapter 5, Section 14.0

of this manual.

4-36

CADJET 2

CADJET 2

Troubleshooting

11.5.4

Loaded Media Not Detected, Media Size Not

Detected, or Plotter Has Incorrect Plot Area

If the plotter doesn’t detect that media is loaded, doesn’t sense the media size, or has an incorrect plot area, there are five possible causes: a.

In some cases, the CADJET 2 will not sense or correctly size certain media, whether roll-feed or sheet media. If this happens, use the Manual Media Loading feature in the Advanced menus.

Refer to Chapter 2 of the CADJET 2 User’s Guide for the procedure.

b.

The optical sensor circuit (Paper Sensor) may be defective, or a connector may be loose.

Go to the SERVICE DIAGNOSTICS

Menu and run DIAGNOSTICS PAPER SENSOR. You will need to replace the Carriage Assembly if the Paper Sensor is not working properly.

Refer to the Disassembly/Assembly procedures in

Chapter 5, Section 8.0.

c.

The Slide Shaft may be set incorrectly. Check the alignment of the Carriage. Refer to Chapter 6, Sections 6.0, 6.1, and 6.2 of this manual for the Cartridge Head Height.

d.

The Paper Sensor voltage may be set incorrectly. See Chapter 6,

Section 6.5 “Adjustment of the Potentiometer” for the testing and correction procedures.

e.

The Trailing Cable may be defective. See Chapter 5, Sections 8.5

and 8.6 for the removal and installation procedures.

4-37

Troubleshooting

11.5.5

Keypad Display Shows LOAD MEDIA Message

When Rollfeed Media is Loaded

If the Keypad Display shows a LOAD MEDIA message, but you have rollfeed media loaded, the plotter may not be configured for roll media.

From the Main Menu, press one of the arrow keys to advance to the display shown below:

MAIN MENU

PRINTER SETUP

Press SELECT and press the DOWN ARROW three times.

If the following display appears,

PRINTER SETUP

ROLL=OFF

the plotter is set for cut sheet media and needs to be changed for rollfeed. To change the setup, press SELECT (the equals sign (=) will blink) and one of the arrow keys so that the display reads as follows:

PRINTER SETUP

ROLL=ON

Press SELECT to save the change (the equals sign (=) will stop blinking). Align the rollfeed media on the Platen and press the LOAD button.

4-38

CADJET 2

CADJET 2

Troubleshooting

11.5.6

Loud Grinding Noise When Media Loads

a.

Loose Drive Shaft Support Brackets. Check to see if the brackets are secured firmly to the Platen. Refer to Chapter 5, Section 11.4

(Figure 5.26) if necessary.

b.

The large 96 Teeth Gear may on the Lower Drive Assembly may be broken.

See Chapter 5, Section 11.0 for instructions for replacing the Lower Drive Assembly.

c.

The Stepper Motor may be defective.

Go to the SERVICE

DIAGNOSTICS Menu and perform the DIAGNOSTICS PAPER

MOTOR test to run the motor from 0 to 1 inches (do not exceed

1 inches) for error results.

If the test runs correctly, this is not causing the grinding noise.

If the test does not run correctly, replace the Stepper Motor. See Chapter 5, Section 11.3 for the replacement procedure. You should also take into consideration the possibility that the Gear on the Stepper Motor may be broken, in which case the Stepper Motor will need to be replaced.

d.

The MPCB Stepper Driver may be defective. Replace the MPCB.

See Chapter 5, Section 4.3.

e.

Defective ROM or RAM.

Go to the SERVICE DIAGNOSTICS menu and perform the ROM and RAM tests to obtain an OK or

ERROR message.

If the read-out is RESULT=OK, this is not causing the grinding noise.

For the ROM test, a read-out of RESULT=ERROR could indicate:

1.

that the Flash EPROM has failed. Replace the MPCB. See

Chapter 5, Section 4.3 for the procedure.

2.

the socket on the MPCB is defective. Replace the MPCB.

See Chapter 5, Section 4.3 for the procedure.

4-39

Troubleshooting

For the RAM test, a read-out of RESULT=ERROR could indicate:

1.

Any extra SIMMS may be installed incorrectly or not fully seated. See Chapter 5, Section 4.5 for the procedure.

2.

The extra SIMMS may be defective or not compatible with the plotter circuits.

See the User’s Manual for information concerning the acceptable SIMMS sizes.

See Chapter 5,

Section 4.5 for the replacement procedure.

3.

The socket on the MPCB may be defective.

Replace the

MPCB. See Chapter 5, Section 4.3 for the procedure.

4-40

CADJET 2

Troubleshooting

11.6

Media Cutting Problems

NOTE

Note: Certain media is more abrasive than other types of media.

Media which is very abrasive (such as canvas) may shorten the life of the Cutter Wheel.

If the cut edges of the media are ragged, or the cut is not complete across the media, you need to replace the Cutter Wheel. This part is available from your local authorized dealer, or directly from ENCAD.

CADJET 2

4-41

Troubleshooting

11.7

Ink Cartridge Problems

1.

WARNING

2.

Ink used in the Cartridges may be harmful if swallowed.

Avoid getting ink in the mouth. Keep Cartridges away from small children.

Use the ACCESS CARTRIDGES button on the LED panel to move the Carriage.

Do not move the Carriage by hand.

Damage to the Carriage may result.

Table Chapter 4 .5: Decision Logic Table Five (DLT 5)

WARNING: OBSERVE ALL STANDARD STATIC AND SAFETY PRECAUTIONS

BEGIN WITH: ASSUMPTIONS LISTED BELOW

ASSUMPTIONS: 1.

CARTRIDGE NOT DAMAGED BY DROPPING, IMPROPER STORAGE, OR TAPPING

ON A HARD SURFACE. (REPLACE IF DAMAGE IS SUSPECTED OR KNOWN.)

2.

CARTRIDGE IS NOT OUT OF INK. (SEE “Determining Ink Level” BELOW TO

DETERMINE WHETHER CARTRIDGE IS OUT OF INK.) COLUMN NUMBERS

CONDITIONS

PORTIONS OF LINES ARE MISSING

RANDOM OR INDIVIDUAL NOZZLES (LESS THAN 5) FAIL

VARIOUS NOZZLES ARE CLOGGED

A SERIES OR BLOCK OF NOZZLES (MORE THAN 5) FAIL

PRIME PLOT GRID SHOWS A ONE ON/ONE OFF PATTERN FOR A CARTRIDGE

ACROSS THE PLOT

1 2 3 4 5 6

N Y

N

N

N

N

Y

Y

Y

Y

ACTIONS

REPEAT PRIME SEVERAL TIMES. SEE SECTION 11.8 IN THIS CHAPTER FOR

INFORMATION ABOUT EVALUATING THE PRIME PLOT.

REMOVE AND REINSTALL CARTRIDGE; REPEAT PRIME. REFER TO CHAPTER 3,

SECTION 6.3, CAUSE #1.

REMOVE AND CLEAN CARTRIDGE; REPEAT PRIME. REFER TO CHAPTER 3,

SECTION 6.2.

CLEAN SERVICE STATION; CLEAN CARTRIDGE AGAIN; REPEAT PRIME. REFER

TO CHAPTER 3, SECTION 4.0.

CLEAN CARRIAGE FLEX CABLE AND CARTRIDGE ELECTRICAL CONTACTS;

REPEAT PRIME. REFER TO CHAPTER 3, SECTION 6.3, CAUSE #2.

PERFORM “Cartridge Failure Test Procedure” IN SECTION 11.9 OR 11.10 BELOW.

REPLACE CARTRIDGE IF NECESSARY; REPEAT PRIME. REFER TO CHAPTER 3,

SECTION 6.1.

REPLACE CARRIAGE; REPEAT PRIME. REFER TO CHAPTER 5, SECTION 8.0 for removal and installation of Carriage Assembly.

REPLACE MPCB; REPEAT PRIME. REFER TO CHAPTER 5, SECTION 4.3 for removal of the MPCB.

CALL ENCAD TECHNICAL SUPPORT (see Chapter 1, Section 3.0).

1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

4-42

CADJET 2

CADJET 2

Troubleshooting

11.7.1

Dried Up Cartridge

If the Cartridge has dried up, it will need to be replaced. In order to prevent this from happening in the future, there are two “preventive maintenance” procedures that should be done:

1.

Check for space between the Cartridge nozzle area and the seals of the Service Station.

If light is seen, check the Seals for wear/damage.

Replace the Service Station if the Seals are worn/damaged. See the removal and reinstallation procedures in

Chapter 5, Section 7.0 of this manual.

Using a new Cartridge, run the PRIME plot after installing the new

Service Station. You may need to repeat the PRIME two or three times before a satisfactory plot is obtained.

See Section 11.8

below for information about evaluating the PRIME plot.

2.

If the Seals are not worn, damaged, or dirty (if ink becomes encrusted and builds up on seals, the cartridges won’t seal properly -- see Chapter 3, Section 4.0 for cleaning procedure), check the Cartridge Height Adjustment.

Sections 6.0, 6.1, and 6.2 of this manual.

See Chapter 6,

After the Carriage Height has been adjusted, install a new

Cartridge and run the PRIME plot. You may need to repeat the

PRIME two or three times before a satisfactory plot is obtained.

See Section 11.8 below for information about evaluating the

PRIME plot.

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Troubleshooting

11.7.2

Determining Ink Level

If the Ink Level Estimator option is being used:

You can check to see which Cartridge is low by using the Current

Ink Level menu. See Chapter 4 of the CADJET 2 User’s Guide for information about this feature. If necessary, replace the Cartridge, load media, and run the PRIME plot. It may be necessary to run the PRIME plot several times in order to obtain a satisfactory plot.

See Section 11.8 below for information about evaluating the

PRIME plot.

If a satisfactory plot cannot be obtained, refer to

Table Chapter 4 .5 above.

If the Ink Level Estimator feature is not being used:

The black Cartridge has an ink-level indicator on the front of the

Cartridge. If the Cartridge is out of ink, discard the Cartridge and replace it. If necessary, replace the Cartridge, load media, and run the PRIME plot. It may be necessary to run the PRIME plot several times in order to obtain a satisfactory plot.

See

Section 11.8 below for information about evaluating the PRIME plot.

If a satisfactory plot cannot be obtained, refer to

Table Chapter 4 .5 above.

The Tri-Color Cartridge does not have the ink-level indicator on the front of the Cartridge. Therefore, the only option is to replace the Cartridge, load media, and run the PRIME plot.

It may be necessary to run the PRIME plot several times in order to obtain a satisfactory plot.

See Section 11.8 below for information about evaluating the PRIME plot.

If a satisfactory plot cannot be obtained, refer to Table Chapter 4 .5 above.

4-44

CADJET 2

Troubleshooting

11.8

PRIME Plot

Before printing and at regular intervals during printing, the plotter wipes the ink cartridge jets at the Service Station. The ink cartridge jets can still become clogged, however, especially with prolonged exposure to the air or with disuse.

Use the PRIME function to clear the jets and to check that the ink cartridges fire properly. We recommend that you prime the Cartridges when they have not been used for a few days to ensure the best possible print quality.

When you press PRIME, a test pattern is printed. The test pattern consists of one wide band of black, three thin bands of each color from the Tri-Color Cartridge, and a series of segmented sloping lines. Each segment in the sloping lines represents one jet.

The bands should be smooth without dark streaks or white lines. The sloping (diagonal) lines should not look fuzzy or contain gaps. If you see discrepancies in the pattern, prime the Cartridges several more times. If you still see discrepancies after priming the plotter several times, you should clean the Cartridges. See Chapter 3, Section 6.2 for cleaning procedures.

If you suspect that an ink cartridge has become clogged during

printing, press PRIME.

The Cartridges will fire into the Service

Station, which will purge the jets.

Printing will resume after this purging.

CADJET 2

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Troubleshooting

11.9

Tri-Color Cartridge Failure Test Procedure

WARNING

1.

2.

Figure Chapter 4 .4: Tri-Color Cartridge Flex

This test procedure is for the Tri-Color Cartridge Flex only.

If you need to test the Black Cartridge, see Section 11.10

below.

Do NOT touch the Cartridge Flex with your fingers. Oils on the skin can damage the circuit.

Using a DVM, verify the resistance between the following points on the suspect Cartridge:

Pin 80 to 65 thru 70, 74 thru 76, 81 thru 84

Pin 64 to 61, 71 thru 73, 77 thru 79, 85 thru 88 (not Pins 62 & 63)

Pin 60 to 38 thru 41, 51 thru 57 (not Pins 58 & 59)

Pin 33 to 34 thru 37, 42 thru 50

36 OHM

36 OHM

36 OHM

36 OHM

If the resistance measured is 0 OHM or OPEN, the Cartridge jet resistor is defective and the Cartridge must be replaced. An incorrect resistance reading will affect print quality.

The Cartridge should be replaced.

4-46

CADJET 2

Troubleshooting

11.10 Black Cartridge Failure Test Procedure

1.

WARNING

2.

This test procedure is for the Black Cartridge (HP

®

No.

51640A) Flex only.

If you need to test the Tri-Color

Cartridge, see Section 11.9 above.

Do NOT touch the Cartridge Flex with your fingers. Oils on the skin can damage the circuit.

The failure rate on the Black Cartridge Flex is very low, so it is not likely that you will need to perform this test. If the Black Cartridge is not performing as you expect, you should first try running the Prime plot several times to try to clear the jets. If this does not solve the problem, please refer to Table Chapter 4 .5, Decision Logic Table

(DLT 5) in this chapter for cleaning procedures.

If you perform the cleaning procedures listed in the Table Chapter 4 .5

and arrive at Action Number 6 “PERFORM ‘Cartridge Failure Test

Procedure,’ ” you will need to perform the procedures given in this section.

CADJET 2

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Troubleshooting

11.10.1 Running the Cartridge Diagnostic Test

You will need to run the plotter’s Cartridge Diagnostic Test to determine which, if any, of the jets are not firing. To run the Cartridge

Diagnostic Test:

1.

Turn on the plotter (you do not need to have it connected to your computer in order to run this test). If power is already on, make sure the following menu is displayed:

MAIN MENU

PRINT MODE

2.

Press the DOWN ARROW once. The display will read:

MAIN MENU

UTILITIES

3.

Press SELECT once. The display will read:

UTILITIES

CALIBRATION

4.

Press the DOWN ARROW once.

a.

If the display reads:

UTILITIES

OPTIONS=ADVANCED

press the UP ARROW twice. The display will read:

UTILITIES

SERVICE

Go to Step 5.

4-48

CADJET 2

CADJET 2

Troubleshooting b.

If the display reads:

UTILITIES

OPTIONS=EASY

press SELECT once, press the UP ARROW once, and press

SELECT once. The display should now read:

UTILITIES

OPTIONS=ADVANCED

Press the UP ARROW twice. The display will read:

UTILITIES

SERVICE

Go to Step 5.

5.

Press SELECT once. The display will read:

SERVICE

INFORMATION

6.

Press the DOWN ARROW once. The display will read:

SERVICE

DIAGNOSTICS

7.

Press SELECT once and the DOWN ARROW three times. The display will read:

DIAGNOSTICS

CARTRIDGE

8.

Press SELECT once.

The unit will now plot the Cartridge

Diagnostics Test.

Press MENU three times and the DOWN

ARROW once to return to the MAIN MENU, PRINT MODE display. Advance the media and press the CUT key.

To interpret this plot, see Section 11.10.2 below.

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Troubleshooting

11.10.2 Interpreting the Cartridge Diagnostic Test

This test plot has a Black band about 1/4” high and 4 sets of Yellow,

Magenta, and Cyan bands. Above the colored bands will appear two rows of numbers and a Black diagonal line which is divided into 104 sections. The two row of numbers, the Black diagonal line, and its first ten sections are illustrated in Figure Chapter 4 .5 below.

(For the purposes of this procedure, you will not need to be concerned with the two rows of numbers and the colored lines printed above the Black diagonal line.)

Each section of the Black diagonal line corresponds to one jet on the

Black Cartridge. The numbers below the Black diagonal line are read from right to left (and from top to bottom for two- and three-digit numbers) to identify each jet. For example, beginning with the bottom row of numbers and reading from the right side of the plot, jet number

1 is the portion of the diagonal line between the numbers 1 and 2, jet number 2 is the portion of the diagonal line between numbers 2 and 3, and jet number 9 is the portion of the diagonal line between numbers 9 and 10. See the sample in Figure Chapter 4 .5 below.

1

0 9 8 7 6 5 4 3 2 1

Figure Chapter 4 .5: Sample of Black Cartridge Diagnostics Test

If any jets are not firing, the section of the diagonal line for that jet will be missing. If any jets are not firing (that is, there are gaps in the diagonal line), go on to Section 11.10.3 “Black Cartridge Flex Test” below.

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CADJET 2

Troubleshooting

11.10.3 Black Cartridge Flex Test

The purpose of this test is determine whether the flex on the Black

Cartridge is OK.

In order to perform the Black Cartridge Failure Test, you will need a 9

Volt Battery plus the necessary probes and resistors and either an

LED or an Ohm Meter. The cartridge has 13 address lines, 8 power pins, and 8 grounds. Each power pin has a ground line. There are a total of 104 jets.

In the diagrams in Figure Chapter 4 .6 below,

P = power pin, A = address line, and G = ground. Use one of the two diagrams below to arrange the setup for the test.

510

LED

9V Battery

10K

A

P

Cartridge

30

G

+

OR

-

10K

9V Battery

A

P

Cartridge

30

G

Setup with LED (no Ohm Meter) Setup with Ohm Meter (no LED)

Figure Chapter 4 .6: Black Cartridge Failure Test Setups

CADJET 2

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Troubleshooting

Figure Chapter 4 .7 below shows the Black Cartridge Flex Dimple

Pattern. The Black Cartridge Flex Test Matrix in Table Chapter 4 .6

below shows the grounds, power pins, address lines, and jet numbers for each jet.

Once you have identified the jet number(s) of the non-functioning jet(s) by examining the plot printed during the

Cartridge Diagnostic Test, use the Black Cartridge Flex Test Matrix to determine which ground, pin, and address line to test. Conduct the test as follows:

1.

Connect 1 probe from the Ohm Meter to one of the 8 power pins.

2.

Connect 1 probe from the Ohm Meter to the 9 Volt Battery and to the correct ground for the power pin.

3.

Connect the 10K resistor from the 9 Volt Battery to the appropriate address line(s) (one at a time) in order to test the jet(s).

4.

You should see 36.4

(+ 1.0

- 2.0

)

5.

If you are testing another jet(s) that has a different ground and power pin, move the probes to that ground and power pin and connect the 10K resistor to the appropriate address line(s).

6.

If the jet(s) tested shows the proper result, you can assume that the flex is OK. In that case, return to Table Chapter 4 .5 in this chapter for further instructions, beginning with “REPLACE

CARTRIDGE IF NECESSARY” (in Action Number 6).

4-52

CADJET 2

Troubleshooting

CADJET 2

Figure Chapter 4 .7: Black Cartridge Flex Dimple Pattern

4-53

Troubleshooting

Table Chapter 4 .6: Black Cartridge Flex Test Matrix

4-54

CADJET 2

Troubleshooting

11.11 Memory Full

MEMORY FULL

PRESS ANY KEY

If the MEMORY FULL error message displays while a plot is being transmitted to the plotter, the I/O buffer has overflowed and the plot will probably be incomplete. The plotter memory is allocated between the

HP-GL I/O and the Raster.

The I/O buffer is for the transfer and configuration of the incoming data. The Raster buffer is used for the storage of the incoming plot.

The default configuration of the allocation is I/O = 128K and

Raster = 1M. If you are sending Raster files, increase the size of the

I/O buffer to decrease the transfer time, freeing up the computer sooner. If you are sending vector files or merged vector/raster files, increase the size of the Raster buffer to allow as much space as possible to store and rasterize the complete file.

To reset the allocation, go to the following menu:

MAIN MENU

PRINT MODE

Press the UP ARROW 4 times to go to

MAIN MENU

PRINTER SETUP

Press SELECT. Press the UP ARROW twice to go to

PRINTER SETUP

MEMORY CONFIG

Press SELECT to go to

MEMORY

I/0 = 128K

CONFIG

RAS=1M

CADJET 2

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Troubleshooting

Press SELECT. Try increasing the amount of memory allocated to the

I/O by pressing the arrow keys.

Press SELECT to save the new values in memory.

Press MENU twice and the DOWN ARROW 4 times to return to the MAIN MENU, PRINT MODE.

Run the file again.

If this does not resolve the MEMORY FULL problem when transferring plots, additional memory must be added to the plotter (refer to Appendix B of the CADJET 2 User's Guide), or purchase ENCAD’s Vector to Raster Conversion Utility.

Another solution may be to ask your software vendor for an HP-RTL device driver. HP-RTL files don’t require raster conversion by the plotter, so memory is not an issue.

11.12 Plotter Hesitates During Plotting

Refer to the procedures in Section 11.11 in this chapter.

11.13 Plot Appearance is not as Expected

1.

Keypad commands were not saved by pressing SELECT after they were entered. Reset the parameters and be sure to press

SELECT after entering each parameter to save the commands.

2.

Plotter emulation mode is not set correctly. Check to see that the proper mode is entered and save by pressing SELECT.

3.

Check to see that the proper driver is installed and selected.

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CADJET 2

Troubleshooting

11.14 Plots are Cut Off.

1.

Check the setting of the MARGINS option in the PAGE FORMAT menu. When MARGINS is set to NORMAL (the default), the plot area is smaller than when MARGINS is set to EXPAND.

Try setting the MARGINS option to EXPAND to make the plot area larger. See Chapter 1, Tables 1.1 and 1.2 of this Service Manual for the Normal and Expanded plot areas for the different media standards.

2.

Check the defined plot area for the loaded media by selecting the

PLOT AREA option in the PAGE FORMAT menu. The plot area is defined by the width of the loaded media, by the setting for the

MARGINS option, and by the selected MEDIA STANDARD in the

PAGE FORMAT menu (see explanation in the previous paragraph).

3.

If the plot area displayed by the PLOT AREA option is not large enough for the image to be printed, try loading wider media. See

Chapter 1, Tables 1.1 and 1.2 of this Service Manual for the plot areas for the different media standards.

4.

The plotter may not have correctly sized the media.

Use the

MANUAL LOAD option to load the media.

See “Manual media loading” in Chapter 2 of the CADJET 2 User’s Guide. You may also want to refer to Section 11.5.4 in this chapter for further assistance.

CADJET 2

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Troubleshooting

11.15 Plotter is Noisy

1.

Noisy operation may be caused by a dirty Slide Shaft. Refer to the

“Slide Shaft Maintenance” procedures in Chapter 3, Section 3.0.

2.

Check for tightness of the Roller Supports by tightening the hardware. See Chapter 6, Section 8.2

3.

The Lower Drive Shaft Rollers may be misaligned.

4.

The Fan Assembly may have something that has fallen into it or it may need to be replaced. Remove the Fan Assembly first to see if anything is loose inside of it.

If not, then replace the Fan

Assembly. See Chapter 5, Section 11.0.

11.16 User Parameters Not Saved When Power Is Cycled

If the user parameters are not as expected when the plotter is turned on, the parameters were not saved by pressing SELECT before turning off the plotter. Go to the desired menu and display the desired menu parameter.

While this value or setting is displayed and the equals sign (=) is flashing, press the SELECT button to save. Save the desired default settings to “USER1.” This User number will be used when the plotter is powered up.

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CADJET 2

Troubleshooting

11.17 Plotter Carriage Moves Erratically

If the plotter Carriage does not move smoothly while plotting or the plot quality is poor, perform the actions below until the problem is corrected.

1.

The Slide Shaft may be dirty. See “Slide Shaft Maintenance” in

Chapter 3, Section 3.0.

2.

Run the Carriage Vibration Test in the DIAGNOSTICS Menu:

DIAGNOSTICS

CARRIAGE VIBRATE

This option tests for Carriage vibration by printing a test pattern of

5 sets of 3 parallel lines bi-directionally.

If there is vibration, check for debris in the grooves of the Servo

Motor Pulley and the Idler Pulley and/or on the inside of the

Carriage Belt. A brush (such as a clean toothbrush) or toothpick can be used to dislodge any debris in the pulley grooves. A clean, dry cloth can be used to clean the inside of the Carriage Belt.

Although the pulleys and belt can be cleaned with the belt in place on the pulleys, you may find it easier to do the cleaning by removing the belt from the Servo Motor Pulley. See Chapter 5,

Sections 8.7 and 8.8 for instructions on removing and replacing the Carriage Belt. Carriage vibration may also be caused by the belt rubbing on the Frame Tensioner or by a noisy Servo Motor.

3.

Run the Servo Motor Test.

DIAGNOSTICS

SERVO MOTOR

Select FAST or SLOW speed to cycle the Servo Motor. Display message will be either RESULT=OK or RESULT=ERROR.

If

ERROR appears, the Servo Motor or driver circuits may be faulty.

Replace the Servo Motor first.

See Chapter 5, Section 5.0 for instructions.

If ERROR still appears, replace the MPCB.

See

Chapter 5, Section 4.3 for instructions.

CADJET 2

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Troubleshooting

CAUTION

4.

The Carriage Belt may not be properly tensioned.

a.

Check the idler assembly frame tensioner, spring, and pulley at the top left end of the plotter.

See Chapter 5,

Section 5.18.

b.

Make sure the belt is properly installed in the Belt Clamp.

Also check to see if the Belt Clamp is cracked.

Refer to

Chapter 5, Section 8.8.

5.

Servo Motor cabling may be intermittent. Check the connections.

6.

Check the screws which hold the Servo Motor in place to make sure the Carriage Belt is not rubbing on the screws. (If the screws were installed at an angle, they may work out of the hole and could interfere with the belt.) See Chapter 5, Section 5.0.

7.

The Slide Shaft alignment may be too low, causing the Cartridges to drag on the media or hit the Upper Roller Supports. Refer to the alignment procedures for the shaft in Chapter 6, Sections 6.0

and 6.1

“Slide Shaft Profile Adjustment (Carriage Height

Adjustment).”

8.

There may be debris on the inside of the metal bushings of the

Carriage Assembly.

The debris may be removed using a dry

Q-Tip or a lint-free cloth.

Using a sharp or metal object to remove debris from the inside of the metal bushings will damage the bushings.

See Chapter 5, Sections 8.2 and 8.3 “Removal of Carriage

Assembly” and “Reinstallation of Carriage Assembly” for removal and reinstallation procedures. If cleaning the bushings does not resolve the problem, replace the Carriage Assembly.

After replacing the Carriage Assembly, see Chapter 6 for calibration instructions (you will not need to perform the Slide Shaft Profile

Adjustment procedure in Section 6.1, but all other sections will need to be done).

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CADJET 2

Troubleshooting

11.18 Media Movement Erratic

If the media moves erratically during plotting or the plot quality is poor, perform the following actions until the problem is corrected.

1.

The Stepper Motor connector (JP5) on the MPCB may be loose or intermittent.

Check the cabling and seat the connector.

See

Chapter 5, Section 11.3.2.

2.

Drive circuits may be faulty.

Replace the Stepper Motor (see

Chapter 5, Section 11.3).

You may also need to replace the

MPCB (be sure to reprogram the Flash EPROM). See Chapter 5,

Section 4.3 and Appendix A.

3.

The media may be slipping due to: a.

Upper Roller Supports are not in proper adjustment.

See

Chapter 6, Sections 7.0 and 8.0 for the “Paper Skew

Adjustment.” b.

Upper Rollers and/or Lower Rollers are dirty. To clean the rollers, see Chapter 3, Section 7.0.

c.

Upper Rollers are worn. If the Upper Roller Supports need to be replaced, see Chapter 5, Section 14.0.

CADJET 2

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Troubleshooting

11.19 LCD or LED Key(s) Inoperative

If there is no response when pressing the LCD or LED key(s):

1.

For LCD keys only. Keypad cable connections are loose. Check the connections at J1 on the Main Printed Circuit Board and J1 on the Keypad PCB. See Chapter 5, Section 6.0.

NOTE

Notes:

For Step 2 below:

1. If one of the arrow keys is the key which is not responding, use the other arrow key to scroll through the menus in order

to reach the DIAGNOSTICS KEYPAD display.

2. If the MENU key is not responding, turn off the plotter and

then turn it on again so that the display will be at the MAIN

MENU, PRINT MODE display. You will then be able to scroll

to the DIAGNOSTICS KEYPAD display.

3. If the SELECT key is not responding, you will not be able to

scroll to the DIAGNOSTICS KEYPAD display to test the

circuitry. Turn off the plotter and then turn it on again. If it still does not respond, follow the instructions in Step 2.a.

below.

2.

For LCD or LED keys.

If a particular key appears to be inoperative, test that key for operation.

Go to the SERVICE

DIAGNOSTICS menu (see your Service Menu chart) and press the DOWN ARROW to go to:

DIAGNOSTICS

KEYPAD

Each of the keys will beep when pressed to test circuitry. If the key does not beep when pressed, turn the plotter off and then turn it on again so that the plotter resets.

Try the DIAGNOSTICS

KEYPAD test again.

4-62

CADJET 2

Troubleshooting a.

For the LCD keys: If the key still does not beep, remove the

Keypad Top Assembly (see Chapter 5, Section 6.1 for the procedure) and press the inoperative key several times.

Check to see if the plastic portion of the key is pushing down the metal button on the Keypad PCB. If necessary, remove the three screws which hold the Keypad PCB to the Keypad

Top and, with the power on, press the metal button on the

Keypad PCB. Check to see if the plotter responds. If the plotter does not respond, replace the Keypad PCB.

b.

For the LED keys: If the key still does not beep, remove the

Right Cover Assembly (see Chapter 5, Section 4.1 for the procedure) and, with the power on, press the metal button on the MPCB several times.

If the plotter does not respond, replace the MPCB Assembly. See Chapter 5, Section 4.3.

3.

For LCD keys only. If Steps 1 and 2 above have been performed and the key is still not responding, the Main PCB is defective.

Replace the Main PCB.

Refer to the procedures in Chapter 5,

Section 4.3.

CADJET 2

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Troubleshooting

11.20 Front Keypad Display Inoperative

If there are no characters displayed on the Keypad Display, but other plotter functions are correct, perform the following actions until the problem is corrected.

1.

Keypad Display cable connections are bad. Check the connection at J1 of the MPCB. See Chapter 5, Section 6.0.

2.

Try reprogramming the Flash EPROM. See Appendix A.

3.

The Keypad Display has failed.

Replace the Display.

See

Chapter 5, Section 6.0.

4.

The Main Printed Circuit Board circuitry has failed. Replace the

Main Printed Circuit Board (see Chapter 5, Section 4.3), and reprogram the EPROM.

5.

EPROM or Flash EPROM failure.

Replace the MPCB.

See

Chapter 5, Section 4.3.

6.

The Display Cable may have been installed backwards. Check the orientation of the flex fingers. See Chapter 5, Section 6.2.

4-64

CADJET 2

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Chapter 4 TROUBLESHOOTING 4-1

1.0 Introduction .........................................................................................................4-1

2.0 Decision Logic Tables .........................................................................................4-2

2.1 Procedure for Using Decision Logic Tables.....................................................4-2

2.2 Decision Logic Tables .....................................................................................4-3

3.0 Service Menu ......................................................................................................4-8

4.0 Service Menu Description ...................................................................................4-9

4.1 Service Information........................................................................................4-10

4.1.1 Information Display Settings ...................................................................4-10

4.1.2 Information Print Settings........................................................................4-13

4.2 Service Diagnostics .......................................................................................4-14

4.3 Service Calibration.........................................................................................4-17

5.0 LED Keys ..........................................................................................................4-18

6.0 LCD Keypad......................................................................................................4-19

7.0 Keypad Messages.............................................................................................4-20

7.1 Plot Received ................................................................................................4-20

7.2 Drying Plot .....................................................................................................4-20

7.3 Insert Media...................................................................................................4-20

7.4 Memory Full ...................................................................................................4-20

7.5 RAM OK ........................................................................................................4-21

7.6 Checksum Error.............................................................................................4-21

7.7 Plotter Error ...................................................................................................4-21

7.8 Ready to Replot.............................................................................................4-21

8.0 Initialization Sequence ......................................................................................4-22

9.0 RS-422/RS-232 Error Messages ......................................................................4-23

10.0 RAM Error .......................................................................................................4-24

11.0 Operation Problems ........................................................................................4-25

11.1 Plotter Does Not Turn On ............................................................................4-25

11.2 Plotter Slow to Initialize................................................................................4-26

11.3 Plotter Will Not Plot......................................................................................4-27

11.3.1 Parallel Interface and Serial Interface Tests .........................................4-29

11.4 No Movement in the Carriage Axis ..............................................................4-31

CADJET 2

4-65

Troubleshooting

11.5 Media Problems ..........................................................................................4-34

11.5.1 Cut Sheet Media Won’t Load................................................................4-34

11.5.2 Media Feeds Out of Plotter When Plot is Completed ...........................4-36

11.5.3 Media Skews or Ripples .......................................................................4-36

11.5.4 Loaded Media Not Detected, Media Size Not Detected, or Plotter Has

Incorrect Plot Area ...........................................................................................4-37

11.5.5 Keypad Display Shows LOAD MEDIA Message When Rollfeed Media is

Loaded.............................................................................................................4-38

11.5.6 Loud Grinding Noise When Media Loads .............................................4-39

11.6 Media Cutting Problems ..............................................................................4-41

11.7 Ink Cartridge Problems................................................................................4-42

11.7.1 Dried Up Cartridge................................................................................4-43

11.7.2 Determining Ink Level ...........................................................................4-44

11.8 PRIME Plot..................................................................................................4-45

11.9 Tri-Color Cartridge Failure Test Procedure .................................................4-46

11.10 Black Cartridge Failure Test Procedure ....................................................4-47

11.10.1 Running the Cartridge Diagnostic Test ...............................................4-48

11.10.2 Interpreting the Cartridge Diagnostic Test ..........................................4-50

11.10.3 Black Cartridge Flex Test ...................................................................4-51

11.11 Memory Full...............................................................................................4-55

11.12 Plotter Hesitates During Plotting................................................................4-56

11.13 Plot Appearance is not as Expected .........................................................4-56

11.14 Plots are Cut Off........................................................................................4-57

11.15 Plotter is Noisy ..........................................................................................4-58

11.16 User Parameters Not Saved When Power Is Cycled ................................4-58

11.17 Plotter Carriage Moves Erratically .............................................................4-59

11.18 Media Movement Erratic ...........................................................................4-61

11.19 LCD or LED Key(s) Inoperative .................................................................4-62

11.20 Front Keypad Display Inoperative .............................................................4-64

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CADJET 2

Troubleshooting

Figure 4.1: LED Keys.................................................................................................4-18

Figure 4.2: LCD Keypad ............................................................................................4-19

Figure 4.3: Parallel and Serial Loop Back Tests........................................................4-30

Figure 4.4: Tri-Color Cartridge Flex ...........................................................................4-46

Figure 4.5: Sample of Black Cartridge Diagnostics Test ...........................................4-50

Figure 4.6: Black Cartridge Failure Test Setups ........................................................4-51

Figure 4.7: Black Cartridge Flex Dimple Pattern........................................................4-53

Table 4.1: Decision Logic Table One (DLT 1) .............................................................4-4

Table 4.2: Decision Logic Table Two (DLT 2) .............................................................4-5

Table 4.3: Decision Logic Table Three (DLT 3)...........................................................4-6

Table 4.4: Decision Logic Table Four (DLT 4).............................................................4-7

Table 4.5: Decision Logic Table Five (DLT 5) ...........................................................4-42

Table 4.6: Black Cartridge Flex Test Matrix...............................................................4-54

CADJET 2

4-67

Chapter 5

DISASSEMBLY/ASSEMBLY

1.0 Introduction

Chapter 5 contains the procedures for removal and replacement of the

CADJET 2 plotter 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 or replacement.

Replacement parts are listed in Chapter 7 and may be ordered through the ENCAD Technical Support and Service Department (see

Chapter 1, Section 3.0).

CADJET 2 5-1

Disassembly/Assembly

NOTE

Note: Whenever components or parts are removed and replaced, calibration of the plotter is necessary. Refer to the

Calibration Procedures in Chapter 6. Also refer to Chapter 1,

Sections 8.0 and 9.0 for information on Line Length Accuracy and Skew.

Removal of the following parts will require complete hardware and firmware calibration after reassembly:

l

Servo Motor Assembly l

MPCB l Carriage Assembly l

Carriage Belt l

Idler Tensioner Assembly l Stabilizer Bracket l l l

Y-Arm Assembly

Slide Shaft

Lower Drive Shaft Assembly l Stepper Motor l

Fan Assembly l

Upper Roller Supports (only the portions listed in

Section 14.2)

5-2 CADJET 2

Disassembly/Assembly

WARNING

CAUTION

NOTE

Disconnect both the power cord and the interface cables before beginning any disassembly procedures. Failure to do this can cause damage to the electronic components of the plotter and expose you to high voltage circuits and possible personal injury.

Integrated circuits can be weakened or inactivated by electrical discharge. It is recommended that you be grounded to a static station by a wrist strap to prevent ESD damage. Anti-static bags are highly recommended for storage or shipment of printed circuit boards.

Note: It is recommended that the plotter be removed from the stand and placed on a stable work surface on foam blocks for servicing.

CADJET 2 5-3

Disassembly/Assembly

2.0 Tools and Equipment Required

Figure Chapter 5 .1 illustrates the CADJET 2 Hardware Kit Assembly, which is listed in Chapter 7. Figure Chapter 5 .2 illustrates the following tools which are recommended to disassemble and reassemble the plotter: l Torque Screwdriver l #1-B6 Special Phillips Bit l

#1 Phillips Screwdriver l

#2 Phillips Screwdriver l #2 Stub Phillips Screwdriver l 1/8” x 6” Slotted Screwdriver l 1/4” x 6” Slotted Screwdriver l

11/32 Magnetized Nut Driver l

5/16 Hex Nut Driver l 7/64 Hex Nut Driver l 1/4” Open End Wrench l 1/4” Open/Box End Angle Wrench l

Wire Cutters l

Needle Nose Pliers l Angled Flat Reamer/ Straight Fork Tip l Machinist Scriber * l Tweezers l

X-ACTO Knife l

ESD Wrist Strap l 4-1/2” x 1” x 1/32” Oil Hardened Precision Ground Flat Stock l 4-1/2” x 2” piece of Translite media l Fixture, Trailing Cable, Tape, Location, P/N 204142 (optional) l

Fixture, Trailing Cable, Location, P/N 204483 (optional)

* Machinist Scriber should have one straight point and one 90

°

bent point.

The following materials also are required: l

Isopropyl Alcohol l

Q-Tips l Lint Free Cloth or Tissue l

Double Sided Tape (1/16” thick) l

Loctite Blackmax, P/N 200172

5-4 CADJET 2

Disassembly/Assembly

CADJET 2

Figure Chapter 5 .1: CADJET 2 Hardware Kit Assembly

5-5

Disassembly/Assembly

5-6

Figure Chapter 5 .2: CADJET 2 Final Assembly Tools

CADJET 2

Disassembly/Assembly

3.0 Stand

If you need to ship the plotter to ENCAD for servicing, please observe all the instructions given below. You must contact ENCAD’s Technical

Support and Service Department prior to shipping the plotter. See

Chapter 1, Section 3.0.

NOTE

Note: When returning the plotter to ENCAD for servicing, remove any extra SIMMS that have been installed. Label all hardware and parts for ease of reassembly. It is not necessary to ship the Stand, Basket, or hardware.

3.1 Removing the Plotter from the Stand

There are two types of stands: a desktop (throwaway) stand and a floor stand which includes a basket. Some of the directions below apply only to the floor stand.

1. Disconnect the power cord and interface cables.

2. Lock both of the stand’s locking casters if you have the floor stand.

3. Remove any extra SIMMS that have been installed. See

Section 4.5.1 “Extra Memory (SIMM) Removal” in this chapter.

4. Remove any roll feed and/or sheet media.

5. Remove both ink Cartridges.

6. Clean both parts of the Service Station. See Chapter 3,

Section 4.0 for cleaning procedures.

7. Move the Carriage Assembly so that it sits on the Service Station.

See Figure Chapter 5 .3.

8. Insert the Carriage Packing and the Fixed Blade Packing as shown in Figure Chapter 5 .3. If these are not available, use the alternate method shown in Section 3.3.

CADJET 2 5-7

Disassembly/Assembly

5-8

Figure Chapter 5 .3: Preparing the Plotter for Shipping

CADJET 2

Disassembly/Assembly

CAUTION

To avoid risk of personal injury or damage to the plotter, we recommend that you have someone help you turn the plotter over to place it in the shipping box.

9. Remove the eight screws which hold the plotter on the stand.

10. Stand close to the plotter. Place one hand around the plotter and grasp the front of the Platen with the other hand. Lift the plotter straight up approximately 4” to clear the legs.

11. Place the plotter upside down in the original shipping box with foam support blocks in place.

3.2 Replacing the Plotter on the Stand

See the CADJET 2 User’s Guide for the plotter assembly procedures if you are using the desktop stand. If you are using the floor stand, have someone help you position the plotter on the stand and hold it in place while you insert and tighten the eight screws which hold the plotter on the stand.

CADJET 2 5-9

Disassembly/Assembly

3.3 Alternate Method for Securing Carriage Assembly and Fixed Blade

1. Position the Carriage Assembly over the Service Station.

2. Place two pieces of nylon filament tape (about two inches long) across the Fixed Blade and press them down onto the Platen, as shown in Figure 5.4.

3. Use a tiewrap to lock the Carriage Assembly in place, as shown in

Figure 5.4. (If you do not have a tiewrap, use a heavy-duty rubberband and place it in the same location as you would the tiewrap. Loop the rubberband through itself and knot it securely.)

Do not use tape to hold the Carriage Assembly in place.

5-10

Figure Chapter 5 .4: Preparing the Plotter for Shipping - Alternate Method

CADJET 2

Disassembly/Assembly

4.0 Right Cover Assembly, MPCB, and SIMMS

4.1 Removing the Right Cover Assembly

Removing the Right Cover Assembly provides access to the SIMMS,

MPCB, and all MPCB connectors (Stepper Motor, Servo Motor, Fan,

Keypad, and Trailing Cable).

CAUTION

NOTE

There is a screw and nut in approximately the middle near the top edge of the Right Side Plate. These have been set at the factory to a specific torque. DO NOT tighten or loosen this screw and nut at any time. See Figure Chapter 5 .25.

Note: If the LED Keypad on the Right Cover Assembly needs to be replaced, the entire Right Cover Assembly must be replaced.

CADJET 2

Figure Chapter 5 .5: Inside View of Right Cover Assembly

5-11

Disassembly/Assembly

To remove the Right Cover Assembly:

1. Remove the Top Cover. Keep the right end of the Top Cover tilted up so that the Retracting Stop and Compression Spring don’t fall out.

2. You may find it helpful to wrap a rubberband around the connector clips on the parallel port to hold them out of the way while the

Right Cover Assembly is being removed.

3. Move the Carriage Assembly to the middle of the Platen.

4. Using a #2 Phillips screwdriver, loosen the top and front screws

(which are captive) and remove the bottom back screw on the inside of the Right Cover (see Figure Chapter 5 .5).

5. Remove the Right Cover. Move the Right Cover towards the back of the unit as you remove it so that it clears the parallel port on the back of the unit. Be very careful when removing the Right Cover so that the LED’s on the MPCB are not damaged.

5-12 CADJET 2

Disassembly/Assembly

4.2 Removing the MPCB Connectors

WARNING

1. Power must be disconnected.

2. Reference Figure Chapter 5 .6 for the locations of the connectors.

3. Grasp the connector, not the wires, to remove the cables.

4. Do not pull the cables from the connectors on the J1 location (Keypad Cable) and JP4 location (Trailing Cable) until they are unlocked. Doing so may cause damage to the cable fingers. Do not pull the lock too hard as you unlock the connectors or the lock may break off.

5. Integrated circuits can be weakened or inactivated by electrical discharge. It is recommended that you be grounded to a static station by an ESD wrist strap to prevent

ESD damage.

Disconnect all 6 connectors on the MPCB so that the MPCB can be removed (see Figure Chapter 5 .6 for positions of the connectors), as follows:

1. Disconnect the Keypad Cable connector at the J1 location. Use the reamer to pull forward on the connector lock and remove the flex cable from the connector.

2. Disconnect the Trailing Cable connector at the JP4 location. Use the thumb and forefinger to pull forward on the connector lock and remove the Trailing Cable from the connector.

3. Disconnect the Servo Motor connector (Red and Blue wires) at the

J6 location. Grasp the Servo Motor connector with the thumb and forefinger and pull straight out.

4. Disconnect the Fan connector (Red and Black wires) at the J5 location. Grasp the Fan connector with the thumb and forefinger and pull straight out.

5. Disconnect the Stepper Motor connector at the JP5 location.

Grasp the Stepper Motor connector with the thumb and forefinger and pull straight out.

6. Disconnect the Power Supply connector at the JP1 location.

Grasp the Power Supply connector with the thumb and forefinger

CADJET 2 5-13

Disassembly/Assembly and pull straight out. At this point, all 6 connectors should be disconnected.

5-14 CADJET 2

Disassembly/Assembly

Figure Chapter 5 .6: MPCB Connectors

CADJET 2 5-15

Disassembly/Assembly

4.3 MPCB

WARNING

1. Power must be disconnected.

2. Integrated circuits can be weakened or inactivated by electrical discharge. It is recommended that you be grounded to a static station by an ESD wrist strap to prevent

ESD damage. For storage or shipment of printed circuit boards, anti-static bags are highly recommended.

NOTE

Note: Remove any extra SIMMS that have been installed if you are shipping the MPCB for servicing or replacement.

4.3.1 Removing the MPCB

To remove the MPCB:

1. Put on an ESD wrist strap.

2. Use a #2 6” Phillips screwdriver to remove the three screws holding the MPCB onto the side plate. The screws are located to the right of J1, to the left of JP4, and to the right of JP1. See

Figure Chapter 5 .6. Hold the top of the MPCB while removing the screws.

3. Place the MPCB in an ESD bag (anti-static bag) in preparation for shipment to ENCAD for replacement or repair, or if it is to be stored for repair at your facility.

5-16 CADJET 2

Disassembly/Assembly

4.3.2 Reinstalling the MPCB

To reinstall the MPCB, reverse the steps followed when removing the

MPCB:

1. Put on an ESD wrist strap.

2. Remove the MPCB from the ESD bag.

3. Hold the MPCB in place on the Right Side Plate while putting in the three screws in the holes located to the right of J1, to the left of

JP4, and to the right of JP1. See Figure Chapter 5 .6. Use a

#2 6” Phillips screwdriver to tighten the screws until firmly tightened.

CADJET 2 5-17

Disassembly/Assembly

4.4 Reinstalling the MPCB Connectors

1. Reinstall the Stepper Motor connector at JP5.

2. Reinstall the Fan connector (Red and Black wires) at J5.

3. Reinstall the Servo Motor connector (Red and Blue wires) at J6.

4. Reinstall the Trailing Cable at JP4.

NOTE

Note: The silver fingers on the Trailing Cable should be facing down while inserting the Trailing Cable into the

JP4 connector.

NOTE

When inserting the Trailing Cable connector, apply pressure on the locking clip towards the MPCB in order to lock the connector in place. Test to make sure the connector is locked by pulling slightly on the cable to see if it comes out.

5. Reinstall the Keypad Cable at J1.

Note: The fingers on the Keypad Cable should be facing the back of the machine when inserting the Keypad Cable into the

J1 connector.

When inserting the Keypad Cable connector, apply pressure on the locking clip towards the MPCB in order to lock the connector in place. Test to make sure the connector is locked by pulling slightly on the cable to see if it comes out.

NOTE

Note: If the MPCB is replaced, the Flash EPROM must be programmed because the Flash EPROM will be blank when the MPCB is shipped from ENCAD. See Appendix A at the end of this manual in order to program the Flash EPROM.

5-18 CADJET 2

Disassembly/Assembly

4.5 Extra Memory (SIMM)

WARNING

1. Power must be disconnected.

2. Integrated circuits can be weakened or inactivated by electrical discharge. It is recommended that you be grounded to a static station by an ESD wrist strap to prevent

ESD damage. For storage or shipment of printed circuit boards, anti-static bags are highly recommended.

4.5.1 Extra Memory (SIMM) Removal

1. The SIMM slots are at a 45

°

angle. Facing the top of the SIMM, push the side clips gently to the outside (away from the SIMM) and lift up and pull out, being careful not to damage the fingers on the top. See Figure Chapter 5 .7, Figure Chapter 5 .8, and

Figure Chapter 5 .7: Location of SIMM

Figure Chapter 5 .9.

Figure Chapter 5 .8: Closeup

View of Clip

CADJET 2 5-19

Disassembly/Assembly

5-20

Figure Chapter 5 .9: Side View of SIMM

Removal

CADJET 2

Disassembly/Assembly

4.5.2 Extra Memory (SIMM) Installation

For proper specifications and dimensions for the SIMM, please refer to the CADJET 2 User’s Guide, Appendix B. The SIMM must be within ENCAD’s specifications and tolerances.

WARNING

NOTE

Note: 1. If you are installing two SIMMS, you must install the bottom one first.

2. If you are installing two SIMMS, the SIMM in the top slot

MUST contain AS MUCH OR MORE capacity than the SIMM in the bottom slot. For example:

16 MB in top slot, 4 MB in bottom slot, or

8 MB in top slot, 8 MB in bottom slot, or

32 MB in top slot, bottom slot empty.

1. The SIMM slots are at a 45

°

angle. Place the SIMM straight into the connector as shown in Figure Chapter 5 .10.

2. Slowly push the SIMM down until the two side clips snap into place. Make sure the SIMM is fully seated.

3. Go to Section 4.6 of this chapter for instructions on replacing the

Right Cover Assembly.

Figure Chapter 5 .10: Side View of SIMM Installation

CADJET 2 5-21

Disassembly/Assembly

4.6 Reinstalling the Right Cover Assembly

1. Make sure that all wires are inside the Right Cover Assembly area as you begin to put the Right Cover Assembly back on so that none of the wires are pinched between the Right Cover Assembly and the Right Side Plate.

2. Align the back of the Right Cover Assembly over the connector clips on the parallel port. Remove the rubber band holding the connector clips together.

3. Reinsert the bottom back screw on the inside of the Right Cover

Assembly. See Figure Chapter 5 .5. Using a #2 Phillips screwdriver, tighten the bottom back screw and the top and front screws. All three screws should be firmly tightened. Do not

overtighten.

4. Put the Top Cover back on.

5-22 CADJET 2

Disassembly/Assembly

5.0 Servo Motor

5.1 Removing the Servo Motor

CAUTION

While removing the Carriage Belt and the screws on the Servo

Motor, don’t touch the Encoder Strip with any tools.

NOTE

Note: The Stand has a cutout in it which allows you to remove the

Servo Motor without removing the Plotter from the Stand.

To remove the Servo Motor, proceed as follows:

1. Disconnect the power cord and the interface cables.

2. Remove the Top Cover.

3. Remove the Trailing Cable Cover from the Y-Arm in order to have easier access to the Frame Tensioner and to the screws which hold the Servo Motor in place. Use a 5/16 Hex Nut Driver to remove the three nuts which secure it to the back of the Y-Arm.

4. Use a #2 6” Phillips screwdriver to remove the back screw on the

Servo Motor. See Figure Chapter 5 .11.

5. Loosen the front screw on the Servo Motor. See Figure Chapter 5

.11.

6. See Figure Chapter 5 .12 and Figure Chapter 5 .11. While you compress the back of the Frame Tensioner with your left index finger, use your right hand or the straight end of the Scriber to gently remove the Carriage Belt from the Servo Motor pulley.

CADJET 2 5-23

Disassembly/Assembly

CAUTION

Make sure that the wires are not scraped against the opening in the bottom of the Platen during the removal of the Servo Motor to avoid accidentally cutting them.

7. Support the Servo Motor with one hand and remove the front screw.

8. Carefully lower the motor part way out of the opening in the bottom of the Platen.

9. Unlock the connector lock on the Servo Motor. Pull the cable out of the connector and finish removing the Servo Motor from the opening.

5-24

Figure Chapter 5 .11: Servo Motor

CADJET 2

Disassembly/Assembly

Figure Chapter 5 .12: Compression of Frame Tensioner

CADJET 2 5-25

Disassembly/Assembly

5.2 Replacing the Servo Motor

CAUTION

1. Make sure that the wires of the Servo Motor cable are not scraped against the opening in the bottom of the Platen during the reinstallation of the Servo Motor to avoid accidentally cutting them.

2. Also, make certain that the connector on the Servo Motor faces the BACK of the Platen. If the connector faces the front of the Platen, the cable will be stretched too tight and may be damaged.

1. Partially reinsert the Servo Motor inside the opening in the bottom of the Platen.

2. Plug the Servo Motor cable into the connector on the Servo Motor.

Make sure that it snaps into place.

3. Guide the Servo Motor into the Platen.

4. Push the Servo Motor pulley through the Platen and Y-Arm and, at the same time, rotate the Servo Motor so that the connector is facing the BACK side of the Platen. Align the screw holes with the screw hole openings.

5. Insert one screw into the Servo Motor and tighten it slightly.

6. Insert the second screw into the Servo Motor and tighten it. Make sure both screws are tight.

7. Compress the back of the Frame Tensioner with your left index finger and wrap the Carriage Belt over the Servo Motor pulley.

Make sure that the three guides on the inside of the belt are inserted in the three pulley grooves.

8. Move the Carriage Assembly back and forth to check the Carriage

Belt tension.

9. Reinstall the Trailing Cable Cover and the Top Cover.

5-26 CADJET 2

Disassembly/Assembly

6.0 Display Assembly

6.1 Removing the Display Assembly

1. Disconnect the power cord and the interface cables.

2. Using a #1 Phillips screwdriver, remove the 3 screws from the back of the Keypad Top Assembly (and, if the Keypad Bottom is damaged, the 2 screws from the underside of the front of the

Keypad Bottom and the three screws which hold the Keypad

Bottom to the Platen). See Figure Chapter 5 .13.

3. If the Right Cover Assembly has not been removed from the plotter, you will need to lift up the left side of Keypad Top

Assembly and pull it slightly to the left in order to get the Keypad

Shim on the right end of the Keypad Top Assembly to clear the overhang from the Right Cover Assembly.

4. Turn the Keypad Top Assembly over.

CADJET 2

Figure Chapter 5 .13: Display Assembly

5-27

Disassembly/Assembly

4. With thumb and index finger, release the connector lock on the

Keypad Cable connector at J1. See Figure Chapter 5 .14.

5. Remove the Keypad Cable.

6. Leave the Keypad Bottom attached to the plotter unless it is damaged.

Figure Chapter 5 .14: Keypad PCB

NOTE

Note: The Keypad PCB is not available separately. It is included as part of the Keypad Top Assembly. See Chapter 7 for the part number.

6.2 Reinstalling the Display Assembly

Reinstall Display Assembly by reversing the procedure used to remove it. When reinserting the Keypad Cable, make sure that the silver fingers on the end of the cable face the Keypad PCB. Also, make sure that the lip on the right side of the Keypad Top Assembly is under the

Right Cover Assembly.

5-28 CADJET 2

NOTE

Disassembly/Assembly

7.0 Service Station Assembly

7.1 Removing the Service Station Assembly

CAUTION

Be sure to clean the Service Station Assembly BEFORE removing it so that ink is not spilled. See Chapter 3, Section 4.0 for the cleaning procedure.

Note: The screw in the bottom of the Service Station Assembly must be in place to attract the magnet on the underside of the top of the Service Station Assembly.

CADJET 2

Figure Chapter 5 .15: Service Station Assembly

5-29

Disassembly/Assembly

NOTE

1. Move the Carriage Assembly to the center of the Platen. Clean the top and bottom parts of the Service Station Assembly per the procedure in Chapter 3. Remove the top of the Service Station

Assembly before removing the bottom of the Service Station

Assembly.

2. Use a #1 Phillips screwdriver to remove the right Cam Actuator.

See Figure Chapter 5 .15.

Note: As you remove the Service Station Bottom, you may want to place a piece of paper or an index card underneath your screwdriver to avoid scratching the paint on the Platen. Also, be careful not to exert too much force in order to avoid breaking the Service Station Bottom.

3. The Service Station Bottom is held in place by two plastic tabs underneath the rim of the Service Station Bottom. See

Figure Chapter 5 .15. Place the tip of the 1/8” x 6” Slotted screwdriver between the front of the Y-Arm and the back rim of the

Service Station Bottom and carefully turn the screwdriver to create enough space for the tip of the 1/4” x 6” Slotted screwdriver. Turn the 1/4” x 6” Slotted screwdriver until the back of the Service

Station Bottom pops out of the opening in the Platen.

4. Pull up slightly on the right end of the Service Station Bottom with the Machinist Scriber.

5. Push in with the 1/4” x 6” Slotted screwdriver on the front edge of the Service Station Bottom until the front tab clears the opening in the Platen.

6. Pull up with your fingers (or with the Machinist Scriber) on the right end of the Service Station Bottom while lifting up the left front edge of the Service Station Bottom with your 1/4” x 6” Slotted screwdriver until the Service Station Bottom is out of the Platen.

5-30 CADJET 2

Disassembly/Assembly

7.2 Reinstalling the Service Station Assembly

NOTE

Note: Be sure the bottom of the Service Station Assembly is oriented properly when reinstalling it. See Figure Chapter 5

.15.

1. If the top of the Service Station Assembly is already in the bottom of the Service Station Assembly, slide it out. Make sure that the screw is in place in the bottom of the Service Station Assembly.

2. Snap the bottom of the Service Station Assembly into the Platen.

3. Slide the top of the Service Station Assembly into the bottom of the Service Station Assembly and push it to the far left position.

4. Use a #1 Phillips screwdriver to reattach the plastic right Cam

Actuator back into place on the front of the Y-Arm. Be careful not

to overtighten the screw or the plastic may break.

CADJET 2 5-31

Disassembly/Assembly

8.0 Left Cover Assembly, Left Side Plate,

Carriage Assembly, Trailing Cable, and

Carriage Belt

8.1 Removing the Left Cover Assembly and Left Side

Plate

CAUTION

There is a screw and nut in approximately the middle near the top edge of the Left Side Plate. These have been set at the factory to a specific torque. DO NOT tighten or loosen this screw and nut at any time. See Figure Chapter 5 .25.

1. Remove both Cartridges and the Top Cover.

2. Using a #2 12” Phillips screwdriver, remove the screw located at the bottom back of the inside of the Left Side Plate. See

Figure Chapter 5 .16.

3. Using a #2 12” Phillips screwdriver, remove the 2 screws on the inside of the Left Side Plate. One screw is located at the top back of the inside of the Left Side Plate. The other screw is located at the front of the inside of the Left Side Plate and is inside the Block

Filler. See Figure Chapter 5 .16. (The screw inside the Block

Filler cannot come out of the Block Filler unless you unscrew the

Block Filler from the Left Side Plate.)

4. Slide the Left Cover Assembly off the end of the unit and set it aside.

5. Using a #2 8” Phillips screwdriver, remove the 4 screws on the outside of the Left Side Plate and set it aside.

5-32 CADJET 2

Disassembly/Assembly

Figure Chapter 5 .16: Inside View of Left Side Plate

CADJET 2 5-33

Disassembly/Assembly

8.2 Removing the Carriage Assembly

NOTE

Note: 1. When removing the Carriage Assembly, the Cartridges, Top

Cover, Left Cover Assembly, and Left Side Plate must first be removed. See Section 8.1 of this chapter.

2. The replacement of the Carriage PCB, the Paper Sensor

Assembly, and the Paper Sensor Flex is very complex and requires special tools and fixtures. Therefore, if any of these components of the Carriage Assembly has failed and needs to be replaced, it is necessary to replace the entire Carriage

Assembly.

WARNING

1. Power must be disconnected.

2. It is recommended that you be grounded to a static station by an ESD wrist strap to prevent ESD damage whenever you are handling the Carriage Assembly.

3. Do not touch the Encoder Strip with any tools when removing the Carriage Belt from the Servo Motor Pulley.

4. Always handle the Trailing Cable with care. Do not twist or turn the cable.

1. Remove the Trailing Cable Cover from the back of the Y-Arm.

Use a 5/16 Hex Nut Driver to remove the three nuts which secure it to the back of the Y-Arm.

2. Use wire cutters to cut the tie wrap holding the Trailing Cable on the Carriage PCB. Be careful not to cut the Trailing Cable.

See Figure Chapter 5 .17.

3. Unlock the Trailing Cable connector (J1) on the Carriage PCB, carefully pull the Trailing Cable away from the double-sided tape, and remove the Trailing Cable. See Figure Chapter 5 .17.

5-34 CADJET 2

Disassembly/Assembly

Figure Chapter 5 .17: Trailing Cable Connector Lock on Carriage PCB

4. See Figure Chapter 5 .12. While you compress the back of the

Frame Tensioner with your left index finger, use your right hand or the straight end of the Scriber to gently remove the Carriage Belt from the Servo Motor pulley.

5. Remove the Compression Spring from the Frame Tensioner and set it aside.

6. 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 Chapter 5 .18 for part names, if necessary.)

7. Use a #1 Phillips screwdriver to remove the plastic Cam Actuator from the left front side of the Y-Arm. See Figure Chapter 5 .18.

CADJET 2 5-35

Disassembly/Assembly

Figure Chapter 5 .18: Left End of Y-Arm

8. Move the Carriage Assembly to the left end of the Slide Shaft and remove it from the Slide Shaft.

9. Place the Carriage Assembly in an ESD (anti-static) bag in preparation for shipment to ENCAD for replacement or repair, or if it is to be stored for repair at your facility.

NOTE

Note: 1. If the Trailing Cable needs to be replaced, see Section 8.5.

2. If the Carriage Belt needs to be replaced, see Section 8.7.

5-36 CADJET 2

Disassembly/Assembly

8.3 Reinstalling the Carriage Assembly

NOTE

Note: Make sure you clean the Slide Shaft before installing the

Carriage Assembly. You may use Isopropyl Alcohol to clean it. Be sure it is dry before installing the Carriage Assembly.

CAUTION

1. Never use Isopropyl Alcohol to clean the brass bushings on the Carriage Assembly. Use only a dry cloth.

2. When you slide the Carriage Assembly onto the Slide Shaft, make sure that the Encoder Strip fits into the slot in the

Slider and the Encoder which are on the Carriage PCB.

1. Make sure the left end of the Trailing Cable extends out beyond the left end of the Stabilizer Bracket.

2. 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. Use your right index finger to guide the belt as you slide the Carriage Assembly from left to right on the Slide Shaft.

3. 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.

CADJET 2 5-37

Disassembly/Assembly

CAUTION

Make sure that the silver fingers on the Trailing Cable face up before inserting the Trailing Cable into the J1 connector lock. See

Figure Chapter 5 .19.

4. Connect the Trailing Cable to the J1 connector lock on the

Carriage PCB. Make sure the silver fingers on the Trailing Cable face up before inserting it into the lock. See Figure Chapter 5 .19.

Slide both sides of the connector lock shut simultaneously.

5. Press the Trailing Cable down onto the double-sided tape on the

Carriage PCB.

6. Put the tie wrap down into the back hole in the Carriage PCB (see

Figure Chapter 5 .19), feed it up through the front hole, and put the end through the fastener.

7. Grasp the loose end of the tie wrap next to the fastener with the side (not the point) of a pair of needlenose pliers. Turn the pliers away from the fastener in order to pull the tie wrap snug. Cut off the excess length of the tie wrap.

8. Slide the Carriage Assembly to about the middle of the Slide Shaft and stretch out the Carriage Belt.

5-38 CADJET 2

Disassembly/Assembly

Figure Chapter 5 .19: Reinstalling the Trailing Cable in J1 Connector

CADJET 2 5-39

Disassembly/Assembly

NOTE

Note: 1. You may want to refer to Figure Chapter 5 .18 while doing

Step 9 through Step 14.

2. One side of the Idler Pulley Assembly has a thicker ring of plastic than the other side. When you insert the Idler Pulley

Assembly between the Frame Tensioner and the Carriage

Belt, the side with the thicker ring of plastic must face up.

See Figure Chapter 5 .18.

9. Insert the Carriage Belt into the Frame Tensioner so that the belt extends about an inch past the Frame Tensioner.

10. Holding the Carriage Belt and Frame Tensioner in one hand, insert the Idler Pulley Assembly into the loop of the belt. Make sure that the side of the Idler Pulley Assembly with the thicker ring of plastic is facing up.

11. 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 grove in the

Frame Tensioner.

12. 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.

13. Fit the Compression Spring over the post at the back of the Y-Arm.

14. Fit the notch in the front end of the Frame Tensioner over the notch in the front of the Y-Bracket.

5-40 CADJET 2

Disassembly/Assembly

15. With your left hand, push the back of the Frame Tensioner towards the right end of the Y-Bracket and, with your right hand, slip the Carriage Belt over the Servo Motor pulley on the right end of the unit. Make sure that the guides in the Carriage Belt are properly fitted over the Servo Pulley.

16. Gently move the Carriage Assembly from end to end and make sure that the Carriage Belt is not rubbing against any other parts.

17. Use a #1 Phillips screwdriver to reattach the plastic left Cam

Actuator back onto the front of the Y-Arm. Before careful not to overtighten the screw or the plastic may break. Make sure the orientation is correct (see Figure Chapter 5 .18).

18. Reattach the Trailing Cable Cover to the back of the Y-Arm.

19. Proceed to Section 8.4.

CADJET 2 5-41

Disassembly/Assembly

8.4 Reinstalling the Left Side Plate and Left Cover

Assembly

1. Align the Left Side Plate against the left end of the Platen, insert the 4 screws, and tighten with a #2 8” Phillips screwdriver as tight as possible.

2. Push the Left Cover Assembly all the way onto the Left Side Plate.

3. Insert the screw into the top back hole on the inside of the Left

Side Plate and tighten slightly. See Figure Chapter 5 .16.

4. Insert the second screw inside the block filler into the Left Side

Plate and tighten slightly. See Figure Chapter 5 .16.

5. Insert the third screw into the bottom back hole of the inside of the

Left Cover Assembly and tighten slightly. See Figure Chapter 5

.16.

6. Tighten the three screws with a #2 12” Phillips screwdriver.

7. Put the Top Cover back on.

8. Reinstall the Cartridges.

5-42 CADJET 2

Disassembly/Assembly

8.5 Removing the Trailing Cable

CAUTION

NOTE

Handle the Trailing Cable with care. Do not twist or turn the cable.

Note: 1. Perform this procedure only if the Trailing Cable is being replaced.

2. If you are replacing only the Trailing Cable, it is not necessary to remove the Carriage Assembly from the Slide

Shaft.

3. If you have already removed the Carriage Assembly from

the Slide Shaft in order to replace the Carriage Assembly

(and you are replacing the Trailing Cable as well), you will need to do only Steps 3, 4 and 7 of this section.

4. The placement of the double-sided tape which holds the

Trailing Cable to the center of the Stabilizer Bracket is important for proper movement of the Carriage Assembly.

You may want to obtain P/N 204142 “Fixture Trailing Cable,

Tape, Location” which is used for the exact placement of both tapes when installing the Trailing Cable. To accurately install the Trailing Cable on the tapes, obtain P/N 204483 “Fixture

Trailing Cable, Location”.

1. Remove the Top Cover.

2. Remove the Trailing Cable Cover from the back of the Y-Arm.

Use a 5/16 Hex Nut Driver to remove the three nuts which secure it to the back of the Y-Arm.

3. Remove the Right Cover Assembly. See Section 4.1.

CADJET 2 5-43

Disassembly/Assembly

4. Disconnect the Trailing Cable connector at the JP4 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 Chapter 5 .6 if necessary.

5. Use wire cutters to cut the tie wrap holding the Trailing Cable on the Carriage PCB. Be careful not to cut the Trailing Cable.

See Figure Chapter 5 .17.

6. Unlock the Trailing Cable connector (J1) on the Carriage PCB, carefully pull the Trailing Cable away from the double-sided tape, and remove the Trailing Cable. See Figure Chapter 5 .17.

7. Pull the Trailing Cable away from the double-sided tape on the

Stabilizer Bracket. Remove the Trailing Cable from the plotter unit.

5-44 CADJET 2

Disassembly/Assembly

8.6 Reinstalling the Trailing Cable

WARNING

Make sure that the silver fingers on the Trailing Cable face up before inserting the Trailing Cable into the J1 connector lock. See

Figure Chapter 5 .19.

NOTE

Note: The placement of the double-sided tape which is in the center of the Trailing Cable is important for proper movement of the

Carriage Assembly. You may want to obtain P/N 204142,

“Fixture Trailing Cable, Tape, Location,” which is used for the exact placement of both tapes when installing the Trailing

Cable, and P/N 204483, “Fixture Trailing Cable, Location,” which is used to accurately install the Trailing Cable.

1. See Figure Chapter 5 .20 during this procedure. Place

P/N 204142 (Fixture, Tape, Trailing Cable, Location) flat on the

Stabilizer Bracket so that the two cutouts are facing you and the right end of the fixture fits over the left edge of the approximately

2 inch cutout at the right end of the Stabilizer Bracket. Apply 2 pieces of 2” double-sided tape to the Stabilizer Bracket. Do not remove the top protective cover on the tapes yet. Remove the fixture after the tapes are in place.

2. Place the Trailing Cable on the Stabilizer Bracket.

3. Route the right end of the Trailing Cable through the Right Side

Plate (see Figure Chapter 5 .29) and connect the Trailing Cable connector at the JP4 location on the MPCB. Be sure to slide both sides of the connector lock shut at the same time. See

Figure Chapter 5 .6 if necessary.

4. Connect the Trailing Cable to the J1 connector lock on the

Carriage PCB. Make sure the silver fingers on the Trailing Cable face up before inserting it into the lock. See Figure Chapter 5 .19.

Slide both sides of the connector lock shut at the same time.

CADJET 2 5-45

Disassembly/Assembly

Figure Chapter 5 .20: Positioning the Trailing Cable on the Stabilizer Bracket

5-46 CADJET 2

CADJET 2

Disassembly/Assembly

5. Press the Trailing Cable down onto the double-sided tape on the

Carriage PCB.

6. Put the tie wrap down into the back hole in the Carriage PCB (see

Figure Chapter 5 .19), feed it up through the front hole, and put the end through the fastener.

7. Grasp the loose end of the tie wrap next to the fastener with the side (not the point) of a pair of needlenose pliers. Turn the pliers away from the fastener in order to pull the tie wrap snug. Cut off the excess length of the tie wrap.

8. Move the Carriage Assembly to the very left end of the Slide Shaft.

9. Place the Trailing Cable Location Fixture, P/N 204483, flat on the

Stabilizer Bracket against the back wall of the Stabilizer Bracket.

10. Remove the top protective cover on the 2” double-sided tape on the right end of the Stabilizer Bracket and press the right end of the Trailing Cable onto the tape.

11. With the Carriage Assembly still at the very left end of the Slide

Shaft and with the Trailing Cable still in line with the Trailing Cable

Location Fixture, P/N 204483, remove the top protective cover on the 2” double-sided tape in the center of the Trailing Cable and press the Trailing Cable onto the tape.

12. Remove the fixture. Slide the Carriage Assembly back and forth several times to make sure that the Trailing Cable does not catch on anything and to make sure that the Carriage Assembly will travel the full length of the Slide Shaft.

5-47

Disassembly/Assembly

8.7 Removing the Carriage Belt from Carriage Assembly

NOTE

Note: 1. All of the procedures covered under this section are based upon the assumption that the Carriage Assembly has already been removed from the Slide Shaft. Refer to Sections 8.1 and 8.2 in this chapter if it has not been removed.

2. Once the Carriage Belt has been installed (Section 8.8), refer to Sections 8.3 and 8.4 in this chapter for reinstallation of the

Carriage Assembly.

Replace the Carriage Belt if it is frayed, cracked, worn, or otherwise damaged.

1. Use the tip of a Slotted screwdriver to release the tension on the end of the metal Belt Clip which goes under the plastic on the

Carriage so that it slides out from under the plastic. See

Figure Chapter 5 .21.

2. Remove the Belt Clip. The Carriage Belt can now be removed.

5-48

Figure Chapter 5 .21: Removing the Carriage Belt

CADJET 2

Disassembly/Assembly

8.8 Installing the Carriage Belt on Carriage Assembly

CAUTION

The placement of the Carriage Belt on the plastic grooves which are on the Carriage Assembly is important so that the belt does not rub on anything. The belt should not be placed flush with the outer end of the plastic grooves. It should be positioned as close to the Carriage PCB as possible while still being on the plastic grooves. See Figure Chapter 5 .22.

1. The “bumps” on the belt (where the ends of the belt are joined together to make the belt continuous) should be positioned over the notches on the Carriage Assembly.

2. Use the metal Belt Clip to secure the belt to the Carriage

Assembly. Make sure there is no gap between the Belt Clip and the Carriage. Use the tip of a Slotted screwdriver to push the ends of the Belt Clip under the plastic on the Carriage Assembly. See

Figure Chapter 5 .21.

3. Once the Carriage Belt has been installed, refer to Sections 8.3 and 8.4 in this chapter for reinstallation of the Carriage Assembly.

CADJET 2

Figure Chapter 5 .22: Placement of Carriage Belt on Carriage

5-49

Disassembly/Assembly

9.0 Power Supply and ON/OFF Switch

9.1 Removing the Power Supply and ON/OFF Switch

WARNING

Make sure that the Power Cord is disconnected from the plotter before beginning this procedure.

NOTE

Note: 1. The Top Cover, Left Cover Assembly, and Left Side Plate must be removed in order to remove either the Power Supply or the ON/OFF Switch. See Section 8.1.

2. You must have the plotter removed from the Stand in order to access all of the screws on the bottom of the Platen which hold the Power Supply in place. See Section 3.1 if necessary.

1. Remove the Top Cover, Left Cover Assembly, and the Left Side

Plate. See Section 8.1.

2. Using a #2 Phillips screwdriver, remove the 4 screws on the bottom of the Platen which hold the Power Supply in place.

3. Pull the Power Supply part way out of the Platen, grasp the connector on the black and white ON/OFF Switch Cable, and remove the cable from the Power Supply.

4. Pull the Power Supply the rest of the way out of the Platen, grasp the connector on the Power Cable coming from the MPCB, and remove the Power Cable from the Power Supply.

5. If the ON/OFF Switch needs to be replaced, push the top of the switch out of the back of the Platen, pry up on the bottom of the switch with a screwdriver (from inside the Platen), and push the switch out of the Platen. Remove the ground wire from the Platen.

5-50 CADJET 2

Disassembly/Assembly

9.2 Installing the Power Supply and ON/OFF Switch

1. If the ON/OFF Switch was removed, push the new switch into place. Position it so the switch is on top and the prongs for the

Power Cord are on the bottom (see Chapter 1, Figure 1.3).

Connect the ground wire to the inside of the Platen (see

Figure Chapter 5 .24).

2. Connect the Power Cable coming from the MPCB to the connector on the Power Supply. Make sure that the ground from the Power

Cable is still connected to the inside of the Platen, at the same location as the ground from the ON/OFF Switch (see

Figure Chapter 5 .24).

3. Insert the Power Supply part way into the Platen.

4. Connect the Power Switch cable to the connector on the Power

Supply.

NOTE

Note: You may find it easier to align the screws with the Power

Supply if you turn the Platen onto its back side.

5. Position the Power Supply in place inside the Platen and insert the screws through the bottom of the Platen and into the Power

Supply. Use a #2 Phillips screwdriver to tighten the screws. (Do not overtighten them).

6. Reinstall the Left Side Plate, Left Cover Assembly, and the Top

Cover. See Section 8.4.

CADJET 2 5-51

Disassembly/Assembly

10.0 Stabilizer Bracket and Encoder Strip

NOTE

Note: 1. If the Encoder Strip is not damaged, do not remove it. It cannot be reused.

2. If the Encoder Strip is damaged, the entire Stabilizer Bracket must be replaced. Follow the directions under Sections 10.1 and 10.2 in this chapter. Contact ENCAD’s Technical

Support and Service department to obtain an RMA number

(see Chapter 1, Section 3.0). Be sure to specify whether you have a D-Size or E-Size model. A new Stabilizer Bracket will be sent to you which will already have the new Encoder Strip installed on it, as well as the tapes for the Trailing Cable.

The person taking your call will explain the procedure for the exchange.

The Encoder Strip is attached to the Stabilizer Bracket with doublesided 3M tape. The Stabilizer Bracket is held on the Y-Arm by means of three screws which go into the back of the Y-Arm. The Encoder

Strip should be inspected for visual damage to windows, noting any cracks, scratches, or bends in the mylar.

5-52

Figure Chapter 5 .23: Encoder Strip

CADJET 2

Disassembly/Assembly

10.1 Removing the Stabilizer Bracket

Refer to the appropriate sections of this chapter and to Figure Chapter

5 .23 while removing the parts listed below:

1. Remove the Cartridges and the Top Cover.

2. Remove the Left Cover Assembly and Left Side Plate. See

Section 8.1.

3. Remove the Trailing Cable Cover, Frame Tensioner, Left Cam

Actuator, and Carriage Assembly. See Section 8.2.

4. Remove the Trailing Cable from the tapes on the Stabilizer

Bracket. See Figure Chapter 5 .23.

5. Use a 7/64 Hex Nut Driver to remove the three screws from the back of the Y-Arm which hold the Stabilizer Bracket on the Y-Arm and remove the Stabilizer Bracket. See Figure Chapter 5 .23.

CADJET 2 5-53

Disassembly/Assembly

10.2 Reinstalling the Stabilizer Bracket

CAUTION

Be very careful not to damage the Encoder Strip as you install the

Stabilizer Bracket.

NOTE

Note: You may want to clean the Slide Shaft and the brass bushings on the Carriage Assembly prior to reinstalling the

Carriage Assembly. You may use Isopropyl Alcohol to clean the Slide Shaft, but you should NOT use it to clean the brass bushings. Use only a clean, dry cloth to clean the brass

bushings.

The new Stabilizer Bracket will already have the new Encoder Strip as well as new tapes for the Trailing Cable attached to it. Refer to

Figure Chapter 5 .23 and to the appropriate sections of this chapter during this procedure.

To reinstall the Stabilizer Bracket:

1. Attach the Stabilizer Bracket to the Y-Arm with the three screws which go through the back of the Y-Arm into the Stabilizer Bracket.

It is easier to do this if you first attach one end, then the other end, and then the center. Put the screws down to the bottom of the slot in the Y-Arm and use the 7/64 Hex Nut Driver to tighten them.

(The exact positioning of the screws in the slot will be done later during the Carriage Height Adjustment in Section 6.2 of Chapter 6.

2. Follow all the steps in Section 8.3 for reinstalling the Carriage

Assembly through Step 17. (The Trailing Cable Cover will be reattached later.)

5-54 CADJET 2

Disassembly/Assembly

3. Slide the Carriage Assembly back and forth a few times to make sure it moves easily. Make certain that it travels easily all the way to the left end of the Slide Shaft so that the Left Cam Actuator engages the Cutter.

4. Once you have checked the movement of the Carriage Assembly, go to Section 8.6, Steps 8-12 for the procedure for attaching the

Trailing Cable to the tapes on the Stabilizer Bracket.

5. Reattach the Trailing Cable Cover.

6. Reattach the Left Side Plate and Left Cover Assembly. See

Section 8.4.

7. Reinstall the Cartridges and the Top Cover.

CADJET 2 5-55

Disassembly/Assembly

11.0 Lower Drive Assembly, Fan Assembly, and

Stepper Motor Assembly (Inner Platen

Parts)

The Inner Platen contains the Lower Drive Assembly, the Fan

Assembly, the Stepper Motor Assembly, the Drive Shaft Supports, and the Foam Block. See Figure Chapter 5 .24. These parts are referred

to collectively as the Inner Platen Parts. (Although the Power

Supply and ON/OFF Switch are also inside the Platen, for the purposes of this manual they are not included when a reference to the

Inner Platen Parts is made.)

5-56

Figure Chapter 5 .24: Inner Platen Parts

CADJET 2

Disassembly/Assembly

11.1 Disassembly of Plotter Before Removing the Inner

Platen Parts

Refer to the indicated sections of this chapter and Figure Chapter 5

.25 as necessary during this procedure. To obtain access to the Inner

Platen Parts:

1. Remove the Top Cover, the Left Cover Assembly and the Left

Side Plate. See Section 8.1.

2. Remove the Right Cover Assembly. See Section 4.1.

3. Disconnect all the connectors from the MPCB. See Section 4.2.

4. Remove the MPCB. See Section 4.3.1.

CAUTION

There is a screw and nut in approximately the middle near the top edge of the Left and Right Side Plates. These have been set at the factory to a specific torque. DO NOT tighten or loosen this screw and nut at any time. See Figure Chapter 5 .25.

5. Remove the Right Side Plate. See Figure Chapter 5 .25. Be sure to disconnect the Power Cable Ground from the inside of the Right

Side Plate.

6. Remove the Display Assembly. See Section 6.1.

7. Remove the Left and Right Rollguides from the back of the Platen.

8. Remove the Trailing Cable Cover.

9. Remove the Power Supply. See Section 9.1.

10. Remove the Servo Motor. See Section 5.1, Steps 4-9.

11. Clean and remove the entire Service Station. See Chapter 3,

Section 4.0 for cleaning procedure and Chapter 5, Section 7.1 for the removal procedure.

12. Go to Section 11.2 below.

CADJET 2 5-57

Disassembly/Assembly

Figure Chapter 5 .25: Disassembly of Plotter Prior to Removing the Inner Platen

Parts

5-58 CADJET 2

Disassembly/Assembly

11.2 Removing the Inner Platen Parts

CAUTION

When you remove the Lower Drive Assembly, make sure that the

Lower Rollers do not catch on any of the openings, screws, or cap nuts inside the Platen. If the Lower Rollers catch on any of these items, they can become damaged, which would affect the Skew and make it necessary to replace the entire Lower Drive Assembly.

NOTE

Refer to Figure Chapter 5 .24 and Figure Chapter 5 .26 during this procedure.

1. Lay Platen on its back.

2. Use a flat screwdriver to pry out the Snap Plug on the bottom side of the Platen.

3. Using a #1 6” or 8” Phillips screwdriver, remove the four screws on the bottom of the Platen which hold the Exhaust in place.

4. Insert your left hand into the opening for the Exhaust and hold the

Fan Assembly in place while using a #2 6” or 8” Phillips screwdriver to remove the 3 flat-head screws on the bottom of the

Platen which hold the Fan Assembly in place. Do not allow the screws to come out at an angle.

5. Lay the Platen on its bottom.

6. Using a #1 6” or 8” Phillips screwdriver, remove the 4 black flathead screws which hold the left and middle Drive Shaft Supports in place. There are two screws in the center of the Platen, and two screws approximately three inches to the left of the left brass bracket. See Figure Chapter 5 .26.

Note: Don’t remove the two screws holding the Stepper Motor

Assembly until Step 9. See Figure Chapter 5 .26.

CADJET 2 5-59

Disassembly/Assembly

Figure Chapter 5 .26: Removing the Lower Drive Shaft Screws

5-60 CADJET 2

NOTE

Disassembly/Assembly

7. Remove the left Drive Shaft Support through the left end of the

Platen and the middle Drive Shaft Support through the Snap Plug opening.

Note: Be very careful when removing the Foam Block so that it does not tear. If it does tear, however, it must be replaced with a new one so that the Inner Platen has sufficient vacuum.

8. Remove the Foam Block which is beside the Stepper Motor

Assembly by putting your index finger into the opening in the top of the Foam Block and pulling it towards you. See Figure Chapter 5

.27.

CADJET 2

Figure Chapter 5 .27: Removing the Foam Block

5-61

Disassembly/Assembly

CAUTION

During Step 9:

When you remove the two screws from the right Drive Shaft

Support which hold the Stepper Motor Assembly (see

Figure Chapter 5 .26), hold the Stepper Motor Assembly with your right hand. If the Stepper Motor Assembly drops and hits hard on the Platen, the wires and/or the Stepper Motor may be damaged.

9. Using a #1 6” or 8” Phillips screwdriver, loosen but do not

remove the 2 black flat-head screws which hold the Stepper Motor

Assembly. Hold the Stepper Motor Assembly with your right hand so it does not drop suddenly and use your left hand to finish unscrewing the two screws and remove them.

CAUTION

During Step 10:

1. Make sure that the Lower Drive Gear on the right end of the

Lower Drive Shaft Assembly does not catch on the edge of the opening in the Platen.

2. Support the Lower Rollers so they do not catch on any of the openings, screws, or cap nuts inside the Platen. If the

Lower Rollers catch on any of these items, they can become damaged, which would affect the Skew and make it necessary to replace the entire Lower Drive Assembly.

3. Do not allow the Fan Assembly to drop as it comes out of the right end of the Platen.

10. Reach into the Fan opening on the bottom of the Platen and use your fingertips to hold up the Fan Assembly so that it clears the openings, screws, and cap nuts on the inside of the Platen while simultaneously pulling the Stepper Motor Assembly and Lower

Drive Shaft Assembly out of the right end of the Platen.

11. Go to Section 11.3 below if the Stepper Motor Assembly needs to be removed. Otherwise, go to Section 11.4.

5-62 CADJET 2

Disassembly/Assembly

11.3 Stepper Motor

11.3.1 Removing the Stepper Motor

NOTE

Note: 1. If the Stepper Motor needs to be replaced, all of the steps from the beginning of Section 11.0 (including all subsections) must be performed.

2. If removing only the Stepper Motor, do not remove the

Bowed Washer, Washer, and Retaining Ring which are between the end of the Lower Drive Assembly and the

Stepper Motor Bracket. See Figure Chapter 5 .28.

3. Do not remove the 20 Teeth Gear from the Stepper Motor.

See Figure Chapter 5 .28.

4. Do not remove the Oilite Bushing from the Stepper Motor

Bracket. (If it should happen to fall out, press it back in as far as it will go.)

5. Do not clean the Oilite Bushing with alcohol. Wipe it with a clean, dry cloth only. See Figure Chapter 5 .28.

1. Once the Inner Platen Parts have been removed, remove the

Stepper Motor from the Stepper Motor Bracket by unhooking the

Extension Spring from the post on the Stepper Motor Bracket.

See Figure Chapter 5 .28.

2. Unscrew the Retainer Spring Post from the Spring Post and remove them from the Stepper Motor Bracket and Stepper Motor

Assembly.

3. Unscrew the Pivot Screw and Pivot Nut and remove them from the

Stepper Motor Bracket and Stepper Motor Assembly.

4. Remove the Stepper Motor from the end of the Lower Drive

Assembly.

5. If you are replacing the Stepper Motor Bracket, you will need to remove the Retaining Ring, Washer, and Bowed Washer which are between the end of the Lower Drive Assembly and the Stepper

Motor Bracket.

CADJET 2 5-63

Disassembly/Assembly

Figure Chapter 5 .28: Lower Drive Assembly and Stepper Motor Assembly

5-64 CADJET 2

NOTE

WARNING

Disassembly/Assembly

11.3.2 Reinstalling the Stepper Motor

Note: 1. If the Oilite Bushing came out of the Stepper Motor Bracket, make sure that it has been reinstalled. Press it into the bracket as far as possible. There should be no gap between the bushing and the bracket.

2. If you did not remove the Stepper Motor Bracket from the

Lower Drive Assembly, skip Step 1.

3. If you are installing a new Stepper Motor Assembly, the gear should have been on the shaft of the motor when you received the motor.

1. Be very careful when you install the Stepper Motor

Assembly onto the Stepper Motor Bracket so that you do not damage the gears on the motor and the Lower Drive

Assembly.

2. Overtightening the Pivot Screw (Step 3 below) can prevent the Stepper Motor from pivoting as intended. DO NOT

OVERTIGHTEN.

1. If you are replacing the Stepper Motor, put the Stepper Motor

Bracket onto the Lower Drive Assembly and then put the Bowed

Washer, the Washer, and the Retaining Ring on over the end of the Lower Drive Assembly. Make sure that the Retaining Ring snaps into the groove in the end of the Lower Drive Assembly.

2. Gently place the Stepper Motor Assembly onto the Stepper Motor

Bracket. Be careful not to damage the gears. Make sure that the gears are meshing with each other.

3. Use the Pivot Screw and Pivot Nut to secure the Stepper Motor

Assembly to the Stepper Motor Bracket. Torque to 6 IN-LB.

4. Hook the Extension Spring onto the Spring Post.

5. Place the Spring Post through the Stepper Motor Assembly and the Stepper Motor Bracket and secure it with the Retainer Spring

Post. Torque to 6 IN-LB.

6. Hook the Extension Spring onto the post on the Stepper Motor

Bracket.

7. Complete the reinstallation of the Inner Platen Parts by following the procedures listed below in Section 11.4.

CADJET 2 5-65

Disassembly/Assembly

11.4 Reinstalling the Inner Platen Parts

CAUTION

When you reinstall the Lower Drive Assembly, make sure that none of the Lower Rollers or the Gear catch on the screws, cap nuts, or openings inside the Platen. If the Lower Rollers catch on any of these items, they can become damaged, which would affect the Skew and make it necessary to replace the entire Lower Drive

Assembly.

Refer as needed to Figure Chapter 5 .24, Figure Chapter 5 .25,

Figure Chapter 5 .26, Figure Chapter 5 .27, and Figure Chapter 5 .29 during this procedure.

1. Insert the Lower Drive Shaft Assembly and Stepper Motor

Assembly part way into the right end of the Platen.

2. Place the Fan Assembly under the Lower Drive Shaft beside the right Lower Drive Gear. Make sure that the Fan Assembly wires face the right end of the Platen and the opening in the Fan

Assembly faces the left end of the Platen.

3. Lay the Stepper Motor Assembly on the palm of your right hand and use your fingertips to hold up the Fan Assembly as you push the Lower Drive Shaft into the Platen. While inserting, you must lift the Fan Assembly over the cap nuts on the inside of the bottom of the Platen and make sure you do not strike the Lower Rollers or the Gear on the Lower Drive Shaft against the screws, cap nuts, or openings in the Platen.

4. Align the right Lower Drive Shaft Support with the screw holes and insert the screws. Using a #2 6” or 8” Phillips screwdriver, tighten them slightly.

5. Insert the middle Lower Drive Shaft Support through the Snap

Plug opening (see Figure Chapter 5 .26), align it with the screw holes, and insert the screws. Using a #2 6” or 8” Phillips screwdriver, tighten them slightly.

5-66 CADJET 2

Disassembly/Assembly

6. Insert the left Lower Drive Shaft Support in the left end of the

Platen so that the shaft goes through the brass bushing in the support. The support should be oriented in the same manner as the support which is by the Stepper Motor. See Figure Chapter 5

.26. Align it with the screw holes, and insert the screws. Using a

#2 6” or 8” Phillips screwdriver, tighten them slightly.

7. Tighten all the screws in the supports until they are snug.

8. Insert the Foam Block. Make sure that the Power Supply Cable is in the opening in the front of the Foam Block. Also make sure that the Stepper Motor Assembly and Fan Assembly cables are at the back corner of the Foam Block. See Figure Chapter 5 .27. Push the Foam Block in until it is flush against the Stepper Motor

Assembly. Make sure it is not tilted at an angle.

9. Turn the Platen onto its back.

CAUTION

Do not overtighten the screws which hold the Fan Assembly in place. The threads in the screw holes will strip very easily.

10. Reach through the opening for the Fan Assembly with your left hand, align the opening in the Fan Assembly with the right edge of the opening in the Platen, and align the three screw holes. If necessary, push the Power Supply Cable up towards the front edge of the Platen so that it is out of the way of the Fan Assembly.

11. Hold the Fan in place with your left hand and insert the screws.

Make sure that the screws go in straight. Using a #2 6” or

8” Phillips screwdriver, tighten them just until snug. Do not overtighten or the threads on the screw holes will strip.

CADJET 2 5-67

Disassembly/Assembly

CAUTION

The Exhaust must be oriented correctly in order to achieve the proper vacuum inside the Platen. See Figure Chapter 5 .24.

12. Reinstall the Exhaust on the outside of the bottom of the Platen.

Using a #2 6” or 8” Phillips screwdriver, tighten the screws until snug.

13. Reinsert the Snap Plug in the bottom of the Platen and turn the

Platen onto its bottom side.

14. Go to Section 11.5.

5-68 CADJET 2

Disassembly/Assembly

11.5 Reassembly of Plotter After Reinstalling the Inner

Platen Parts

1. Reinstall the Servo Motor. See Section 5.2.

2. Reinstall the Display Assembly. See Section 6.2.

3. Reinstall the Service Station Assembly. See Section 7.2.

4. Make sure the Ground from the Power Cable is still connected to the inside of the Platen, at the same location as the ON/OFF

Switch Ground. See Figure Chapter 5 .24. Reinstall the Power

Supply. See Section 9.2.

5. Reinstall the Left and Right Rollguides.

6. Reinstall the Left Side Plate. See Section 8.4, Step 1.

7. Attach the Ground from the Power Cable to the inside of the Right

Side Plate (near the front edge). Route all the wires from the

Servo Motor Assembly, Stepper Motor Assembly, Fan Assembly, and Power Supply through the bottom slot on the Right Side Plate.

See Figure Chapter 5 .29. Secure the Right Side Plate to the

Platen with four screws. See Figure Chapter 5 .25.

CAUTION

1. Feed the Trailing Cable and the Keypad Flex Cable through the openings in the Right Side Plate. Make sure they are not over the top of the Right Side Plate.

2. Make sure the silver fingers are facing up when they are routed through the Right Side Plate. See Figure Chapter 5

.29.

8. Route the Trailing Cable (with the silver fingers facing up) through the top slot in the Right Side Plate.

CADJET 2 5-69

Disassembly/Assembly

Figure Chapter 5 .29: Routing of Wires and Cables on Right Side Plate and MPCB

5-70 CADJET 2

CADJET 2

Disassembly/Assembly

9. Secure the MPCB to the Right Side Plate using three screws. See

Section 4.3.2 and Figure Chapter 5 .29. Make sure the Trailing

Cable is not pinched between the stand-off and the MPCB.

10. Bring the Trailing Cable around the bottom of the MPCB and connect it at the JP4 connector. Make sure the silver fingers

face down when the Trailing Cable is inserted into the connector.

11. Route the Keypad Cable through the top left hole in the Right Side

Plate. Bring the Keypad Cable down around the flat edge of the

MPCB beneath the J1 connector. Connect the Keypad Cable at the J1 connector on the MPCB. The silver fingers must face the

back side of the plotter when the Keypad Cable is inserted

into the connector.

12. Reconnect the Servo Motor wire (Red and Blue) to the J6 connector, the Stepper Motor wire to the JP5 connector, and the

Fan wire (Red and Black) to the J5 connector. Reference

Figure Chapter 5 .6.

13. Reinstall the Trailing Cable Cover.

14. Reinstall the Right Cover Assembly. Make sure that none of the harnesses or cables are pinched between the cover assembly and the Right Side Plate. See Section 4.6.

15. Reinstall the Left Cover Assembly and the Filler Block. See

Section 8.4, Steps 2-6.

16. Reinstall the Top Cover.

The entire plotter is now reassembled.

5-71

Disassembly/Assembly

12.0 Fixed Blade

12.1 Removing the Fixed Blade

These instructions are given even though it is very unlikely that the

Fixed Blade will ever need to be replaced.

1. Park the Carriage Assembly at the Service Station and disconnect the power.

2. Use a flat tip screwdriver or the Machinist Scriber to remove the

Fixed Blade. Pry up gently on one end of the Fixed Blade and carefully loosen it along the length of the Platen.

3. If any of the Fixed Blade Spacers come loose when the Fixed

Blade is removed, reattach them according to the instructions in

Section 12.2 below

5-72

Figure Chapter 5 .30: Fixed Blade

CADJET 2

Disassembly/Assembly

12.2 Reinstalling the Fixed Blade

NOTE

Note: You will not need to perform this step if all the Fixed Blade

Spacers remained in place during the removal of the Fixed

Blade.

1. See Figure Chapter 5 .30. Place the Fixed Blade Spacers 2”(13 for E-Size and 9 for D-Size) and the Fixed Blade Spacer 1” into the groove in the Platen. Be sure to keep all spacers away from the openings for the Upper Rollers.

2. Place the Fixed Blade into the groove. The right end of the Fixed

Blade should be about 1/2” to the left of the edge of the Service

Station. Make sure that the angled ends of the Fixed Blade

point towards the back of the Platen, as shown in

Figure Chapter 5 .30, to avoid damage to the Cutter.

3. Install the Fixed Blade Clips (14 for E-Size and 10 for D-Size) into the groove. A Fixed Blade Clip should be placed opposite each

Fixed Blade Spacer. Make sure that the Fixed Blade Clips are seated all the way to the bottom of the groove. Also make sure that the Fixed Blade is seated all the way to the bottom of the

Fixed Blade Spacers.

4. Secure the Fixed Blade and the Fixed Blade Spacers (if any came out during the removal of the Fixed Blade) to the Platen, using the

Blackmax Loctite at the “B” locations shown in Figure Chapter 5

.30.

CADJET 2 5-73

Disassembly/Assembly

13.0 Cutter Wheel

13.1 Removing the Cutter Wheel

WARNING

Be very careful whenever you handle the Cutter Assembly. The

Cutter Wheel is extremely sharp.

In the event that the Cutter Wheel should become dull, it may be replaced with a new wheel. It is not necessary to replace the entire

Cutter Assembly. Use the following procedure:

1. Disconnect the power to the plotter.

2. Move the Carriage Assembly to the center of the Platen.

3. Use a pair of needle nose pliers to unhook the spring on the left side of the Cutter Assembly from the Carriage Assembly.

4. Lift the Cutter Assembly away from the Carriage Assembly.

5. Remove the four screws (Item 9 in Figure Chapter 5 .31) from the

Cover Cutter (Item 2).

6. Remove the Cutter Wheel (Item 7) from the Lower Link Cutter

(Item 4).

5-74 CADJET 2

Disassembly/Assembly

CADJET 2

Figure Chapter 5 .31: Cutter Assembly

5-75

Disassembly/Assembly

13.2 Replacement of Cutter Wheel

If the entire Cutter Assembly came apart when the Cutter Wheel was removed, begin with Step 1. If the Cutter Assembly did not come apart, begin with Step 4.

1. Place the Delta Link Cutter (Item 3 in Figure Chapter 5 .31) onto the Frame Cutter (Item 1).

2. Place the Cutter Toggle Spring (Item 8) between the two Cutter

Spring Pivots (Item 6). Then place them into the Delta Link Cutter

(Item 3).

3. Place the Lower Link Cutter (Item 4) onto the Delta Link Cutter

(Item 3).

4. Place the Cutter Wheel (Item 7) onto the Lower Link Cutter

(Item 4).

NOTE

Note: The Cutter Wheel is flat on one side and is beveled on the other side. The beveled edge of the Cutter Wheel must face the Cover Cutter. See Figure Chapter 5 .31.

5. Place and secure the Cover Cutter (Item 2) to the Frame Cutter

(Item 1), using the four screws (Item 9).

NOTE

Note: The Cover Cutter and the Frame Cutter must be aligned accurately with each other when reassembling the Cutter; that is, the edges must match up and the Cutter Wheel must turn freely. If this is not done correctly, the Cutter Wheel will bind and will not function properly.

6. Place the Actuator Link Cutter (Item 5) on the back of the Frame

Cutter (Item 1).

7. Reinstall the Cutter Assembly on the Carriage Assembly.

8. Use a pair of needle nose pliers to reattach the spring on the left side of the Cutter Assembly to the Carriage Assembly.

5-76 CADJET 2

Disassembly/Assembly

14.0 Upper Roller Supports

NOTE

Note: 1. This procedure is to be used only if the Upper Roller

Supports become worn or damaged.

2. It is highly recommended that ALL the Upper Roller Supports be replaced at the same time rather than just those that are worn or damaged. This will ensure that all rollers have an equal amount of use time and wear.

3. You will need the 4-1/2” x 1” x 1/32” piece of Oil Hardened

Precision Ground Flat Stock and also the piece of Translite media in the list of recommended tools and fixtures in

Section 2.0.

4. If you need assistance during this procedure, call ENCAD's

Technical Support and Service department. See Chapter 1,

Section 3.0.

CADJET 2 5-77

Disassembly/Assembly

14.1 Removing the Upper Roller Supports

CAUTION

1. During the removal procedure, especially Steps 5, 6, 7, and

8, you must be very careful not to damage the Lower Drive

Assembly Rollers, the Slide Shaft, the Encoder Strip, the

Carriage Belt, and the Trailing Cable. The Upper Roller

Supports and any tools used should not be allowed to come into contact with any of these parts.

2. Never attempt to repair and reuse the Upper Roller Supports once you have removed them. Always replace them with new Upper Roller Supports.

1. Remove the Top Cover, Left Cover Assembly, and the Left Side

Plate. See Section 8.1.

2. Use the Hex Nut Driver #5/16 to remove the 3 nuts which secure the Trailing Cable Cover to the back of the Y-Bracket and remove the Trailing Cable Cover.

3. Depress the back of the Frame Tensioner (see Figure Chapter 5

.12) and slip the Carriage Belt off the Servo Motor Pulley. (The

Carriage Belt only needs to be loose during this procedure; it does not need to be removed. Lift both sides of the Carriage Belt out of the Y-Bracket and loop them over the front of the Slide Shaft.)

CAUTION

During Step 4:

YOU MUST NOT DISTURB THE 3 SCREWS ON

THE BACK OF THE Y-BRACKET WHICH HOLD ON

THE STABILIZER BRACKET (see Figure Chapter

5

.23

). If these are in any way disturbed, the

Carriage Head Height will be changed, which will affect the line quality.

5-78 CADJET 2

Disassembly/Assembly

4. Use the #1 Phillips Screwdriver to remove the screws which hold the far left Upper Roller Support on the Y-Bracket. (The screws are located on the back of the Y-Bracket. See Figure Chapter 5

.35.) MAKE SURE YOU ARE LOOSENING THE CORRECT

SCREWS AND NOT THE ONES WHICH HOLD ON THE

STABILIZER BRACKET (see Figure Chapter 5 .23)!

5. Using your fingers, pull the Upper Roller Support forward. Insert the 4-1/2” x 1” x 1/32” piece of Oil Hardened Precision Ground Flat

Stock underneath the Upper Roller Support and push the Flat

Stock towards the back of the unit so that it completely covers the

Lower Roller. Bend the front of the Upper Roller Support up with your fingers. As you bend up the front end of the Upper Roller

Support , the bottom back part of it will also be bending up slightly.

It should be bent as shown below in Figure Chapter 5 .32.

Figure Chapter 5 .32: Upper Roller Support - Normal and Bent for Removal

CADJET 2 5-79

Disassembly/Assembly

6. After the Upper Roller Support is bent as much as possible, replace the Flat Stock with the piece of Translite media to protect the Lower Roller. Push the Upper Roller Support towards the back of the unit and grasp the lower tab of it with the Needlenose

Pliers. Guide the lower tab of the Upper Roller Support up past the front of the Stabilizer Bracket. See Figure Chapter 5 .33.

Make sure the Upper Roller Support does not catch on the front edge of the Trailing Cable and that it does not damage the Slide

Shaft.

Figure Chapter 5 .33: Removing the Old Upper Roller Support

5-80 CADJET 2

Disassembly/Assembly

7. If the Upper Roller Support does not come out easily, repeat

Step 5 again to put more of a bend in the Upper Roller Support and then try to remove it. If the Upper Roller Support still does not come out easily, you may find it necessary to use a pair of

Needlenose Pliers to bend up the bottom tab of the Upper Roller

Support. Use extreme caution so that the pliers do not

damage the Slide Shaft or the Encoder Strip.

8. Working from the far left Upper Roller Support to the far right

Upper Roller Support, follow Steps 4 through 7 for each of the remaining Upper Roller Supports. As you do so, be sure to keep the Carriage Belt looped over the front of the Slide Shaft so it is not damaged. ALSO, MAKE SURE YOU ARE LOOSENING THE

CORRECT SCREWS AND NOT THE ONES WHICH HOLD ON

THE STABILIZER BRACKET!

CADJET 2 5-81

Disassembly/Assembly

CAUTION

1. When you remove the far right Upper Roller Support, you may need to lift up the double-sided tape which holds down the Trailing Cable at that point on the Stabilizer Bracket so that the Trailing Cable can be moved slightly to prevent damage as you remove the Upper Roller Support. See

Figure Chapter 5 .20. We recommend using an X-Acto Knife to lift up the tape (leave the tape attached to the Trailing

Cable). Before loosening the tape, you should mark its exact position with a pen or marker.

2. There is also a tape in the center of the Stabilizer Bracket, but it should not be necessary to loosen it in order to remove the Upper Roller Supports near it. If you do need to loosen it, however, you should not loosen the other tape at the right-hand side of the Stabilizer Bracket at the same time. Always mark the exact position of the tapes and leave one of the tapes in place while the other is loose. Correct positioning of these tapes is essential for the proper operation of the Carriage Assembly.

3. Be sure to press the tape back down again after the roller is removed. If you have to use a new piece of tape, make sure it is put down in exactly the same place on the Stabilizer

Bracket by using the Fixture, Trailing Cable, Tape, Location

(P/N 204142).

5-82 CADJET 2

Disassembly/Assembly

14.2 Installing the Upper Roller Supports

CAUTION

Make sure that you do not install the Upper Roller Supports upside down. Once they are inside the Y-Bracket, you will have to destroy them in order to take them out. See Figure Chapter 5 .35 for the correct orientation of the Upper Roller Supports.

Have the piece of Translite media in place so that the Lower Roller is protected while you install the new Upper Roller Supports. Make sure that the Carriage Belt is kept looped over the front of the Slide Shaft while installing the new Upper Roller Supports, as follows:

1. Place the roller end of an Upper Roller Support behind the Slide

Shaft (between the back of the Slide Shaft and the front of the

Stabilizer Bracket) and push it forward as far as possible through the Upper Roller Support opening in the front of the Y-Bracket.

See Figure Chapter 5 .34.

CADJET 2

Figure Chapter 5 .34: Inserting New Upper Roller Supports

5-83

Disassembly/Assembly

2. Push forward very firmly on the back of the Upper Roller Support until the back of it clears the front of the Stabilizer Bracket and snaps into place so that the entire Upper Roller Support is down inside the Y-Bracket.

3. Grasping the roller between your fingers, move the Upper Roller

Support into place. Make sure the point on top back of the Upper

Roller Support is in its hole in the Y-Bracket. See Figure Chapter

5 .35.

Figure Chapter 5 .35: Positioning Upper Roller Supports

5-84 CADJET 2

NOTE

Disassembly/Assembly

4. Keep pressure on the front of the Upper Roller Support while putting in the screws. Make sure the Upper Roller Support is centered in its opening. Tighten the screws until snug (no more than 3.0 In. Lbs. + 0.5 if using a torque screwdriver). MAKE

SURE YOU ARE TIGHTENING THE CORRECT SCREWS AND

NOT THE ONES WHICH HOLD ON THE STABILIZER

BRACKET!

Note: To help center the Upper Roller Support, we suggest you:

1. Push the front of the Upper Roller Support towards the right side of the opening as you put in the left screw and tighten it a few turns.

2. Push the front of the Upper Roller Support towards the left side of the opening as you put in the right screw and tighten it a few turns.

3. Alternate between the two screws as you tighten them evenly so that both sides become snug at about the same time.

5. Repeat Steps 1 through 4 for the rest of the Upper Roller

Supports.

CADJET 2 5-85

Disassembly/Assembly

6. Put the Carriage Belt back into place in the Y-Bracket. a. See Section 8.3, Steps 8 through 15 and Figure Chapter 5

.18 for the correct assembly of the Frame Tensioner

Assembly. b. Make sure that the Carriage Belt is not twisted. One way to check this is by standing at the left end of the plotter and looking down the length of the inside of the Y-Bracket. c. You can also check for twisting by moving the Carriage

Assembly as far as possible to the left end of the Slide Shaft. d. Once you are certain there is no twisting of the Carriage Belt, slide the Carriage back and forth a few times to make sure that it slides smoothly.

7. Reattach the Trailing Cable Cover to the Y-Bracket using the

5/16 Hex Nut Driver to tighten the 3 nuts.

8. Reattach the Left Side Plate and the Left Cover Assembly. See

Section 8.4

9. Because you have replaced the Upper Roller Supports, it is necessary to perform the following portions of Chapter 6: l

Section 7.0, “Paper Skew Setup” l Sections 8.0 through 8.4.4, “Paper Skew Adjustment”

Because the Carriage Belt was loosened during this procedure, you will need to verify the Deadband Adjustment by performing the following portions of Chapter 6: l Sections 11.0 through 11.2.1, “Deadband Calibration”

10. Replace the Top Cover after you have finished Step 9.

5-86 CADJET 2

Disassembly/Assembly

Chapter 5 DISASSEMBLY/ASSEMBLY 5-1

1.0 Introduction......................................................................................................... 5-1

2.0 Tools and Equipment Required .......................................................................... 5-4

3.0 Stand .................................................................................................................. 5-7

3.1 Removing the Plotter from the Stand .............................................................. 5-7

3.2 Replacing the Plotter on the Stand ................................................................. 5-9

3.3 Alternate Method for Securing Carriage Assembly and Fixed Blade ............ 5-10

4.0 Right Cover Assembly, MPCB, and SIMMS ..................................................... 5-11

4.1 Removing the Right Cover Assembly............................................................ 5-11

4.2 Removing the MPCB Connectors ................................................................. 5-13

4.3 MPCB............................................................................................................ 5-16

4.3.1 Removing the MPCB .............................................................................. 5-16

4.3.2 Reinstalling the MPCB............................................................................ 5-17

4.4 Reinstalling the MPCB Connectors ............................................................... 5-18

4.5 Extra Memory (SIMM) ................................................................................... 5-19

4.5.1 Extra Memory (SIMM) Removal ............................................................. 5-19

4.5.2 Extra Memory (SIMM) Installation .......................................................... 5-21

4.6 Reinstalling the Right Cover Assembly ......................................................... 5-22

5.0 Servo Motor ...................................................................................................... 5-23

5.1 Removing the Servo Motor ........................................................................... 5-23

5.2 Replacing the Servo Motor............................................................................ 5-26

6.0 Display Assembly ............................................................................................. 5-27

6.1 Removing the Display Assembly................................................................... 5-27

6.2 Reinstalling the Display Assembly ................................................................ 5-28

7.0 Service Station Assembly................................................................................. 5-29

7.1 Removing the Service Station Assembly ...................................................... 5-29

7.2 Reinstalling the Service Station Assembly .................................................... 5-31

8.0 Left Cover Assembly, Left Side Plate, Carriage Assembly, Trailing Cable, and

Carriage Belt........................................................................................................... 5-32

8.1 Removing the Left Cover Assembly and Left Side Plate .............................. 5-32

8.2 Removing the Carriage Assembly................................................................. 5-34

CADJET 2 5-87

Disassembly/Assembly

8.3 Reinstalling the Carriage Assembly .............................................................. 5-37

8.4 Reinstalling the Left Side Plate and Left Cover Assembly............................ 5-42

8.5 Removing the Trailing Cable......................................................................... 5-43

8.6 Reinstalling the Trailing Cable ...................................................................... 5-45

8.7 Removing the Carriage Belt from Carriage Assembly .................................. 5-48

8.8 Installing the Carriage Belt on Carriage Assembly........................................ 5-49

9.0 Power Supply and ON/OFF Switch .................................................................. 5-50

9.1 Removing the Power Supply and ON/OFF Switch........................................ 5-50

9.2 Installing the Power Supply and ON/OFF Switch.......................................... 5-51

10.0 Stabilizer Bracket and Encoder Strip.............................................................. 5-52

10.1 Removing the Stabilizer Bracket................................................................. 5-53

10.2 Reinstalling the Stabilizer Bracket .............................................................. 5-54

11.0 Lower Drive Assembly, Fan Assembly, and Stepper Motor Assembly (Inner

Platen Parts) .......................................................................................................... 5-56

11.1 Disassembly of Plotter Before Removing the Inner Platen Parts................ 5-57

11.2 Removing the Inner Platen Parts ................................................................ 5-59

11.3 Stepper Motor ............................................................................................. 5-63

11.3.1 Removing the Stepper Motor ............................................................... 5-63

11.3.2 Reinstalling the Stepper Motor ............................................................. 5-65

11.4 Reinstalling the Inner Platen Parts.............................................................. 5-66

11.5 Reassembly of Plotter After Reinstalling the Inner Platen Parts................. 5-69

12.0 Fixed Blade .................................................................................................... 5-72

12.1 Removing the Fixed Blade.......................................................................... 5-72

12.2 Reinstalling the Fixed Blade ....................................................................... 5-73

13.0 Cutter Wheel .................................................................................................. 5-74

13.1 Removing the Cutter Wheel........................................................................ 5-74

13.2 Replacement of Cutter Wheel .................................................................... 5-76

14.0 Upper Roller Supports.................................................................................... 5-77

14.1 Removing the Upper Roller Supports ......................................................... 5-78

14.2 Installing the Upper Roller Supports ........................................................... 5-83

5-88 CADJET 2

Disassembly/Assembly

Figure 5.1: CADJET 2 Hardware Kit Assembly ........................................................... 5-5

Figure 5.2: CADJET 2 Final Assembly Tools .............................................................. 5-6

Figure 5.3: Preparing the Plotter for Shipping ............................................................. 5-8

Figure 5.4: Preparing the Plotter for Shipping - Alternate Method ............................ 5-10

Figure 5.5: Inside View of Right Cover Assembly ..................................................... 5-11

Figure 5.6: MPCB Connectors .................................................................................. 5-15

Figure 5.7: Location of SIMM .................................................................................... 5-19

Figure 5.8: Closeup View of Clip ............................................................................... 5-19

Figure 5.9: Side View of SIMM Removal................................................................... 5-20

Figure 5.10: Side View of SIMM Installation.............................................................. 5-21

Figure 5.11: Servo Motor .......................................................................................... 5-24

Figure 5.12: Compression of Frame Tensioner ........................................................ 5-25

Figure 5.13: Display Assembly.................................................................................. 5-27

Figure 5.14: Keypad PCB ......................................................................................... 5-28

Figure 5.15: Service Station Assembly ..................................................................... 5-29

Figure 5.16: Inside View of Left Side Plate ............................................................... 5-33

Figure 5.17: Trailing Cable Connector Lock on Carriage PCB.................................. 5-35

Figure 5.18: Left End of Y-Arm ................................................................................. 5-36

Figure 5.19: Reinstalling the Trailing Cable in J1 Connector .................................... 5-39

Figure 5.20: Positioning the Trailing Cable on the Stabilizer Bracket........................ 5-46

Figure 5.21: Removing the Carriage Belt .................................................................. 5-48

Figure 5.22: Placement of Carriage Belt on Carriage ............................................... 5-49

Figure 5.23: Encoder Strip ........................................................................................ 5-52

Figure 5.24: Inner Platen Parts ................................................................................. 5-56

Figure 5.25: Disassembly of Plotter Prior to Removing the Inner Platen Parts ......... 5-58

Figure 5.26: Removing the Lower Drive Shaft Screws.............................................. 5-60

Figure 5.27: Removing the Foam Block .................................................................... 5-61

Figure 5.28: Lower Drive Assembly and Stepper Motor Assembly ........................... 5-64

Figure 5.29: Routing of Wires and Cables on Right Side Plate and MPCB .............. 5-70

Figure 5.30: Fixed Blade ........................................................................................... 5-72

Figure 5.31: Cutter Assembly.................................................................................... 5-75

Figure 5.32: Upper Roller Support - Normal and Bent for Removal .......................... 5-79

CADJET 2 5-89

Disassembly/Assembly

Figure 5.33: Removing the Old Upper Roller Support .............................................. 5-80

Figure 5.34: Inserting New Upper Roller Supports ................................................... 5-83

Figure 5.35: Positioning Upper Roller Supports........................................................ 5-84

5-90 CADJET 2

Chapter 6

CALIBRATION

1.0 Introduction

When using the CADJET 2 to plot drawings with both color and black, the “Cartridge Calibration - Horizontal and Vertical” procedure in

Section 12.0 of this chapter must be performed each time you remove or change one of the ink Cartridges. (This procedure aligns the

Tri-Color Cartridge to the Black Cartridge.)

The other procedures presented in this chapter should be performed only by authorized ENCAD Service Centers after the plotter has been serviced or anytime there appears to be a problem with plot quality.

See Chapter 5, Section 1.0 for a list of parts whose servicing or replacement requires the calibration of the plotter.

NOTE

WARNING

Note: 1. The procedures in this chapter should be performed in the order in which they are presented.

2. For your convenience in recording the readings during procedures in this chapter, photocopy the CADJET 2

Calibration Worksheet (Figure Chapter 6 .16) at the end of this chapter.

1. In order to prevent possible damage to the Cutter, it is extremely important that you always verify -- and, if necessary, perform -- the Slide Shaft Profile Adjustment

(Section 6.1) and the Cartridge Head Height Adjustment

(Section 6.2) prior to downloading firmware or performing any other function which will activate the Cutter. If the adjustments are incorrect and the Cutter is activated, the

Cutter will be damaged by contact with the Platen’s Fixed

Blade. If adjustments are necessary, begin with Section 6.0,

“Adjustments Prior to Calibration.”

2. Whenever you move the Carriage with the Height Gauge installed, lift up the gauge tip to prevent damage to the gauge.

CADJET 2

6-1

Calibration

2.0 Required Supplies and Tools

l

Media: Architectural, 4 mil, 24 LBS. opaque

E (36" x 48"), D (36" x 24") and B (11" x 17") sizes l U.S.A. 110V power cord (P/N 200353) l Cartridge, Black, 104 JET (P/N 203280) l

Cartridge, Tri-Color (P/N 203115) l 36" long precision ruler l 1/4" open and box end wrench, C.A.L. l

Static Station with wrist strap l

Phillips screwdriver #1 & #0 l Torque screwdriver pre-set at 12 in. lbs., with 7/64 Allen bit l

Torque screwdrivers pre-set at 3 in. lbs., with P0 Phillips bilts l

Screwdriver, 1.6 mm., flat blade, and GLIPTAL (P/N 200697) l IBM Compatible Computer, 386SX - 16 MHz, 2 MEG OF RAM

40 MEG HD MINIMUM l

Parallel Cable l Special firmware download Serial Cable (P/N 203977)

6-2 CADJET 2

NOTE

Calibration l

Ultrasonic Cleaner l

Fixture, Carriage Height Test Cartridge (P/N 204279) l Fixture, Carriage Height and Tilt Measurement (P/N 204278) l

Fixture, Shaft/Platen Profile Measurement (P/N 204171) l

Linear Gauge, Slim type, LGB-110E, code #542-232

(MITUTOYO) (optional) l Linear Gauge Counter, LGm1E, code #542-330 (MITUTOYO)

(optional) l Display Unit, code #572-031A (MITUTOYO) (optional) l Linear Gauge, code #575-312 (MITUTOYO) (optional) l

MITUTOYO User’s Manual (optional) l

Multimeter, BECKMAN IND. #DM15XL or equivalent l Calculator, magnifier, and flash light

Note: A dial micrometer alignment gauge will be available shortly to replace the MITUTOYO system.

CADJET 2

6-3

Calibration

3.0 Required Documentation and Files

The following documentation and files will be necessary in order to perform the procedures described in this chapter: l Final Assembly Drawings - refer to Appendix C of this Service

Manual l CADJET 2 User’s Guide l

Emergency Flash ROM Boot Procedure - refer to Appendix A of this Service Manual. The files for this procedure are available on the CADJET 2 Utilities Disk which is provided with the plotter. The Utilities Disk may also be obtained from

ENCAD’s Technical Support and Service BBS (see Chapter 1,

Section 3.0 of this manual). To download the Utilities Disk from the BBS, follow the instructions given below under

“Downloading Files From the BBS.” This procedure is used to download the firmware if the plotter is “brain dead” (i.e., the

Flash EPROM is blank or corrupt). l Printer Firmware Upgrade Procedure - refer to Appendix B of this Service Manual. The files for this procedure are included on the CADJET 2 Utilities Disk. This procedure is used to download the firmware if the plotter does not have the current version of the firmware (the Flash EPROM is not blank or corrupt). l

Line Quality Acceptance Standards - ENCAD ships a “Gold

Standard” plot with each plotter. This is a Master Plot sample which can be used for comparison purposes when you are servicing a plotter. Section 14.0 gives the instructions for performing the “Line Quality Plot (Computer) Test.” The results of this test should be compared to the “Gold Standard” shipped with each plotter. In order to perform this test, you will need to download the following files from the BBS:

CJ2GS.PLT (for E-Size plotters)

CJ2GSD.PLT (for D-Size plotters)

6-4 CADJET 2

Calibration

4.0 Downloading Files From the BBS

See Chapter 1, Section 3.0 for the ENCAD Technical Support and

Service BBS telephone numbers.

1. At the BBS Main Menu, press “F” for the Files Menu.

2. At the Files Menu, press “D” to download a file.

3. To download the CADJET DOS Utilities Disk, type:

CJDOS15.ZIP

4. To download the Line Quality Acceptance Standards, type:

CJ2GS.PLT for E-Size plotters

CJ2GSD.PLT for D-Size plotters

5. After the files have been downloaded and communications have been ended, the CADJET DOS Utilities Disk files need to be unzipped onto a floppy disk. Insert a floppy disk into your B: drive

(or A: drive, depending upon your particular configuration) and, at the C:\ prompt, type:

PKUNZIP CJDOS15.ZIP B: (or, CJDOS15.ZIP A:)

CADJET 2

6-5

Calibration

6. Type DIR B: (or DIR A:) to make certain that you have the files listed below:

INSTALL.EXE*

INSTALL.DAT*

DISK.ID*

USERGUID.TXT

CADUTIL.001*

205495.ZIP**

ENCADXXX.ROM

GO.EXE

MENUTREE.RTL

HOUSED.XPF

4775CD.XPF

* Files marked with “ * ” will not be transferred to your hard drive when the installation is performed.

** 205495.ZIP contains the following files and will also need to be unzipped:

DOWNLOAD.EXE

DOWNLOAD.HLP

DOWNLOAD.CFG

BDM_CODE.BDC

BDM2CODE.BDC

BDM_DATA.BDT

BDM2DATA.BDT

7. If all the above files are present on your floppy disk, at the C:\ prompt type B:\INSTALL (or A:\INSTALL) to install the Utilities

Disk files onto your hard disk. (Be sure you unzip 205495.ZIP

first.)

8. To use the Emergency Flash ROM Boot Procedure, see

Appendix A of this service manual. To do a Printer Firmware

Upgrade, see Appendix B of this service manual.

9. The files CJ2GS.PLT and CJ2GSD.PLT for the Line Quality

Acceptance Standards should be saved for use in Section 14.0,

“Line Quality Plot (Computer) Test.”

6-6 CADJET 2

5.0 Numbering Sequence of Upper Roller

Supports

NOTE

Calibration

Note: When performing the adjustments, be aware of the numbering sequence of the Upper Roller Supports as shown in Figure Chapter 6 .1.

Figure Chapter 6 .1: Upper Roller Supports Numbering Sequence

CADJET 2

6-7

Calibration

6.0 Adjustments Prior to Calibration

WARNING

WARNING

NOTE

1. Unplug the plotter from the power supply.

2. For static control, you must be grounded to a static station by a wrist strap. This is important whenever you are removing or installing the Carriage or the MPCB.

Note: The procedures given in Sections 6.1 and 6.2 are for use with the MITUTOYO system. A new dial micrometer adjustment gauge will be available shortly to replace the MITUTOYO system.

The following steps must be performed after unplugging the plotter:

1. Power-up the Digital Carriage Height Measurement System per instructions in the manufacturer's manual (MITUTOYO User's

Manual).

2. Wipe clean the Encoder Strip’s top surface (no cleaning fluid).

See Chapter 3, Section 5.0 of this Service Manual for maintenance procedures for the Encoder Strip.

3. Wipe clean the Slide Shaft with a lint-free cloth (Scott Rags-In-A-

Box or equivalent). See Chapter 3, Section 3.0.

4. Remove the Trailing Cable Support.

6-8 CADJET 2

Calibration

6.1 Slide Shaft Profile Adjustment

NOTE

Note: This procedure is for use with the MITUTOYO system. A new dial micrometer adjustment gauge will be available shortly to replace the MITUTOYO system.

The purpose of this procedure is to verify the absolute height and profile of the Slide Shaft with respect to the Platen. You will need the following: l Shaft/Platen Profile Measurement Fixture, P/N 204171; l MITUTOYO’s Linear Gauge, Slim type, LGB-110E, code #542-232; and l

MITUTOYO’s Linear Gauge Counter, LGm1E, code #542-330. l

A copy of the CADJET 2 Calibration Worksheet (see

Figure Chapter 6 .16), which will be referred to as “the

Calibration Worksheet.”

1. Prior to performing any test, park the Carriage on the Service

Station.

2. Holding the gauge in your hand, push (in this sequence) the

ZERO, PSET, and LOAD buttons on the display unit. It should read: 1.5340.

3. Install the Shaft/Platen Profile Measurement Fixture on the Slide

Shaft. Make sure that the tip of the probe touches the Platen.

4. Once the gauge is installed: a. lift the gauge, b. move it to the right, and c. park it at the starting position (aligned with the Inner

Stand Off Screw - see Figure Chapter 6 .2).

This will allow you to obtain the most stable reading. d. Record the display's reading in the box marked “RIGHT” in

Part 1 of the Calibration Worksheet.

CADJET 2

6-9

Calibration

6-10

Figure Chapter 6 .2: Inner Stand Off Screws and Turnbuckle

CADJET 2

Calibration

5. a. Lift the gauge and move it to the center position of the shaft

(left of the Turnbuckle Block - see Figure Chapter 6 .2). b. Record the display's reading in the box marked “CENTER” in

Part 1 of the Calibration Worksheet.

6. a. Lift the gauge and move it to the left position of the shaft

(aligned with the Inner Stand Off Screw - see

Figure Chapter 6 .2). b. Record the display's reading in the box marked “LEFT” in

Part 1 of the Calibration Worksheet.

7. a. On the lines marked “LEFT” and “RIGHT” in Part 1 of the

Calibration Worksheet, write the readings obtained in the left and right positions and add them up. b. Divide the result by two and write down the result (the average). c. If the gauge's reading in the center is equal to this result (the average), then no profile adjustment is necessary; otherwise, lift the gauge and move the Carriage to the center position and perform the following adjustment:

Adjust the Shaft Profile/Height in the center of the Platen by turning the Turnbuckle up/down (see Figure Chapter 6

.2). Observe the display and set the height at the average number (within +/- .001" tolerance) obtained above in Step 7.b. above.

8. Once the Shaft Profile/Height to Platen is measured and recorded in all three locations, verify that the height numbers (all measurements) fall within 1.4340 +/- .0100”.

If the measured numbers do not fall within 1.424-1.444”, stop the procedure and call ENCAD’s Technical Support and Service department. See Chapter 1, Section 3.0.

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6-11

Calibration

6.2 Cartridge Head Height Adjustment

NOTE

Note: This procedure is for use with the MITUTOYO system. A new dial micrometer adjustment gauge will be available shortly to replace the MITUTOYO system.

NOTE

6.2.1 Gauge Setup Procedure

You will need the following: l

the Carriage Height and Tilt Measurement Fixture,

P/N 204278; l MITUTOYO’s Linear Gauge, code #572-312; and l

the Display Unit, code #572-031A.

Note: 1. The Display Unit should have a Display Preset Number on a label attached above the LCD. This Display Preset Number is determined when the gauge is calibrated by ENCAD and equals the zero point for that gauge.

2. The Linear Gauge should also have a number on a label attached to the gauge. This number is the variance (+/-) allowed from the Display Preset Number.

1. Holding the Linear Gauge in your hand, push the PSET button twice on the Display Unit. The number on the LCD should match the number on the label attached above the LCD on the Display

Unit.

2. Check that the Linear Gauge is functional by pressing the tip of the Linear Gauge all the way inwards against a flat surface. When you do so, check the number on the LCD. The number on the

LCD should read within the variance allowed from the Display

Preset Number. If it does not, call ENCAD’s Technical Support and Service department. See Chapter 1, Section 3.0.

6-12 CADJET 2

Calibration

3. Install the Carriage Height and Tilt Measurement Fixture,

P/N 204278. See Figure Chapter 6 .3.

4. Unlatch the levers on the Carriage to make space for the insertion of the Linear Gauge.

5. Hold the Linear Gauge by the Cartridge body and insert it into the space by pressing it down until it makes contact with the bottom of the Carriage.

6. Holding the Cartridge body in position, push the Cartridge towards the rear until its vertical wall completely bottoms out with the

Carriage. The Indexing Edge on the Cartridge should slide completely under the Carriage Overhang, and you should hold the

Cartridge down while pushing the Cartridge towards the back of the plotter. Maintain pressure on the Cartridge while you turn the lever up to firmly position the Cartridge head against the Flex

Cable and lock it inside the Carriage. See Figure Chapter 6 .4

(which shows the procedure for installing a typical Black

Cartridge).

CADJET 2

6-13

Calibration

6-14

Figure Chapter 6 .3: Carriage Height Measurement Fixture

CADJET 2

Calibration

Figure Chapter 6 .4: Installation of Typical Black Cartridge

CADJET 2

6-15

Calibration

Table 6.1 below is to be used to select the Carriage height settings based on the absolute shaft height/profile settings recorded on the

Calibration Worksheet during the Slide Shaft Profile Adjustment procedure in Section 6.1 above.

Table Chapter 6 .1: Carriage Height Settings Chart

6-16 CADJET 2

Calibration

6.2.2 Cartridge Head Height Adjusting Procedure

WARNING

NOTE

Use extreme care to make sure that the Carriage does not scratch

the Code Strip (Encoder Strip) during this procedure.

Adjustment of the Cartridge head heights is performed using the three screws on the back of the Y-Arm which attach the Stabilizer Bracket to the Y-Arm. See Chapter 5, Figure 5.23 for identification of these screws. Do not loosen all three screws at the same time. The sequence of adjustment must be followed as described below: a. loosen, adjust, and tighten the left screw b. loosen, adjust, and tighten the center screw c. loosen, adjust, and tighten the right screw.

1. Move the gauge to the left position. Loosen the left screw.

Moving the screw head up/down will move the Stabilizer Bracket up/down until it is at the required height. Check the counter's display while adjusting. Look at the Calibration Worksheet and find the shaft height at the left position. Go to Table Chapter 6 .1 above and find the Carriage height value associated with that shaft height. Once the required height is selected and adjusted to, tighten the screw gently.

2. Move the gauge and park it in the center position. Loosen the center screw, select the height from the chart in Table Chapter 6

.1, and adjust the center screw. Tighten the screw gently.

3. Move the gauge and park it in the right position. Loosen the right screw, select the height from the chart in Table Chapter 6 .1, and adjust the right screw. Tighten the screw gently.

4. Tighten all screws and torque the three screws to 8 in.-lbs.

Note: 1. Tightening of the screws will change the reading on the display. When adjusting, always allow for a change in the height of up to .002".

2. Do not adjust the screws out of sequence. If you find that a screw has to be readjusted, the adjusting procedure must be repeated from Step 1 of Section 6.2.2.

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Calibration

6.2.3 Verify Head Height Values

1. Move the Carriage (with the gauge installed in the holder for the

Black Cartridge) to the center of the Platen, next to the Turnbuckle

(see Figure Chapter 6 .2). Record the reading in Part 2 of the

Calibration Worksheet.

2. Move the Carriage (with the gauge installed in the holder for the

Black Cartridge) to the left location of the Platen. Record the reading in Part 2 of the Calibration Worksheet.

3. Move the Carriage (with the gauge installed in the holder for the

Black Cartridge) to the right location of the Platen. Record the reading in Part 2 of the Calibration Worksheet.

4. If the values are not within specification, repeat the adjustment procedure. Remove the gauge if all values are within specification.

5. Install a set of full Cartridges and proceed to Section 6.3, “Encoder

Strip Location/Visual Check.”

6-18 CADJET 2

Calibration

6.3 Encoder Strip Location/Visual Check

Check that the Encoder Strip clears both sides and the bottom of the

Encoder module.

CAUTION

1. Make sure that the Slider does not come into contact with or deflect the Encoder Strip at any point during the Carriage

Axis travel.

2. Make sure that the Encoder does not come into contact with the Stabilizer Bracket.

If contact is visually detected or heard (squeaking noise), then readjust the tilt/height of Carriage until clearance is obtained. Repeat all the steps from Section 6.0, “Adjustments Prior to Calibration,” up to and including this Section 6.3, “Encoder Strip Location/Visual Check.”

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6-19

Calibration

6.4 Idler Pulley and Belt Position Check

The Idler Pulley must be in a horizontal position. It must not be misaligned or move up and down, causing the belt to rub against the tensioning mechanism. The belt must always clear the tensioner housing.

If there should be a problem with the alignment of the Belt, refer to

Chapter 5, Figure 5.18 of this CADJET 2 Service Manual for information concerning the proper alignment of the Idler Pulley

Assembly in the Frame Tensioner. The side of the Idler Pulley

Assembly with the thicker ring of plastic must face up. If the Idler

Pulley is in the correct position and the problem is still present, report the unit to ENCAD’s Technical Support and Service department. See

Chapter 1, Section 3.0.

Note that the spring must be engaged in the assembly and clearance should be achieved with no manual intervention. The Carriage Belt must clear the bottom of the Stabilizer Bracket by at least .015.” Run the Carriage from left to right and back. Observe the motion of the

Carriage Belt. Insert a 0.15” flat shim stock under the Stabilizer

Bracket. If the shim deflects the Carriage Belt when it is flush under the Stabilizer Bracket, call ENCAD’s Technical Support and Service department. See Chapter 1, Section 3.0.

6-20 CADJET 2

Calibration

6.5 Power Up and ROM Verification Test

6.5.1 Functional Test

WARNING

1. IF THE MACHINE DOESN'T POWER-UP, IT MUST BE

TURNED OFF IMMEDIATELY TO ELIMINATE ANY DAMAGE

UNTIL THE PROBLEM CAN BE RESOLVED.

2. For static control, you must be grounded to a static station by a wrist strap. This is important when removing or installing EPROM's, Carriage, and MPCB.

3. Do not slide the Carriage at any time when the power is

"ON." This may damage the plotter. Use the ACCESS

CARTRIDGES key instead.

4. When moving the plotter around, disconnect the power from the plotter each time.

All you need to do for the Functional Test is to connect power to the unit and turn the ON/OFF Switch to the “ON” position. The purpose of this test is to verify that the unit powers up. If it does not power up, see the Decision Logic Tables in Chapter 4.

CADJET 2

6-21

Calibration

NOTE

Note: 1. If the plotter is “brain dead” (i.e., the Flash EPROM is blank or corrupt), the firmware must be downloaded to the plotter using the Serial Port and the “Emergency Flash ROM Boot

Procedure” on the CADJET 2 Utilities Disk. See Appendix A of this service manual for the procedure.

2. If the plotter is not “brain dead” (i.e., the Flash EPROM is not blank or corrupt) but does not have the latest firmware version, the firmware may be loaded through the Parallel Port or the Serial Port (parallel is faster) using the Printer

Firmware Upgrade on the CADJET 2 Utilities Disk. See

Appendix B of this service manual for the procedure.

3. If the Carriage Assembly has been removed or changed,

or if the Carriage Height has been changed, you must do whichever firmware download is appropriate (even if the plotter has the latest firmware version) and perform the

“Adjustment of the Paper Sensor Potentiometer” in

Section 6.5.2 below during the download.

6-22 CADJET 2

WARNING

Calibration

6.5.2 Adjustment of the Paper Sensor Potentiometer

1. When adjusting the Potentiometer, take extreme care not to touch any of the components with the probe other than the

Test Point Pad on the board. See Figure Chapter 6 .5.

2. For static control, you must be grounded to a static station by a wrist strap.

CADJET 2

Figure Chapter 6 .5: Top View of Carriage Board

6-23

Calibration

NOTE

Note: 1. You will not use any media during this adjustment procedure.

2. During this procedure, the Carriage Assembly must not be positioned over the openings in the Platen for the Lower

Rollers.

3. The range for the voltage will be 1.4 to 1.6 Volts.

4. After the Paper Sensor Potentiometer Adjustment, any change in the Carriage Height will require readjustment of the

Paper Sensor Value for that height.

5. The voltage at the Potentiometer Adjustment Test Point will vary slightly with temperature. If the voltage is rechecked at a later time, it does not need to be readjusted if it is in the range of 1.4 to 1.6 Volts.

1. Perform the procedure in Appendix A or Appendix B for the firmware download. During the download, the Fan will come on.

During this time, adjust the Paper Sensor Potentiometer.

2. Adjust the Potentiometer on the Paper Sensor Harness Assembly using the flowchart in Table Chapter 6 .2 below.

6-24 CADJET 2

Table Chapter 6 .2: Potentiometer Adjustment Flowchart

Calibration

CADJET 2

6-25

Calibration

3. Wait for the download to finish. The plotter will briefly show a copyright message on the Keypad Display and then perform internal diagnostics. The following display indicates that the automatic diagnostic tests were acceptable and the firmware 4 MG

RAM is installed.

MAIN MENU

PRINT MODE

4. The Carriage should move from the right side to the left side and return to the Service Station. The Cutter will be activated at the left side of the Platen and de-activated at the Service Station when the Carriage returns.

5. Proceed to Section 7.0, “Paper Skew Setup.”

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Calibration

7.0 Paper Skew Setup

1. Power must be connected to the plotter. Go to the following display:

MAIN MENU

PRINT MODE

2. Press the Down Arrow 4 times. The display will read:

MAIN MENU

PRINTER SET UP

3. Press SELECT. The display will read:

PRINTER SETUP

EMULATION=HPGL2

4. Press the Down Arrow 2 times. The display will read:

PRINTER SETUP

ROLL FEED=ON

5. Press SELECT. The display will read:

PRINTER SETUP

ROLL FEED=ON

6. Press the Down Arrow. The display will read:

PRINTER SETUP

ROLL FEED=OFF

7. Press SELECT, then MENU, and then the Down Arrow 4 times until the display reads:

MAIN MENU

PRINT MODE

8. Proceed to Section 8.0, “Paper Skew Adjustment.”

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Calibration

8.0 Paper Skew Adjustment

NOTE

The purpose of the Paper Skew Adjustment is to make certain that the

Pinch Roller in the Upper Roller Support stays centered on its shaft and/or has a gap when the Lower Roller is rotated forward for approximately two full revolutions. In other words, the Pinch Roller should not drift rapidly to the left or to the right when the Lower Roller is rotated forward for two full revolutions. (Slow drifting is acceptable.)

Use the torque screwdriver with the P0 bit to adjust the Upper Roller

Support mounting screws.

Note: 1. Use the sequence given in Section 8.1 as you do the steps given in Section 8.4.

2. Read and follow ALL of the information in Sections 8.1, 8.2, and 8.3 before you begin Section 8.4.

6-28 CADJET 2

Calibration

8.1 Paper Skew Adjustment Sequence

It is very important that the sequence for the adjustment given in this section be observed. Refer to Figure Chapter 6 .1 for the numbering sequence of the Upper Roller Supports.

NOTE

Note: The rollers should be adjusted moving from the right side

of the Platen to the left side of the Platen.

1. Load a sheet of B-Size paper and adjust Rollers #8, #7, and #6, following the directions in Section 8.4.

2. Load a sheet of D-Size paper and adjust Rollers #5 and #4, following the directions in Section 8.4.

NOTE

Note: If you are not working with an E-Size unit, Step 3 below will not be used.

3. Load a sheet of E-Size paper and adjust Rollers #3, #2, and #1, following the directions in Section 8.4.

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Calibration

8.2 Mounting Screw Information

NOTE

Note: Read everything in Section 8.2 before beginning

Section 8.4. Make sure you understand this material before you proceed to Section 8.4.

1. The torque requirements for the Upper Roller Support mounting screws is 3 In.-Lbs.

±

0.5.

2. Turning the mounting screw clockwise will tighten the screw.

Turning the mounting screw counterclockwise will loosen the screw.

3. Figure Chapter 6 .6 shows the Upper Roller Support and the mounting screws. You must stand behind the plotter in order to adjust the mounting screws on the Upper Roller Supports.

Figure Chapter 6 .6: Upper Roller Support and Mounting Screws

6-30 CADJET 2

Calibration

4. If the mounting screw on the right side is loosened (turned counterclockwise), the roller will move to the left. If the mounting screw on the left side is loosened (turned counterclockwise), the roller will move to the right. NEVER LOOSEN OR TIGHTEN

BOTH MOUNTING SCREWS AT THE SAME TIME ON THE

SAME UPPER ROLLER SUPPORT.

5. If you have loosened one of the mounting screws and the roller has moved, and you need to move the roller in the opposite direction, you must tighten that mounting screw BEFORE loosening the other screw to move the roller in the opposite direction. When tightening the first screw, turn it clockwise with the torque screwdriver until the maximum torque is reached. Then loosen the other screw. AGAIN, NEVER LOOSEN OR TIGHTEN

BOTH MOUNTING SCREWS AT THE SAME TIME ON THE

SAME UPPER ROLLER SUPPORT.

6. It is extremely important that you maintain downward pressure

(towards the floor) on the head of each screw at the same time as you tighten or loosen the screws. Each screw must be completely at the bottom edge of its hole in the back of the Y-Bracket. If this

is not done, the Upper Roller Support will not be perfectly

level and will not perform its function properly.

7. Following all of the information in Section 8.2 precisely will ensure that the Upper Roller Support springs are deflected and the lower tail of the springs will always be pressed against the Y-Arm’s vertical wall (without a gap) as shown in Figure Chapter 6 .7.

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6-31

Calibration

Figure Chapter 6 .7: Correct Positioning of the Spring in the Upper Roller

Support

6-32 CADJET 2

Calibration

8.3 Other Functional Requirements

The paper skew has a tendency to increase as the size of paper increases (B-Size through E-Size). When adjusting the skew, make sure that:

1. the skew for B-Size paper is as close to the low end of the range as possible; and

2. a minimum gap still remains between all Upper Roller Supports and the Y-Arm. The test for acceptable gap is that a piece of bond paper can be inserted through the gap without interference; that is, the gap must be at least the thickness of a piece of bond paper.

See Figure Chapter 6 .8. Avoid adjusting the Upper Roller

Supports so that they touch the Y-Arm's cut outs.

Figure Chapter 6 .8: Test for Minimum Acceptable Gap

CADJET 2

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Calibration

8.4 Adjustment of Upper Roller Supports

NOTE

Note: Be sure to perform the adjustment according to the sequence given in Section 8.1.

8.4.1 Visual Verification

Make sure that the roller is centered in the Y-Arm. The gap between the roller and the Y-Arm should be approximately equal on both sides of the roller. See Figure Chapter 6 .9.

Figure Chapter 6 .9: Visual Verification of Gap between Roller and Y-Arm

6-34 CADJET 2

NOTE

Calibration

8.4.2 Observation of Paper Skew at Rear Media

Alignment Mark

To adjust Load

Rollers #8, #7, and #6 B-Size paper, with 11” side against rollers

Rollers #5 and #4 D-Size paper, with 24” side against rollers

Rollers #3, #2, and #1 E-Size paper, with 36” side against rollers

1. Position a sheet of the appropriate size paper for loading. The cut corner should be the top right corner of the paper as you load it.

Make sure the correct side is up against the rollers, and the righthand side is aligned with the Front Media Alignment Mark on the front of the Platen.

Note: Make sure that there is no gap between the right edge of the paper and the left edge of the Front Media Alignment Mark on the Platen.

2. Hold the media and press LOAD. The paper will be pulled in past the Platen's groove. The paper will roll forward (out) and stop.

CADJET 2

6-35

Calibration

3. Check to make sure that the gap between the right edge of the paper and the left edge of the Rear Media Alignment Mark (on back of the Platen) is within 2 line widths (0.12”). See

Figure Chapter 6 .10.

Figure Chapter 6 .10: Paper Skew Acceptance Range for Rear Media Alignment

Mark

6-36 CADJET 2

Calibration

8.4.3 Observation of Paper Skew at Front Media

Alignment Mark

1. Press FEED MEDIA and then the UP ARROW to move the media forward while you observe the paper skew at the Front Media

Alignment Mark.

2. The paper should be returning to its pre-loading location, preferably without any skew (gap). Engineering specification requires the skew to be within 0.00” - 0.06” (approximately one width of Platen's line). See Figure Chapter 6 .11.

Figure Chapter 6 .11: Paper Skew Acceptance Range for Front Media Alignment

Mark

NOTE

Note: 1. If the criteria in Sections 8.4.2 and 8.4.3 is not met, adjust the rollers according to Section 8.4.4 until the criteria is met.

2. If the criteria is met for Rollers #8, #7, and #6, adjust Rollers

#5 and #4, beginning with Section 8.4.1. After Rollers #5 and

#4 are adjusted (if you have an E-Size model), adjust Rollers

#3, #2, and #1, beginning with Section 8.4.1. Once all rollers are adjusted, proceed to Section 9.0.

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Calibration

NOTE

8.4.4 Adjustment of the Mounting Screws

Figure Chapter 6 .12 shows how the motion (rapid drifting to the right or to the left) of the roller determines which mounting screw should be tightened in order to eliminate the motion of the roller so that the roller stays in the center of the shaft and/or there is a gap when the Lower

Roller is rotated forward.

Note: Pay attention to the orientation in Figure Chapter 6 .12.

Figure Chapter 6 .12: Motion of Rollers and Adjustment of Mounting Screws

NOTE

Note: After the mounting screw has been tightened to the maximum torque setting available on the screwdriver, if the roller still moves rapidly and touches, loosen the other mounting screw to gain more adjustment range.

Once you have completed the adjustment of Rollers #8, #7, and #6, adjust Rollers #5 and #4, beginning with Section 8.4.1. After Rollers

#5 and #4 are adjusted (if you have an E-Size model), adjust Rollers

#3, #2, and #1, beginning with Section 8.4.1.

Once all rollers are adjusted, proceed to Section 9.0.

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Calibration

9.0 Plotting PRIME Pattern

In preparation for plotting the PRIME pattern and for performing the

Electrical Calibration procedures, do the following:

1. The plotter should already be powered up and you should be at

(or, if necessary, go to) the following display:

MAIN MENU

PRINT MODE

2. Press the DOWN ARROW once. The display will read:

MAIN MENU

UTILITIES

3. Press SELECT. The display will read:

UTILITIES

CALIBRATION

4. Press the DOWN ARROW. The display will read:

UTILITIES

OPTIONS=EASY

5. Press SELECT and immediately press the UP ARROW. The display will read:

UTILITIES

OPTIONS=ADVANCED

6. Press SELECT and MENU. The display will read:

MAIN MENU

UTILITIES

CADJET 2

6-39

Calibration

CAUTION

NOTE

7. Press the UP ARROW until the display reads:

MAIN MENU

PRINT MODE

8. Load D-Size paper with the 36" side up against the rollers on the

Platen.

9. Press ACCESS CARTRIDGE. The Carriage will move out of the

Service Station.

10. Install a new Tri-Color Ink Cartridge and a new Black-104 JET

Cartridge, following the procedures for Cartridge installation in the

CADJET 2 User’s Guide.

Do not ever wipe the ink Cartridges with any highly fibrous materials like tissues or paper towels. The Service Station automatically wipes the ink Cartridges.

Note: 1. When installing the Black Cartridge, refer to Figure Chapter 6

.4. Make sure that the Indexing Edge completely slides under the Carriage Overhang. Hold the Cartridge down while pressing forward, and keep pressure on the Cartridge while turning the lever up to lock the Cartridge into place.

2. Do not push either Cartridge down AFTER the lever has been turned up to lock the Cartridge into place. When the lever is turned up, the Cartridge will automatically be put into the desired position for the best contact with the Flex Cable.

11. Press ACCESS CARTRIDGE. The Carriage will automatically return to the Service Station. Press MENU. The display will read:

MAIN MENU

PRINT MODE

6-40 CADJET 2

Calibration

12. Press PRIME. The plotter will fire the heads and plot the prime pattern. Examine the pattern for the following problems: l streaks or white lines within the color bands, and/or l

gaps or fuzzy lines in the sloping horizontal lines.

If these conditions are present, a. prime the heads at least 3 times to make sure all inkjets are firing. b. If the inkjets still misfire, press ACCESS CARTRIDGE. Pull out the misfiring Cartridge and immerse its jet plate in an ultrasonic cleaner for about 20 seconds, gently blot dry, and reinstall it in the Carriage. (The jet plate should not rest on

the bottom of the ultrasonic cleaner.) Repeat the prime test. c. If failure is still evident, pull out the Cartridge and replace it with a new Cartridge and repeat the test. Make sure that there is no misfiring using the new Cartridge. If misfiring is observed, contact ENCAD’s Technical Support and Service department (see Chapter 1, Section 3.0.).

13. The plotter has passed the PRIME test if misfiring is no longer observed using a second set of Cartridges.

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Calibration

NOTE

Note: During these tests check the overall functioning of the plotter.

Listen for:

1. any loud sounds from the Stepper Motor Assembly,

2. squeaking from the Roller Assemblies,

3. rubbing noises from the Drive Shaft,

4. or the Belt rubbing against the Pulleys or Stabilizer Bracket.

Also,

5. watch the tensioning mechanism for any adverse movement, such as the tension being too tight on the belt or rubbing, squeaking, or "chirping" noises.

6. check for Servo Motor noises or any visible Carriage vibration.

Readjust the plotter if these sounds or conditions are present. If the problem persists and cannot be corrected, call ENCAD's

Technical Support and Service department (see Chapter 1,

Section 3.0).

6-42 CADJET 2

Calibration

10.0 XY Calibration

1. This procedure allows you to calibrate the X-Axis (also referred to as the Paper Axis or Vertical Axis) and the Y-Axis (also referred to as the Carriage Axis or Horizontal Axis).

2. The XY Calibration values are only used when the USE XY

CALIBRATION option is set to ON.

3. When you set the XY Calibration values, all subsequent images are plotted using the new values until you manually reset the calibration.

4. XY calibration should not be used for merged vector/raster images.

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Calibration

10.1 Calibrating the Y-Axis (Carriage Axis or Horizontal

Axis Calibration)

1. Load a sheet of D-Size paper (24” side against the rollers). Press

DOWN ARROW. The display will read:

MAIN MENU

UTILITIES

2. Press SELECT. The display will read:

UTILITIES

CALIBRATION

3. Press SELECT. The display will read:

CALIBRATION

CARTRIDGE

4. Press DOWN ARROW. The display will read:

CALIBRATION

USE XY CALIB=NO

5. Press SELECT, DOWN ARROW, and SELECT. The display will read:

CALIBRATION

USE XY CALIB=YES

6. Press DOWN ARROW. The display will read:

CALIBRATION

XY=ENGLISH

6-44 CADJET 2

Calibration

7. Press DOWN ARROW. The display will read:

CALIBRATION

PAPER AXIS

8. Press DOWN ARROW. The display will read:

CALIBRATION

CARRIAGE AXIS

9. Press SELECT. The plotter will draw a horizontal line that it expects to be 21.00” +/- 0.05” long. The display will read:

CARRIAGE AXIS

WIDTH=21.00”

10. Press FEED MEDIA and DOWN ARROW to unload the paper and measure the line that was drawn. If the line is 21.00” +/- 0.05” long, proceed to Section 10.2 below and perform the X-Axis

Calibration.

If the line is not 21.00” +/- 0.05” long, press SELECT, and then press the UP ARROW or DOWN ARROW until the displayed value matches the distance that you measured. Press SELECT to save the new value. Reload the paper. The display will read:

ROLL=OFF CUT=ON

SAVE MEDIA=ON

Press MENU. Press SELECT. Another 21.00” line will be drawn.

Press FEED MEDIA and DOWN ARROW to unload the paper.

Verify that the line length is correct. Proceed to Section 10.2 and calibrate the X-Axis.

CADJET 2

6-45

Calibration

10.2 Calibrating the X-Axis (Paper Axis or Vertical Axis

Calibration)

1. Load a sheet of D-Size paper (24” side against the rollers). The display will read:

ROLL=OFF CUT=ON

SAVE MEDIA=ON

2. Press MENU and UP ARROW. The display will read:

CALIBRATION

PAPER AXIS

3. Press SELECT. The display will read:

PAPER AXIS

LENGTH=33.00

4. The plotter will draw an upside down “T” on the top center of the paper, will feed the paper into the plotter, and will draw another “T” on the bottom center of the paper. Unload the paper.

5. Measure the distance between the horizontal lines from the top center to the bottom center. The distance should be

33.00” +/- 0.05”. If the distance is correct, proceed to Section 11.0 and perform the Deadband Calibration.

If the distance is not 33.00” +/- 0.05”, press SELECT and then press the UP ARROW or DOWN ARROW until the displayed value matches the distance you measured. Press SELECT to save the new value. Reload the paper and press MENU and

SELECT. The plotter will redraw the marks. Unload the paper and verify that the distance between the horizontal lines is correct.

Then proceed to Section 11.0, “Deadband Calibration”.

6-46 CADJET 2

Calibration

11.0 Deadband Calibration

NOTE

Deadband Calibration compensates for minute differences created when bi-directional plotting is used. Figure Chapter 6 .13 shows how to correct the differences. The CADJET 2 Service Menu provides for both Slow Deadband and Fast Deadband Calibration.

Note: Uni-directional plotting is not affected by deadband.

→ ←

Figure Chapter 6 .13: Deadband Alignment

CADJET 2

6-47

Calibration

11.1 Slow Deadband Calibration

The SLOW DEADBAND calibration shows the speed-dependent

Carriage height at 16 regions across the Platen with the values shown in ZERO OR ONE. This value is displayed on both the menu and on paper. The plotter setup must be in the "NORMAL" mode to run deadband.

1. Press MENU until the display reads:

MAIN MENU

UTILITIES

2. Press SELECT. The display will read:

UTILITIES

CALIBRATION

3. Press the UP ARROW once. The display will read:

UTILITIES

SERVICE

4. Press SELECT & the DOWN ARROW twice. The display will read:

SERVICE

CALIBRATION

5. Press SELECT. The display will read:

CALIBRATION

DEADBAND=XX *

* = DEFAULT NUMBER

6-48 CADJET 2

Calibration

6. Press the DOWN ARROW three times. The display will read:

CALIBRATION

SLOW DEADBAND=X *

* = DEFAULT VALUE

7. Load a sheet of D-Size paper turned sideways along the

36" length.

8. Press SELECT. The plotter will print several vertical lines in

16 regions. See Figure Chapter 6 .13. Each line consists of 3 smaller segments. The speed values will also be printed for each region. Look at the alignment of the center segments with the upper/lower segments over all 16 regions.

9. If the 3 segments in each line across all the regions are not visually aligned, press the UP ARROW once. The display will read:

CALIBRATION

SLOW DEADBAND=1

10. Press SELECT twice. The plotter will print the deadband plot again. Look at the alignment of the center segments with the upper/lower segments over all 16 regions. If the 3 segments in each line across all 16 regions are aligned, press SELECT. You have just chosen the Slow Deadband value that best suits this plotter. Record this value in Part 3 of the Calibration Worksheet.

11. If the alignment is still not satisfactory, return to

CALIBRATION

SLOW DEADBAND=0

and press SELECT. Do not choose any other values. Record this value in Part 3 of the Calibration Worksheet.

CADJET 2

6-49

Calibration

11.2 Fast Deadband (Height Calibration)

The FAST DEADBAND (also called the HEIGHT CALIBRATION) shows the region-dependent Carriage height at 16 regions across the

Platen with the values shown in mils, or 1/1000s of an inch. This value is displayed on both the menu and on paper.

1. Press the DOWN ARROW once. The display will read:

CALIBRATION

DEADBAND=XX

2. Press SELECT. The plotter will print two fast deadband patterns with the speed and height values in 16 regions in two consecutive rows. The lower row of deadband will be printed at a slower speed than the upper row of deadband. Therefore, if the upper row segments are aligned and acceptable, the lower row segments will also be as good or better in the alignment with each other. Record this value in Part 3 of the Calibration Worksheet.

6-50 CADJET 2

Calibration

11.2.1 Adjusting Fast Deadband; Vertical Lines (All) and Vertical Lines (One)

If the alignment is not satisfactory, then a different DEADBAND number must be selected until a satisfactory result is achieved. See

Figure Chapter 6 .13. Adjustment is made by increasing or decreasing the value for DEADBAND, as follows:

1. Press the UP ARROW or DOWN ARROW to change the number to a higher or lower value.

2. Once the desired value is reached (usually 54, 66, or 79, but not limited to these values), press SELECT.

3. Press SELECT again. The plotter will print a new set of lines

(visually inspect over the entire 16 regions). If the results are still not acceptable, repeat the above steps to obtain the best fast deadband value. Record this value in Part 5 of the Calibration

Worksheet.

4. Press SELECT and the DOWN ARROW twice. The display will read:

CALIBRATION

VERTICAL LINES (ALL)

5. Press SELECT. This causes 16 single 1.5" high vertical lines to be drawn one segment at a time in bi-directional mode. See

Figure Chapter 6 .14 for a sample.

5 (31,0

)

4 (31,0

)

3 (31,0

)

(31,0

)

2

Figure Chapter 6 .14: Vertical Lines (All)

ALL,F,S(31,0

)

1

CADJET 2

6-51

Calibration

6. Press the UP ARROW. The display will read:

CALIBRATION

VERTICAL LINES (ONE)

7. Press SELECT. The plotter will draw 16 single 1.5" high vertical lines one line at a time in uni-directional mode. See

Figure Chapter 6 .15 for a sample.

6 (31,0

)

5 (31,0

)

4 (31,0

)

3 (31,0

)

(31,0

)

2

Figure Chapter 6 .15: Vertical Lines (One)

ONE,F,S(31,0

)

1

8. Visually inspect the lines and compare against the printout of the

Line Quality Acceptance Standards files CJ2GS.PLT or

CJ2GSD.PLT (see “Required Documentation and Files” in

Section 3.0 of this chapter). If sub-standard lines at various regions exist, repeat Steps 1-7 above and change the numbers to a more acceptable value which will meet the line quality minimum acceptance criteria for Line Quality and White Space.

9. Continue as needed until the DEADBAND lines in NORMAL mode are showing a satisfactory deadband calibration. If after

10 minutes and/or a total of 8 trials of various values the minimum standard cannot be met, stop and call ENCAD's Technical

Support and Service department. See Chapter 1, Section 3.0.

10. Press MENU 3 times. The display will read:

MAIN MENU

UTILITIES

6-52 CADJET 2

12.0 Cartridge Calibration - Horizontal and

Vertical

Calibration

NOTE

Note: 1. When plotting drawings with both color and black, the

Cartridge Calibration must be performed each time the

Cartridges are removed or changed.

2. If the plotting being done does not require any use of the

Tri-Color Cartridge, Sections 12.0 and 13.0 can be skipped.

This procedure aligns the Tri-Color Cartridge to the Black Cartridge.

Horizontal Calibration performs an adjustment between the nozzles of the Cartridges horizontally. Vertical Calibration performs an adjustment between the nozzles of the Cartridges vertically. Minute differences may occur between Cartridges due to Cartridge alignment in the Carriage Assembly. The Horizontal and Vertical Calibration allows the user to minimize these variables.

1. Begin at the following display:

MAIN MENU

UTILITIES

2. Press SELECT. The display will read:

UTILITIES

CALIBRATION

3. Press SELECT. The display will read:

CALIBRATION

CARTRIDGE

CADJET 2

6-53

Calibration

4. Press SELECT. The display will read:

CALIBRATION

HORIZONTAL=0

The plotter will begin printing three sets of color line patterns (see the CADJET 2 User’s Guide, Appendix A for samples of these patterns): a. CURRENT HEADS

The first pattern shows the horizontal/vertical values of the heads. The heads are properly aligned when the colored +’s line up horizontally and vertically with the black alignment marks. b. COLOR HORIZONTAL HEAD-TO-HEAD CALIBRATION

The second pattern is used to align the two Cartridge heads horizontally. The number below each set of lines represents an alignment value. c. COLOR VERTICAL HEAD-TO-HEAD CALIBRATION

The third pattern is used to align the two Cartridge heads vertically. The number below each set of lines represents an alignment value.

6-54 CADJET 2

Calibration

12.1 Adjusting the Horizontal Head-to-Head Calibration

If adjustment is required for horizontal Head-to-Head, adjust the values as follows:

1. With the display set at

CALIBRATION

HORIZONTAL=X

(X = current alignment value) press SELECT and then the UP ARROW or DOWN ARROW to select the alignment value matching the best horizontal alignment in the horizontal print out.

2. Once the matching alignment value is reached, press SELECT to save the setting.

3. If adjustment is required for vertical Head-to-Head, proceed to

Section 12.2.

If no adjustment is required for vertical Head-to-Head, press

MENU and press SELECT again. The plotter will print a new set of three patterns. The new head-to-head pattern will reflect the latest settings which you have chosen. Make sure that the

“CURRENT HEADS” printout is properly aligned. If it is still not satisfactory, repeat the adjustment until satisfactory results are obtained. Then proceed to Section 13.0.

CADJET 2

6-55

Calibration

12.2 Adjusting the Vertical Head-to-Head Calibration

If adjustment is required for vertical Head-to-Head, then adjust the values as follows:

1. With the display set at

CALIBRATION

HORIZONTAL=X

press the DOWN ARROW to change the display to:

CALIBRATION

VERTICAL=X

(X = current alignment value)

2. Press SELECT and then the UP ARROW or DOWN ARROW to select the alignment value matching the best vertical alignment in the vertical print out.

3. Once the matching alignment value is reached, press SELECT to save the setting.

4. Press MENU and press SELECT again. The plotter will print a new set of three patterns. The new head-to-head pattern will reflect the latest settings which you have chosen. Make sure that the “CURRENT HEADS” printout is properly aligned. If it is still not satisfactory, repeat the adjustment until satisfactory results are obtained. Then proceed to Section 13.0.

6-56 CADJET 2

13.0 Color Deadband Calibration

NOTE

Calibration

Note: If the plotting being done does not require any use of the

Tri-Color Cartridge, Section 13.0 can be skipped.

The purpose of the Color Deadband Calibration is to adjust the color cartridge so that it prints the straightest lines possible.

1. Press MENU twice. The display will read:

UTILITIES

CALIBRATION

2. Press the UP ARROW twice. The display will read:

UTILITIES

MANUFACTURING

3. Press SELECT and the DOWN ARROW. The display will read:

MANUFACTURING

COLOR DB

4. Press SELECT. The display will read:

COLOR DB

YELLOW DB=X

X = CURRENT VALUE FOR

YELLOW DB

The plotter will begin printing two rows of four vertical lines (black, cyan, magenta, and yellow) 1/2” long across the paper one segment at a time. The black lines will appear thinner and straighter than the color lines. The color segments should be as close to being a straight line as you can detect. If the COLOR DB is acceptable, record the value in Part 3 of the Calibration

Worksheet and proceed to Section 14.0. If it is not acceptable, proceed to Section 13.1.

CADJET 2

6-57

Calibration

13.1 Adjusting the Color Deadband Value

When adjusting the COLOR DB values, the value for each color is adjusted separately. Usually, a value of zero or one are the best values that can be selected for this calibration.

1. With the display set at

COLOR DB

YELLOW DB=X

X = CURRENT VALUE FOR

YELLOW DB press SELECT and the UP ARROW or DOWN ARROW to change the value. Press SELECT to save the new value.

2. Press the DOWN ARROW. The display will read:

COLOR DB

MAGENTA DB=X

X = CURRENT VALUE FOR

MAGENTA DB

3. Press SELECT and the UP ARROW or DOWN ARROW to change the value. Press SELECT to save the new value.

4. Press the DOWN ARROW. The display will read:

COLOR DB

CYAN DB=X

X = CURRENT VALUE FOR

CYAN DB

5. Press SELECT and the UP ARROW or DOWN ARROW to change the value. Press SELECT to save the new value.

6-58 CADJET 2

Calibration

6. Press MENU. The display will read:

MANUFACTURING

COLOR DB

7. Press SELECT. A new pattern for COLOR DEADBAND will be printed. Compare these patterns with the previous pattern and choose between them for the straightest color lines. If neither pattern is satisfactory, perform the adjust again with another value until you have selected the DEADBAND values which achieve the best results. Record the value in Part 3 of the Calibration

Worksheet and proceed to Section 14.0.

CADJET 2

6-59

Calibration

14.0 Line Quality Plot (Computer) Test

1. Press MENU twice. The display will read:

MAIN MENU

UTILITIES

2. Press the UP ARROW until the display reads:

MAIN MENU

PRINT MODE

3. Press SELECT. The display will read:

PRINT MODE

MODE=NORMAL

The plotter is now set to NORMAL mode.

4. Connect the parallel cable from the computer to the rear of the plotter. Load a D-Size sheet with the 36 inch side against the upper rollers.

5. Turn the computer on. At the C: prompt, type on the keyboard:

GO CJ2GS.PLT (for CADJET 2 E-Size plotters) or,

GO CJ2GSD.PLT (for CADJET 2 D-Size plotters)

6-60 CADJET 2

Calibration

6. Press RETURN to send the plot file to the plotter. The

COMPUTER screen will show:

GO NJ-----.PLT

SENDING.........

7. On the plotter, the display will read:

PROCESSING ---K

If the display does not show PROCESSING ---K, the MPCB has

FAILED the communication test. Check to see if the parallel cable is the correct type and is connected. If so, perform diagnostics of the MPCB.

8. When the processing of the plot is successfully completed, the

Carriage will move to the left and the paper will be cut. The Cutter must cut the full length of the paper in one pass and the Cutter

Wheel must travel inside the Platen's groove freely and without any obstruction due to the adjusted position of the Carriage

Assembly/Slide Shaft.

If a Cutter malfunction is experienced, call ENCAD's Technical

Support and Service department (see Chapter 1, Section 3.0).

If no further adjustment is needed and the Cutter performs satisfactorily, compare the plot against the “Gold Standard” plot sample for this plotter (see Section 3.0). The plotter is now fully calibrated and ready to use.

CADJET 2

6-61

Calibration

SERIAL #:

PART 1:

SIZE: D E SOFTWARE REVISION:

SLIDE SHAFT PROFILE ADJUSTMENT

LEFT CENTER RIGHT

SHAFT HEIGHT:

LEFT:

RIGHT: +

SUM:

DIVIDED BY 2 =

PART 2:

BLACK

AVERAGE

ACTUAL

AFTER CARTRIDGE HEIGHT ADJUSTMENT

LEFT CENTER RIGHT

NOTE: ALL VALUES MUST BE BETWEEN .050 AND .070

PART 3:

DEADBAND VALUES

BLACK SLOW DEADBAND VALUE:

DEADBAND (FAST) VALUE:

TRI-COLOR SLOW DEADBAND VALUE:

Figure Chapter 6 .16: CADJET 2 Calibration Worksheet

6-62 CADJET 2

Calibration

Chapter 6 CALIBRATION 6-1

1.0 Introduction......................................................................................................... 6-1

2.0 Required Supplies and Tools ............................................................................. 6-2

3.0 Required Documentation and Files .................................................................... 6-4

4.0 Downloading Files From the BBS....................................................................... 6-5

5.0 Numbering Sequence of Upper Roller Supports ................................................ 6-7

6.0 Adjustments Prior to Calibration ......................................................................... 6-8

6.1 Slide Shaft Profile Adjustment ........................................................................ 6-9

6.2 Cartridge Head Height Adjustment ............................................................... 6-12

6.2.1 Gauge Setup Procedure......................................................................... 6-12

6.2.2 Cartridge Head Height Adjusting Procedure........................................... 6-17

6.2.3 Verify Head Height Values ..................................................................... 6-18

6.3 Encoder Strip Location/Visual Check............................................................ 6-19

6.4 Idler Pulley and Belt Position Check ............................................................. 6-20

6.5 Power Up and ROM Verification Test ........................................................... 6-21

6.5.1 Functional Test ....................................................................................... 6-21

6.5.2 Adjustment of the Paper Sensor Potentiometer ..................................... 6-23

7.0 Paper Skew Setup............................................................................................ 6-27

8.0 Paper Skew Adjustment ................................................................................... 6-28

8.1 Paper Skew Adjustment Sequence............................................................... 6-29

8.2 Mounting Screw Information ......................................................................... 6-30

8.3 Other Functional Requirements .................................................................... 6-33

8.4 Adjustment of Upper Roller Supports............................................................ 6-34

8.4.1 Visual Verification ................................................................................... 6-34

8.4.2 Observation of Paper Skew at Rear Media Alignment Mark .................. 6-35

8.4.3 Observation of Paper Skew at Front Media Alignment Mark.................. 6-37

8.4.4 Adjustment of the Mounting Screws ....................................................... 6-38

9.0 Plotting PRIME Pattern..................................................................................... 6-39

10.0 XY Calibration................................................................................................. 6-43

10.1 Calibrating the Y-Axis (Carriage Axis or Horizontal Axis Calibration).......... 6-44

10.2 Calibrating the X-Axis (Paper Axis or Vertical Axis Calibration) .................. 6-46

11.0 Deadband Calibration..................................................................................... 6-47

CADJET 2

6-63

Calibration

11.1 Slow Deadband Calibration ........................................................................ 6-48

11.2 Fast Deadband (Height Calibration) ........................................................... 6-50

11.2.1 Adjusting Fast Deadband; Vertical Lines (All) and Vertical Lines (One)6-51

12.0 Cartridge Calibration - Horizontal and Vertical ............................................... 6-53

12.1 Adjusting the Horizontal Head-to-Head Calibration .................................... 6-55

12.2 Adjusting the Vertical Head-to-Head Calibration ........................................ 6-56

13.0 Color Deadband Calibration ........................................................................... 6-57

13.1 Adjusting the Color Deadband Value.......................................................... 6-58

14.0 Line Quality Plot (Computer) Test .................................................................. 6-60

6-64 CADJET 2

Calibration

Figure 6.1: Upper Roller Supports Numbering Sequence ........................................... 6-7

Figure 6.2: Inner Stand Off Screws and Turnbuckle ................................................. 6-10

Figure 6.3: Carriage Height Measurement Fixture .................................................... 6-14

Figure 6.4: Installation of Typical Black Cartridge ..................................................... 6-15

Figure 6.5: Top View of Carriage Board.................................................................... 6-23

Figure 6.6: Upper Roller Support and Mounting Screws ........................................... 6-30

Figure 6.7: Correct Positioning of the Spring in the Upper Roller Support ................ 6-32

Figure 6.8: Test for Minimum Acceptable Gap.......................................................... 6-33

Figure 6.9: Visual Verification of Gap between Roller and Y-Arm............................. 6-34

Figure 6.10: Paper Skew Acceptance Range for Rear Media Alignment Mark......... 6-36

Figure 6.11: Paper Skew Acceptance Range for Front Media Alignment Mark ........ 6-37

Figure 6.12: Motion of Rollers and Adjustment of Mounting Screws......................... 6-38

Figure 6.13: Deadband Alignment ............................................................................ 6-47

Figure 6.14: Vertical Lines (All) ................................................................................. 6-51

Figure 6.15: Vertical Lines (One) .............................................................................. 6-52

Figure 6.16: CADJET 2 Calibration Worksheet......................................................... 6-62

Table 6.1: Carriage Height Settings Chart ................................................................ 6-16

Table 6.2: Potentiometer Adjustment Flowchart ....................................................... 6-25

CADJET 2

6-65

Chapter 7

REPLACEMENT PARTS LIST

1.0 Introduction

This chapter lists the part names and part numbers for field replaceable parts and assemblies of the CADJET 2 Color Inkjet

Plotter. Section 2.0 is the numerical listing, Section 3.0 is the alphabetical listing, and Section 4.0 is an alphabetical listing with drawings. Each section is subdivided as follows:

1. Parts used on both the D-Size and the E-Size models.

2. Parts used only on the D-Size model.

3. Parts used only on the E-Size model.

The parts and assemblies may be ordered through your local authorized dealer or ENCAD, Inc.’s Technical Support and Service department (see Chapter 1, Section 3.0).

CADJET 2 7-1

Replacement Parts List

2.0 Numerical Listing

2.1 Parts Used in both D-Size and E-Size (Numerical)

PART # DESCRIPTION

200172.......................................................................................... LOCTITE BLACK MAX

200353............................................................................. CORD, LINE, SJT, GRAY 9 FT a

202010 .........................................................SPRING, COMPRESSION (TOP COVER)

202512 (P/N will be changing) ..................................... CASTER, NON-LOCKING, TWIN

202513 (P/N will be changing) ...............................................CASTER, LOCKING, TWIN

203233...................................................................................ASSY, SERVICE STATION

203265........................................................................................ ASSY, SERVO MOTOR b b

203343-1 ..................................................................................... FRAME, TENSIONER

203345-1 .................................................................................................. ASSY, IDLER c

203440-1 .........................................................................................KEYPAD, BOTTOM

203443............................................................................................................ASSY, FAN b

203447 ................................................................... SPRING, COMPRESSION (IDLER)

203477-2.............................................................................. ASSY, ROLLGUIDE, RIGHT

203476......................................................................................... ASSY, COVER, RIGHT

203480-1..................................................................................... FOAM, BOTTOM, LEFT

203481-1...................................................................................FOAM, BOTTOM, RIGHT d

203485 ..............................................................................................SCREWS, STAND c

203488.......................................................................................... ASSY, KEYPAD TOP c

205111................................................................................................ CABLE, KEYPAD

203533........................................................................................... ASSY, COVER, LEFT

203556-2......................................................SUPPORT, DRIVE SHAFT (middle support)

203614.................................................................................................... ASSY, CUTTER

203622-1.............................................................................................. CUTTER, WHEEL

203637-2......................................................................................ASSY, PINCH ROLLER

203644-1.........................................................................................................CLIP, BELT

203646................................................................ CAM, ACTUATOR (LEFT AND RIGHT)

203788-1............................................................................................. FOAM, TOP, LEFT

203789-1...........................................................................................FOAM, TOP, RIGHT

203868-1................................................................................................ROLL SUPPORT

203918-2...................................................................................SPRING, ROLL HOLDER

203977......................................................................................................CABLE, RS422

204973..............................................................................................SIDEPLATE, RIGHT

204968................................................................................................ SIDEPLATE, LEFT a

204246 ........................................................................................ STOP, RETRACTING

204384.................................................................................................. ASSY, EXHAUST e

205329 ......................................................................................................ASSY, MPCB

204849..................................................................................................POWER SUPPLY

204599................................................... ON/OFF SWITCH (POWER ENTRY MODULE)

7-2 CADJET 2

Replacement Parts List

PART # DESCRIPTION

204854 ................................................................................................ ASSY, CARRIAGE

205377 ................................................................................................... MANUAL, USER

204859 ..................................................................ASSY, ADI DRIVER DISK, CADJET 2

204860 ..................................................... ASSY, WINDOWS DRIVER DISK, CADJET 2

204861 ................................................................ ASSY, DOS UTILITY DISK, CADJET 2

204916 .................................. ASSY, BRACKET, DRIVE SHAFT (left bracket w/bushing)

204967 ..............................................................................................MANUAL, SERVICE

204969 ................................................................................... ASSY, ROLLGUIDE, LEFT

204994 ................................................................................ LABEL, SET (identifies keys)

205079 ......................................................................................................FOAM, BLOCK

205107 ................................................................................... LABEL, LOGO, CADJET 2

205128 ......................................... ASSY, STEPPER MOTOR SERVICE (includes Gear) d

205188................................................. ASSY, HARDWARE KIT CADJET 2, SERVICE

205350 ........ ASSY, STEPPER MOTOR BRACKET, SERVICE (right bracket w/bushing)

NOTE

Note:

a

If you are ordering the Assy, Top Cover (either P/N 204367-5 or P/N 204367-7; see Sections 2.2 or 2.3), the Stop,

Retracting (P/N 204246) and the Spring, Compression

(P/N 202010) are not included. They must be ordered separately.

b

These parts make up the Idler Service Assembly. If the whole assembly is being replaced, you may order

P/N 203940 Assy, Idler Service rather than ordering the individual pieces.

c

These parts make up the entire Display Keypad. P/N 203488 includes the Keypad PCB, the Cover, and the Keys; it does not include the Keypad Cable or the Keypad Label. If the

Keypad Cable (P/N 205111) or the Keypad Label (included in

P/N 204994), they must be ordered in addition to

P/N 203488.

d

The 8 Stand Screws (P/N 203485) are not included in the

Assy, CADJET 2 Hardware Kit, (P/N 205188). Also not included in the Hardware Kit are the 4 long Stand Screws

(P/N has not yet been determined) which are 1/4 x 20 x 2.5.

All of the Stand Screws are included with the Floor Stand when it is ordered. e

The MPCB has the Flash EPROM already mounted, but it is not programmed.

CADJET 2 7-3

Replacement Parts List

2.2 D-Size Unique Parts (Numerical)

PART # DESCRIPTION

203800-32.............................................................................. ANGLE, TRAILING CABLE

205175..................................................................................ASSY, LEGS AND BASKET

203772-2.............................................................................. BOX, PLOTTER, CADJET 2

203778................................................................................................ CABLE, TRAILING

203903...................................................................................................... BELT, RIBBED

204007-31.................................................................................................. SLIDE SHAFT a

204367-5 ........................................................................................ ASSY, TOP COVER

204551...........................................................ASSY, STABILIZER BRACKET, SERVICE

204848............................................................................................PLATEN, MACHINED

204917-31.....................................................................................ASSY, LOWER DRIVE

NOTE

Note:

a

If you are ordering the Assy, Top Cover, the Stop, Retracting

(P/N 204246) and the Spring, Compression (P/N 202010) are not included. They must be ordered separately.

7-4 CADJET 2

Replacement Parts List

2.3 E-Size Unique Parts (Numerical)

PART # DESCRIPTION

203230 .......................................................................................................... BELT, 3 RIB

203448 ................................................................................................ CABLE, TRAILING

203479-2 ..............................................................................BOX, PLOTTER, CADJET 2

205174 ................................................................................. ASSY, LEGS AND BASKET

203800-3 ................................................................................ANGLE, TRAILING CABLE

204007-2 .................................................................................................... SLIDE SHAFT a

204367-7.........................................................................................ASSY, TOP COVER

204550 ...........................................................ASSY, STABILIZER BRACKET, SERVICE

204847 ........................................................................ PLATEN, MACHINED, CADJET 2

204917-1 ...................................................................................... ASSY, LOWER DRIVE

NOTE

Note:

a

If you are ordering the Assy, Top Cover, the Stop, Retracting

(P/N 204246) and the Spring, Compression (P/N 202010) are not included. They must be ordered separately.

CADJET 2 7-5

Replacement Parts List

3.0 Alphabetical Listing

3.1 Parts Used in both D-Size and E-Size (Alphabetical)

DESCRIPTION PART #

ASSY, ADI DRIVER DISK, CADJET 2 ..................................................................204859

ASSY, BRACKET, DRIVE SHAFT (left bracket w/bushing)...................................204916

ASSY, CARRIAGE.................................................................................................204854

ASSY, COVER, LEFT............................................................................................203533

ASSY, COVER, RIGHT .........................................................................................203476

ASSY, CUTTER.....................................................................................................203614

ASSY, DOS UTILITY DISK, CADJET 2.................................................................204861

ASSY, EXHAUST ..................................................................................................204384

ASSY, FAN ............................................................................................................203443 d b

ASSY, HARDWARE KIT CADJET 2, SERVICE .................................................205188

ASSY, IDLER .................................................................................................. 203345-1 c

ASSY, KEYPAD TOP ..........................................................................................203488 e

ASSY, MPCB.......................................................................................................205329

ASSY, PINCH ROLLER..................................................................................... 203637-2

ASSY, ROLLGUIDE, LEFT....................................................................................204969

ASSY, ROLLGUIDE, RIGHT ............................................................................. 203477-2

ASSY, SERVICE STATION ...................................................................................203233

ASSY, SERVO MOTOR ........................................................................................203265

ASSY, STEPPER MOTOR BRACKET, SERVICE (right bracket w/bushing) ........205350

ASSY, STEPPER MOTOR SERVICE (includes Gear) ..........................................205128 c

ASSY, WINDOWS DRIVER DISK, CADJET 2......................................................204860

CABLE, KEYPAD ................................................................................................205111

CABLE, RS422 ......................................................................................................203977

CAM, ACTUATOR (LEFT AND RIGHT) ................................................................203646

CASTER, LOCKING, TWIN ...............................................202513 (P/N will be changing)

CASTER, NON-LOCKING, TWIN......................................202512 (P/N will be changing)

CLIP, BELT ........................................................................................................ 203644-1

CORD, LINE, SJT, GRAY 9 FT .............................................................................200353

CUTTER, WHEEL ............................................................................................. 203622-1

FOAM, BLOCK ......................................................................................................205079

FOAM, BOTTOM, LEFT .................................................................................... 203480-1

FOAM, BOTTOM, RIGHT .................................................................................. 203481-1

FOAM, TOP, LEFT ............................................................................................ 203788-1

FOAM, TOP, RIGHT .......................................................................................... 203789-1 b

FRAME, TENSIONER ..................................................................................... 203343-1 c

KEYPAD, BOTTOM......................................................................................... 203440-1

LABEL, LOGO, CADJET 2 ....................................................................................205107

LABEL, SET (identifies keys).................................................................................204994

7-6 CADJET 2

Replacement Parts List

DESCRIPTION PART #

LOCTITE BLACK MAX ......................................................................................... 200172

MANUAL, SERVICE ............................................................................................. 204967

MANUAL, USER ................................................................................................... 205377

ON/OFF SWITCH (POWER ENTRY MODULE) ................................................... 204599

POWER SUPPLY ................................................................................................. 204849

ROLL SUPPORT ............................................................................................... 203868-1 d

SCREWS, STAND.............................................................................................. 203485

SIDEPLATE, LEFT................................................................................................ 204968

SIDEPLATE, RIGHT ............................................................................................. 204973 b a

SPRING, COMPRESSION (IDLER) ................................................................... 203447

SPRING, COMPRESSION (TOP COVER)......................................................... 202010

SPRING, ROLL HOLDER .................................................................................. 203918-2 a

STOP, RETRACTING......................................................................................... 204246

SUPPORT, DRIVE SHAFT (middle support) ..................................................... 203556-2

NOTE

Note:

a

If you are ordering the Assy, Top Cover (either P/N 204367-5 or P/N 204367-7; see Sections 2.2 or 2.3), the Stop,

Retracting (P/N 204246) and the Spring, Compression

(P/N 202010) are not included. They must be ordered separately.

b

These parts make up the Idler Service Assembly. If the whole assembly is being replaced, you may order

P/N 203940 Assy, Idler Service rather than ordering the individual pieces.

c

These parts make up the entire Display Keypad. P/N 203488 includes the Keypad PCB, the Cover, and the Keys; it does not include the Keypad Cable or the Keypad Label. If the

Keypad Cable (P/N 205111) or the Keypad Label (included in

P/N 204994), they must be ordered in addition to

P/N 203488.

d

The 8 Stand Screws (P/N 203485) are not included in the

Assy, CADJET 2 Hardware Kit, (P/N 205188). Also not included in the Hardware Kit are the 4 long Stand Screws

(P/N has not yet been determined) which are 1/4 x 20 x 2.5.

All of the Stand Screws are included with the Floor Stand when it is ordered. e

The MPCB has the Flash EPROM already mounted, but it is not programmed.

CADJET 2 7-7

Replacement Parts List

3.2 D-Size Unique Parts (Alphabetical)

DESCRIPTION PART #

ANGLE, TRAILING CABLE ............................................................................. 203800-32

ASSY, LEGS AND BASKET ..................................................................................205175

ASSY, LOWER DRIVE .................................................................................... 204917-31

ASSY, STABILIZER BRACKET, SERVICE ...........................................................204551 a

ASSY, TOP COVER........................................................................................ 204367-5

BELT, RIBBED ......................................................................................................203903

BOX, PLOTTER, CADJET 2 ............................................................................. 203772-2

CABLE, TRAILING.................................................................................................203778

PLATEN, MACHINED............................................................................................204848

SLIDE SHAFT.................................................................................................. 204007-31

NOTE

Note:

a

If you are ordering the Assy, Top Cover, the Stop, Retracting

(P/N 204246) and the Spring, Compression (P/N 202010) are not included. They must be ordered separately.

7-8 CADJET 2

Replacement Parts List

3.3 E-Size Unique Parts (Alphabetical)

DESCRIPTION PART #

ANGLE, TRAILING CABLE................................................................................ 203800-3

ASSY, LEGS AND BASKET ................................................................................. 205174

ASSY, LOWER DRIVE ...................................................................................... 204917-1

ASSY, STABILIZER BRACKET, SERVICE .......................................................... 204550 a

ASSY, TOP COVER ........................................................................................ 204367-7

BELT, 3 RIB .......................................................................................................... 203230

BOX, PLOTTER, CADJET 2.............................................................................. 203479-2

CABLE, TRAILING................................................................................................ 203448

PLATEN, MACHINED, CADJET 2........................................................................ 204847

SLIDE SHAFT .................................................................................................... 204007-2

NOTE

Note:

a

If you are ordering the Assy, Top Cover, the Stop, Retracting

(P/N 204246) and the Spring, Compression (P/N 202010) are not included. They must be ordered separately.

CADJET 2 7-9

Replacement Parts List

4.0 Alphabetical Listing with Drawings

4.1 Drawings - Parts Used in both D-Size and E-Size

Figure Chapter 7 .1: Assy, Bracket, Drive Shaft - P/N 204916

(left bracket w/bushing)

7-10

Figure Chapter 7 .2: Assy, Carriage - P/N 204854

CADJET 2

Replacement Parts List

Figure Chapter 7 .3: Assy, Cover, Left - P/N 203533

Figure Chapter 7 .4: Assy, Cover, Right - P/N 203476

CADJET 2

Figure Chapter 7 .5: Assy, Cutter - P/N 203614

7-11

Replacement Parts List

Figure Chapter 7 .6: Assy, Exhaust - P/N 204384

Figure Chapter 7 .7: Assy, Fan - P/N 203443

NOTE

Note: 1. See Chapter 5, Figure 5.1 for the contents of the Hardware

Kit.

2. The Hardware Kit does not include the stand screws. See

Figure Chapter 7 .36, P/N 203485.

Figure Chapter 7 .8: Assy, Hardware Kit CADJET 2, Service - P/N 205188

7-12

Figure Chapter 7 .9: b

Assy, Idler - P/N 203345-1

CADJET 2

Replacement Parts List

Figure Chapter 7 .10: c

Assy, Keypad Top - P/N 203488

CADJET 2

Figure Chapter 7 .11: e

Assy, MPCB - P/N 205329

7-13

Replacement Parts List

Figure Chapter 7 .12: Assy, Pinch Roller - P/N 203637-2

Figure Chapter 7 .13: Assy, Rollguide, Left - P/N 204969

7-14

Figure Chapter 7 .14: Assy, Rollguide, Right - P/N 203477-2

CADJET 2

Replacement Parts List

Figure Chapter 7 .15: Assy, Service Station - P/N 203233

Figure Chapter 7 .16: Assy, Servo Motor - P/N 203265

Figure Chapter 7 .17: Assy, Stepper Motor Bracket, Service - P/N 205350

(right bracket w/bushing)

CADJET 2 7-15

Replacement Parts List

Figure Chapter 7 .18: Assy, Stepper Motor Service (includes Gear) - P/N 205128

Figure Chapter 7 .19: c

Cable, Keypad - P/N 205111

7-16 CADJET 2

Replacement Parts List

Figure Chapter 7 .20: Cable, RS422 Mini-DIN8 - P/N 203977

Figure Chapter 7 .21: Cam, Actuator (Left and Right) - P/N 203646

Figure Chapter 7 .22: Caster, Locking, Twin - P/N 202513 (P/N will be changing)

CADJET 2 7-17

Replacement Parts List

Figure Chapter 7 .23: Caster, Non-Locking, Twin - P/N 202512 (P/N will be changing)

Figure Chapter 7 .24: Clip, Belt - P/N 203644-1

7-18 CADJET 2

Replacement Parts List

Figure Chapter 7 .25: Cutter, Wheel - P/N 203622-1

Figure Chapter 7 .26: Foam, Block - P/N 205079

CADJET 2

Figure Chapter 7 .27: Foam, Bottom, Left - P/N 203480-1

7-19

Replacement Parts List

Figure Chapter 7 .28: Foam, Bottom, Right - P/N 203481-1

Figure Chapter 7 .29: Foam, Top, Left - P/N 203788-1

Figure Chapter 7 .30: Foam, Top, Right - P/N 203789-1

7-20 CADJET 2

Replacement Parts List

Figure Chapter 7 .31: b

Frame, Tensioner - P/N 203343-1

Figure Chapter 7 .32: c

Keypad, Bottom - P/N 203440-1

Figure Chapter 7 .33: ON/OFF Switch (Power Entry Module) - P/N 204599

CADJET 2 7-21

Replacement Parts List

Figure Chapter 7 .34: Power Supply - P/N 204849

Figure Chapter 7 .35: Roll Support - P/N 203868-1

Figure Chapter 7 .36: d

Screws, Stand - P/N 203485

NOTE

Note: There are also four long Stand Screws which are 1/4 x 20 x

2.5. The P/N for them has not yet been determined. All of the Stand Screws are included with the Floor Stand when it is ordered.

7-22 CADJET 2

Replacement Parts List

Figure Chapter 7 .37: Sideplate, Left - P/N 204968

CADJET 2

Figure Chapter 7 .38: Sideplate, Right - P/N 204973

7-23

Replacement Parts List

Figure Chapter 7 .39: b

Spring, Compression (Idler) - P/N 203447

Figure Chapter 7 .40: a

Spring, Compression (Top Cover) - P/N 202010

7-24

Figure Chapter 7 .41: Spring, Roll Holder - P/N 203918-2

CADJET 2

Replacement Parts List

Figure Chapter 7 .42: a

Stop, Retracting - P/N 204246

Figure Chapter 7 .43: Support, Drive Shaft (middle support) - P/N 203556-2

CADJET 2 7-25

Replacement Parts List

4.2 Drawings - D-Size Unique Parts

NOTE

Figure Chapter 7 .44: Angle, Trailing Cable - P/N 203800-32

Note: The stand and basket assembly shown below is changing.

Drawings of it were not available at the time of publication.

However, the Part Number shown below is the Part Number for the NEW stand and basket assembly.

7-26

Figure Chapter 7 .45: Assy, Legs and Basket - P/N 205175

CADJET 2

Replacement Parts List

Figure Chapter 7 .46: Assy, Lower Drive - P/N 204917-31

Figure Chapter 7 .47: Assy, Stabilizer Bracket, Service - P/N 204551

CADJET 2

Figure Chapter 7 .48: a

Assy, Top Cover - P/N 204367-5

7-27

Replacement Parts List

Figure Chapter 7 .49: Belt, Ribbed - P/N 203903

Figure Chapter 7 .50: Cable, Trailing - P/N 203778

7-28

Figure Chapter 7 .51: Platen, Machined - P/N 204848

CADJET 2

Replacement Parts List

Figure Chapter 7 .52: Slide Shaft - P/N 204007-31

CADJET 2 7-29

Replacement Parts List

4.3 Drawings - E-Size Unique Parts

NOTE

Figure Chapter 7 .53: Angle, Trailing Cable - P/N 203800-3

Note: The stand and basket assembly shown below is changing.

Drawings of it were not available at the time of publication.

However, the Part Number shown below is the Part Number for the NEW stand and basket assembly.

7-30

Figure Chapter 7 .54: Assy, Legs and Basket - P/N 205174

CADJET 2

Replacement Parts List

Figure Chapter 7 .55: Assy, Lower Drive - P/N 204917-1

Figure Chapter 7 .56: Assy, Stabilizer Bracket, Service - P/N 204550

CADJET 2

Figure Chapter 7 .57: a

Assy, Top Cover - P/N 204367-7

7-31

Replacement Parts List

Figure Chapter 7 .58: Belt, 3 Rib - P/N 203230

Figure Chapter 7 .59: Cable, Trailing - P/N 203448

7-32

Figure Chapter 7 .60: Platen, Machined - P/N 204847

CADJET 2

Replacement Parts List

Figure Chapter 7 .61: Slide Shaft - P/N 204007-2

NOTE

Note:

a

If you are ordering the Assy, Top Cover (either P/N 204367-5 or P/N 204367-7; see Sections 2.2 or 2.3), the Stop,

Retracting (P/N 204246) and the Spring, Compression

(P/N 202010) are not included. They must be ordered separately.

b

These parts make up the Idler Service Assembly. If the whole assembly is being replaced, you may order

P/N 203940 Assy, Idler Service rather than ordering the individual pieces.

c

These parts make up the entire Display Keypad. P/N 203488 includes the Keypad PCB, the Cover, and the Keys; it does not include the Keypad Cable or the Keypad Label. If the

Keypad Cable (P/N 205111) or the Keypad Label (included in

P/N 204994), they must be ordered in addition to

P/N 203488.

d

The 8 Stand Screws (P/N 203485) are not included in the

Assy, CADJET 2 Hardware Kit, (P/N 205188). Also not included in the Hardware Kit are the 4 long Stand Screws

(P/N has not yet been determined) which are 1/4 x 20 x 2.5.

All of the Stand Screws are included with the Floor Stand when it is ordered. e

The MPCB has the Flash EPROM already mounted, but it is not programmed.

CADJET 2 7-33

Replacement Parts List

Chapter 7 REPLACEMENT PARTS LIST 7-1

1.0 Introduction ........................................................................................................ 7-1

2.0 Numerical Listing................................................................................................ 7-2

2.1 Parts Used in both D-Size and E-Size (Numerical)......................................... 7-2

2.2 D-Size Unique Parts (Numerical) .................................................................... 7-4

2.3 E-Size Unique Parts (Numerical) .................................................................... 7-5

3.0 Alphabetical Listing ............................................................................................ 7-6

3.1 Parts Used in both D-Size and E-Size (Alphabetical) ..................................... 7-6

3.2 D-Size Unique Parts (Alphabetical) ................................................................ 7-8

3.3 E-Size Unique Parts (Alphabetical)................................................................. 7-9

4.0 Alphabetical Listing with Drawings ................................................................... 7-10

4.1 Drawings - Parts Used in both D-Size and E-Size ........................................ 7-10

4.2 Drawings - D-Size Unique Parts ................................................................... 7-26

4.3 Drawings - E-Size Unique Parts.................................................................... 7-30

7-34 CADJET 2

Replacement Parts List

Figure 7.1: Assy, Bracket, Drive Shaft - P/N 204916 (left bracket w/bushing) .......... 7-10

Figure 7.2: Assy, Carriage - P/N 204854 .................................................................. 7-10

Figure 7.3: Assy, Cover, Left - P/N 203533............................................................... 7-11

Figure 7.4: Assy, Cover, Right - P/N 203476 ............................................................ 7-11

Figure 7.5: Assy, Cutter - P/N 203614 ...................................................................... 7-11

Figure 7.6: Assy, Exhaust - P/N 204384 ................................................................... 7-12

Figure 7.7: Assy, Fan - P/N 203443 .......................................................................... 7-12

Figure 7.8: Assy, Hardware Kit CADJET 2, Service - P/N 205188............................ 7-12

Figure 7.9: b

Assy, Idler - P/N 203345-1.................................................................... 7-12

Figure 7.10: c

Assy, Keypad Top - P/N 203488......................................................... 7-13

Figure 7.11: e

Assy, MPCB - P/N 205329 ................................................................. 7-13

Figure 7.12: Assy, Pinch Roller - P/N 203637-2........................................................ 7-14

Figure 7.13: Assy, Rollguide, Left - P/N 204969 ....................................................... 7-14

Figure 7.14: Assy, Rollguide, Right - P/N 203477-2.................................................. 7-14

Figure 7.15: Assy, Service Station - P/N 203233 ...................................................... 7-15

Figure 7.16: Assy, Servo Motor - P/N 203265........................................................... 7-15

Figure 7.17: Assy, Stepper Motor Bracket, Service - P/N 205350 (right bracket w/bushing)........................................................................................................... 7-15

Figure 7.18: Assy, Stepper Motor Service (includes Gear) - P/N 205128 ................. 7-16

Figure 7.19: c

Cable, Keypad - P/N 205111 .............................................................. 7-16

Figure 7.20: Cable, RS422 Mini-DIN8 - P/N 203977................................................. 7-17

Figure 7.21: Cam, Actuator (Left and Right) - P/N 203646 ....................................... 7-17

Figure 7.22: Caster, Locking, Twin - P/N 202513 (P/N will be changing).................. 7-17

Figure 7.23: Caster, Non-Locking, Twin - P/N 202512 (P/N will be changing) .......... 7-18

Figure 7.24: Clip, Belt - P/N 203644-1 ...................................................................... 7-18

Figure 7.25: Cutter, Wheel - P/N 203622-1............................................................... 7-19

Figure 7.26: Foam, Block - P/N 205079 .................................................................... 7-19

Figure 7.27: Foam, Bottom, Left - P/N 203480-1 ...................................................... 7-19

Figure 7.28: Foam, Bottom, Right - P/N 203481-1.................................................... 7-20

Figure 7.29: Foam, Top, Left - P/N 203788-1 ........................................................... 7-20

Figure 7.30: Foam, Top, Right - P/N 203789-1 ......................................................... 7-20

Figure 7.31: b

Frame, Tensioner - P/N 203343-1 ...................................................... 7-21

CADJET 2 7-35

Replacement Parts List

Figure 7.32: c

Keypad, Bottom - P/N 203440-1......................................................... 7-21

Figure 7.33: ON/OFF Switch (Power Entry Module) - P/N 204599 ........................... 7-21

Figure 7.34: Power Supply - P/N 204849.................................................................. 7-22

Figure 7.35: Roll Support - P/N 203868-1................................................................. 7-22

Figure 7.36: d

Screws, Stand - P/N 203485 .............................................................. 7-22

Figure 7.37: Sideplate, Left - P/N 204968................................................................. 7-23

Figure 7.38: Sideplate, Right - P/N 204973 .............................................................. 7-23

Figure 7.39: b

Spring, Compression (Idler) - P/N 203447 ......................................... 7-24

Figure 7.40: a

Spring, Compression (Top Cover) - P/N 202010................................ 7-24

Figure 7.41: Spring, Roll Holder - P/N 203918-2 ...................................................... 7-24

Figure 7.42: a

Stop, Retracting - P/N 204246............................................................ 7-25

Figure 7.43: Support, Drive Shaft (middle support) - P/N 203556-2 ......................... 7-25

Figure 7.44: Angle, Trailing Cable - P/N 203800-32 ................................................. 7-26

Figure 7.45: Assy, Legs and Basket - P/N 205175 ................................................... 7-26

Figure 7.46: Assy, Lower Drive - P/N 204917-31...................................................... 7-27

Figure 7.47: Assy, Stabilizer Bracket, Service - P/N 204551 .................................... 7-27

Figure 7.48: a

Assy, Top Cover - P/N 204367-5........................................................ 7-27

Figure 7.49: Belt, Ribbed - P/N 203903 .................................................................... 7-28

Figure 7.50: Cable, Trailing - P/N 203778 ................................................................ 7-28

Figure 7.51: Platen, Machined - P/N 204848 ............................................................ 7-28

Figure 7.52: Slide Shaft - P/N 204007-31 ................................................................. 7-29

Figure 7.53: Angle, Trailing Cable - P/N 203800-3 ................................................... 7-30

Figure 7.54: Assy, Legs and Basket - P/N 205174 ................................................... 7-30

Figure 7.55: Assy, Lower Drive - P/N 204917-1........................................................ 7-31

Figure 7.56: Assy, Stabilizer Bracket, Service - P/N 204550 .................................... 7-31

Figure 7.57: a

Assy, Top Cover - P/N 204367-7........................................................ 7-31

Figure 7.58: Belt, 3 Rib - P/N 203230 ....................................................................... 7-32

Figure 7.59: Cable, Trailing - P/N 203448 ................................................................ 7-32

Figure 7.60: Platen, Machined - P/N 204847 ............................................................ 7-32

Figure 7.61: Slide Shaft - P/N 204007-2 ................................................................... 7-33

7-36 CADJET 2

Appendix A

EMERGENCY FIRMWARE DOWNLOAD

PROCEDURE

NOTE

Note: 1. This procedure should be used to download firmware if the

Flash EPROM is blank or corrupt, or if the firmware upgrade using the parallel cable does not work.

2. This procedure must be performed with a RS422 Serial Cable only. A parallel cable will not work. This cable is available from ENCAD, Inc. The Part Number is 203977. See

Chapter 7 of this manual. If you prefer to make your own cable, see Figure Appendix A .1 at the end of this appendix.

1. Connect the RS422 Serial Cable to the computer and the plotter.

2. You should use the most current version of the firmware, which is

CJDOS15.ZIP (as of the date of publication of this manual). It is available on ENCAD’s BBS. You may also contact our Help Desk to obtain the most recent version if you do not have access to the

BBS. See Chapter 1, Section 3.0.

3. Type B:\INSTALL and press <Enter>.

(Or, type A:\INSTALL if your floppy drive is designated as “A.”)

4. Answer “YES” or “NO” to “Do you want to print the

USERGUIDE.TXT now?” and press <Enter>.

5. Select the disk drive on which you want the DOS Utilities installed.

Press <Enter>.

6. Specify the destination subdirectory where the files are to be installed. Press <Enter>.

7. Select the parts of the DOS Utilities you want to install by pressing

SPACEBAR to toggle between “YES” and “NO.” Press <Enter>.

CADJET 2 A-1

Appendix A

NOTE

WARNING

8. After the installation is completed, type CD CADUTIL (or CD and the subdirectory specified in Step 6 above) and press <Enter>.

Note: If you are already in the subdirectory where the files were installed, this step is not necessary.

9. Type CADUTIL and press <Enter>.

10. Type 3 and press <Enter> <Enter>.

11. Press and hold the "PRIME" Key on the plotter and power up the plotter.

12. Release the "PRIME" Key when the plotter’s Fan comes on.

13. Press <Enter> on the computer.

14. The Emergency Download will now clear and reload your plotter’s

Firmware.

DO NOT HALT THIS PROCESS UNTIL IT IS COMPLETED.

15. When the process is completed, reset the plotter’s User Settings to the desired selections and start plotting again.

16. If you need assistance with the above procedures, please call

ENCAD's Help Desk at the number listed in Chapter 1,

Section 3.0 of this manual.

A-2 CADJET 2

Appendix A

CADJET 2

Figure Appendix A .1: Cable, RS422 Mini-DIN8, P/N 203977

A-3

Appendix B

PRINTER FIRMWARE UPGRADE

PROCEDURE

NOTE

Note: 1. This procedure can be performed with a parallel cable or a

RS422 Serial Cable (parallel is faster). The RS422 Serial

Cable is available from ENCAD, Inc. The Part Number is

203977. See Chapter 7 of this manual. If you prefer to make your own cable, see Figure A.1 at the end of Appendix A.

2. This procedure cannot be used if the Flash EPROM is blank or corrupt). See Appendix A.

1. Connect the Parallel Cable (or the RS422 Serial Cable) to the computer and the plotter.

2. Insert the Utilities Disk provided with your plotter. You should use the most current version of the firmware, which is CJDOS15.ZIP

(as of the date of publication of this manual). It is also available on ENCAD’s BBS. You may also contact our Help Desk to obtain the most recent version if you do not have access to the BBS.

See Chapter 1, Section 3.0.

3. Power up the plotter. Wait until the Carriage has traveled across the Platen and returned to the Service Station. Type B:\INSTALL and press <Enter>.

(Or, type A:\INSTALL if your floppy drive is designated as “A.”)

4. Answer “YES” or “NO” to “Do you want to print the

USERGUIDE.TXT now?” and press <Enter>.

5. Select the disk drive on which you want the DOS Utilities installed.

Press <Enter>.

6. Specify the destination subdirectory where the files are to be installed. Press <Enter>.

CADJET 2 B-1

Appendix B

NOTE

NOTE

7. Select the parts of the DOS Utilities you want to install by pressing

SPACEBAR to toggle between “YES” and “NO.” Press <Enter>.

8. After the installation is completed, type CD CADUTIL (or CD and the subdirectory specified in Step 6 above) and press <Enter>.

Note: If you are already in the subdirectory where the files were installed, this step is not necessary.

9. Type CADUTIL and press <Enter>.

10. Type 1 and press <Enter>.

11. After a few seconds, the download will stop and the following message will appear on your computer:

WARNING! THE NEXT PROCEDURE WILL ERASE THE CURRENT PRINTER

OPERATING SYSTEM. THIS PROCEDURE MUST NOT BE INTERRUPTED.

PLEASE INSURE THAT THE PRINTER IS NOT DISTURBED DURING THIS TIME.

12. Press <Enter> to continue with the download.

Note: If at this point there is an error message reporting “PLOTTER

NOT ON LINE,” the parallel download is not going to work.

In this case, you need to call ENCAD’s Help Desk (see

Chapter 1, Section 3.0) and order ENCAD’s RS422 Serial

Cable P/N 203977. (Be sure to tell the Help Desk that you have received this error message.)

13. After the Firmware has been upgraded, disconnect the power cord and power up the plotter again.

14. When the process is completed, reset the plotter’s User Settings to the desired selections and start plotting again.

15. If you need assistance with the above procedures, please call

ENCAD's Help Desk at the number listed in Chapter 1,

Section 3.0 of this manual.

B-2 CADJET 2

Appendix C

FINAL ASSEMBLY DRAWINGS

This appendix contains the Final Assembly Drawings for the

CADJET 2. Callouts of the part numbers and descriptions for all numbered items are provided on the pages preceding the drawings.

When ordering parts, please be aware that not all the parts listed on these pages are available at a component level; they may be available only as part of an assembly. See Chapter 7 of this manual for parts and assemblies which are available.

CADJET 2 C-1

Appendix C

D-Size Final Assembly Callouts

ITEM # PART #

32

33

35

36

38

39

40

41

42

47

48

79

80

82

84

16

17

18

19

21

23

26

28

29

30

4

5

6

7

8

9

10

12

13

15

86

88

103

128

DESCRIPTION

400010

204848

H, KEPNUT, 6-32

PLATEN, MACHINED, CADJET 2 - D

204973 SIDEPLATE, RIGHT

200172 H, LOCTITE BLACK MAX

203556-2 SUPPORT, DRIVE SHAFT

201013 H, SCREW, 6-32 X 3/8 PFH BLK

203440-1 KEYPAD, BOTTOM

203443 ASSY, FAN

203433

201042

SCREW, #10 X 3/4, PFH, ZN

H, SCREW, 6-32 X 1/2 PPH

203411-32 BLADE, FIXED - D

203828-2 SPACER, FIXED BLADE, 2 IN

203423 CLIP, FIXED BLADE

203828-1 SPACER, FIXED BLADE, 1 IN

204599 ON/OFF SWITCH (ASSY, POWER ENTRY MODULE)

204929-31 ASSY, CABLE, OUTPUT - D

204959 CLAMP, CABLE 1/4

203477-2 ASSY, ROLLGUIDE RIGHT

204969

203442

ASSY, ROLLGUIDE LEFT

SCREW, 8-32 X 3/4 SEM

204386

400011

H, SCREW 8-32 X 1/2 PPH

H, KEPNUT, 8-32

203658-1 BLOCK, FILLER

204968

203742

205329

SIDEPLATE, LEFT

PLUG, PLATEN

ASSY, PCB MAIN

205109

205111

LABEL, GROUND

CABLE, KEYPAD

204994 LABEL, SET

203918-2 SPRING, ROLL HOLDER

205079 FOAM, BLOCK

204917-31 ASSY, LOWER DRIVE - D

202518 H, WASHER, .380 ID X .625

203831

205350

RING, RETAINING, C-TYPE

ASSY, STEPPER MOTOR BRACKET, SERVICE

(right bracket w/bushing)

205128

204920

203488

203233

ASSY, STEPPER MOTOR

WASHER, BOWED

ASSY, KEYPAD TOP

ASSY, SERVICE STATION

C-2 CADJET 2

Appendix C

D-Size Final Assembly Callouts (continued)

ITEM # PART # DESCRIPTION

223

243

263

283

317

318

319

320

321

322

323

203476

203533

204384

204916

204449

204828

205107

205110

ASSY, COVER, RIGHT

ASSY, COVER, LEFT

ASSY, EXHAUST

ASSY, BRACKET, DRIVE SHAFT (left bracket w/bushing)

LIT, IMPORTANT NOTICE

LABEL, ID REAR, CADJET 2 - D

LABEL, LOGO, CADJET 2

INSERT, MENU TREE

204367-5 ASSY, TOP COVER, CADJET 2 - D

202010

204246

SPRING, COMPRESSION

STOP, RETRACTING

378 N/A ASSY, Y-ARM, CADJET 2 - D

Breakout of Major Components of ASSY, Y-ARM:

163 204854 ASSY, CARRIAGE

380

383

204007-31

203637-2

SHAFT, SLIDE, CADJET 2 - D

ASSY, PINCH ROLLER

389

390

392

204551

203778

203265

ASSY, STABILIZER BRACKET, SERVICE, CADJET 2 - D

CABLE, TRAILING, CADJET 2 - D

ASSY, SERVO MOTOR

428 203800-32 ANGLE, TRAILING CABLE - D

CADJET 2 C-3

Appendix C

E-Size Final Assembly Callouts

ITEM # PART #

32

33

35

36

38

39

40

41

42

47

48

79

80

82

84

16

17

18

19

21

23

26

28

29

30

4

5

6

7

8

9

10

12

13

15

86

88

103

128

DESCRIPTION

400010

204847

H, KEPNUT, 6-32

PLATEN, MACHINED, CADJET 2 - E

204973 SIDEPLATE, RIGHT

200172 H, LOCTITE BLACK MAX

203556-2 SUPPORT, DRIVE SHAFT

201013 H, SCREW, 6-32 X 3/8 PFH BLK

203440-1 KEYPAD, BOTTOM

203443 ASSY, FAN

203433

201042

SCREW, #10 X 3/4, PFH, ZN

H, SCREW, 6-32 X 1/2 PPH

203411-2 BLADE, FIXED - E

203828-2 SPACER, FIXED BLADE, 2 IN

203423 CLIP, FIXED BLADE

203828-1 SPACER, FIXED BLADE, 1 IN

204599 ON/OFF SWITCH (ASSY, POWER ENTRY MODULE)

204929-1 ASSY, CABLE, OUTPUT - E

204959 CLAMP, CABLE 1/4

203477-2 ASSY, ROLLGUIDE RIGHT

204969

203442

ASSY, ROLLGUIDE LEFT

SCREW, 8-32 X 3/4 SEM

204386

400011

H, SCREW 8-32 X 1/2 PPH

H, KEPNUT, 8-32

203658-1 BLOCK, FILLER

204968

203742

205329

SIDEPLATE, LEFT

PLUG, PLATEN

ASSY, PCB MAIN

205109

205111

LABEL, GROUND

CABLE, KEYPAD

204994 LABEL, SET

203918-2 SPRING, ROLL HOLDER

205079 FOAM, BLOCK

204917-1 ASSY, LOWER DRIVE - E

202518 H, WASHER, .380 ID X .625

203831

205350

RING, RETAINING, C-TYPE

ASSY, STEPPER MOTOR BRACKET, SERVICE

(right bracket w/bushing)

205128

204920

203488

203233

ASSY, STEPPER MOTOR

WASHER, BOWED

ASSY, KEYPAD TOP

ASSY, SERVICE STATION

C-4 CADJET 2

Appendix C

E-Size Final Assembly Callouts (continued)

ITEM # PART # DESCRIPTION

223

243

263

283

317

318

319

320

321

322

323

203476

203533

204384

204916

204449

205106

205107

205110

ASSY, COVER, RIGHT

ASSY, COVER, LEFT

ASSY, EXHAUST

ASSY, BRACKET, DRIVE SHAFT (left bracket w/bushing)

LIT, IMPORTANT NOTICE

LABEL, ID REAR, CADJET 2 - E

LABEL, LOGO, CADJET 2

INSERT, MENU TREE

204367-7 ASSY, TOP COVER, CADJET 2 - E

202010

204246

SPRING, COMPRESSION

STOP, RETRACTING

378 N/A ASSY, Y-ARM, CADJET 2 - E

Breakout of Major Components of ASSY, Y-ARM:

163 204854 ASSY, CARRIAGE

380

383

204007-2

203637-2

SHAFT, SLIDE, CADJET 2 - E

ASSY, PINCH ROLLER

389

390

392

204550

203448

203265

ASSY, STABILIZER BRACKET, SERVICE, CADJET 2 - E

CABLE, TRAILING, CADJET 2 - E

ASSY, SERVO MOTOR

428 203800-3 ANGLE, TRAILING CABLE - E

CADJET 2 C-5

Appendix C

CADJET 2

Figure Appendix C .1: CADJET 2 D-Size Final Assembly Drawing

C-6

Appendix C

CADJET 2

Figure Appendix C .2: CADJET 2 E-Size Final Assembly Drawing

C-7

Appendix D

SCHEMATICS

This section contains the CADJET 2 Schematics for:

PART DESCRIPTION PART #

SCHEMATIC

DOC. # REVISION # OF PAGES

Main PCB Assembly

Keypad PCB Assembly

Carriage PCB Assembly

Flex Circuit

205329

203455-1

204941

204950

205325

203456

204937

204946

A

A

A

A

9 pages

1 page

2 pages

1 page *

_____________

*

There is a typographical error on this schematic in the bottom right-hand corner. It currently reads:

Sheet 2 of 1. Since there is only one page for this schematic, it should read: Sheet 1 of 1.

CADJET 2 D-1

A

D

C

B

8 7 6

Notes:

1. Circuitry to keep OrCAD from rejecting note sheet

J P1

1

2

3

4

5

6

P O WER

C 84

0.001uF

C 75

220uF

10V

+5V

C 85

0.001uF

2. Memory Map

0000 0000 - 00FF FFFF Flash RAM

(See 204579 for EPLD-generated select terms.)

0C00 0000 - 0FFF FFFF Base DRAM

2000 0000 - 3FFF FFFF Optional SIMM RAM

3. OrCAD Page Link Statements

|LINK

| cpu.sch

| glue.sch

| dram.sch

| flash.sch

| simm.sch

| io.sch

| io2.sch

| stepper.sch

4. Because the industry standard for 128 megabyte

SIMM's has not assigned a pin to A12, the current design does not support single bank

128 megabyte SIMM's. Dual bank 128 megabyte

SIMM's must be used until A12 is defined, A26 and A27 are mux'ed and provided as A12 to the

SIMM, and the EPLD equations modified.

5. REVISION HISTORY

Initial Release:

ECN No. 84108

A TO B:

B TO C:

C TO D:

ECN No. 84196

ECN No. 84324

Added capacitors C92 to C96 for CISPR22-A compliance.

ECN No. 84458

Changed R86 and R87 from 4.7Kohms to 2Kohms.

D TO E: ECN No. 84457

Changed R17 to R28 from 75 ohms to 33 ohms.

Added test jumpers to flash chip selects for use with EST.

Changed R157 to R172 from 75 ohms to 33 ohms.

Added square test post holes to DRAMOE* and GACS*.

Changed taps on delay line from 10/30 nsec to 15/30 nsec.

+24V

C 76

2200uF

35V

5 4

+24V

3

U 42

LM317T

VI VO

2

+5V

R155

1K

1 %

R156

2.49K

1 %

8 7 6 5 4

3 2 1

3

16-SEP-97 UPDATED PER ECN 86088.

ENCAD, Incorporated

6059 Cornerstone Court West

San Diego, CA 92121-3734

Title

Enhanced Main Board (205325.sch)

Size

B

Document Number

205325

Date: Monday, November 04, 2002

2

Sheet 1

1 o f 9

R e v

F

F

A

D

C

B

D

C

B

A

8 7 6

+5V

D[0..15]

D[0..15]

+5V

R 12

4.7K

1

2

3

U1

A0

A1

A2

24C08

+5V

R2

SDA

SCL

TEST

(2B3)

4.7K

5

6

7

EECLK

R1

4.7K

EED ATA

R179

4.7k

T306

R180

4.7k

(2C3)

R174

75

R4

4.7K

R3

4.7K

B E RR

D 0

D 1

D 2

D 3

D 4

D 5

D 6

D 7

D 8

D 9

D 10

D 11

D 12

D 13

D 14

D 15

T14

T15

T16

T17

T18

T19

T20

T21

T30

T31

+5V

+5V

D S *

RES ET*

U3

DS1233D

RES

J1

KYBD/DSP

1

2

3

4

1

+5V

(3B2)

(3B2)

RESET*

RES ET*

(3C8,5A8,8D6,9C8)

(3C5)

(3C5)

(3C5)

(3C5)

TXD1

R5

47K

RXD1

(3B1)

(7B7)

R 11

4.7K

T313

T32

T33

T34

T35

D REQ1*

D REQ2*

T314

T315

T36

D SACK0*

D SACK1*

RXDO

BKPT*

R 15

B D I N

B KPT*

47K

F R EEZE

T37

T38

BDOUT

T39

T40

DTRCLK

SERDATA

T41

SERD ATA

T43

TXD0 (7B8)

T44

T45

R 10

4.7K

+5V

T316

(3B1)

TGATE2*

T48

T49

TOUT2 (3B4)

T310

T311

T312

T305

MOTOROLA

BDM PORT

J 7

5

7

1

3

9

2

4

6

8

10

C ONN_BDM

B E RR

B KPT*

F R EEZE

B D I N

BDOUT

+5V

R175

10K

R6

150

R7

10M

X2

3.6864MHz

C 12

22pF

92

C 13

22pF

X1

11

10

9

7

8

117

118

119

120

121

122

109

110

111

112

115

116

125

127

128

129

84

85

87

28

30

29

75

73

74

88

76

77

81

95

98

12

141

142

93

96

94

97

24

25

26

27

DSACK0

DSACK1

IPIPE/BDOUT

IFETCH/BDIN

BKPT/BDCLK

FREEZE

SCLK

RXD0

TXD0

CTS0

31

32

33

34

D7

D8

D9

D10

D11

D12

D13

D14

D15

D0

D1

D2

D3

D4

D5

D6

HALT

BERR

BR

BGACK

BG

DONE1

DONE2

DREQ1

DREQ2

DACK1

DACK2

RESET

RXD1

TXD1

CTS1

TIN1

TGATE1

TOUT1

TIN2

TGATE2

TOUT2

TCK

TMS

TDI

TDO

89

X2

5

8 7 6 5

4 3 2 1

(3D4,5B6,6B7,7D4,8D6,

U2

68340

PA0/A24

PA1/A25

PA2/A26

PA3/A27

PA4/A28

PA5/A29

PA6/A30

PA7/A31

PB0/MODCK

PB3/IRQ3*

PB5/IRQ5*

PB6/IRQ6*

PB7/IRQ7*

RTSA/OP0

RTSB/OP1

OP4

OP6

80

86

82

83

CS0*/AVEC*

CS1*/IRQ1*/PB1

CS2*/IRQ2*/PB2

CS3*/IRQ4*/PB4

DS

AS

5

6

R/W

RMC

2

1

FC0

FC1

FC2

FC3

SIZE0

SIZE1

4

3

40

39

38

37

108

107

106

104

22

105

101

100

99

130

131

132

133

136

137

138

139

A7

A8

A9

A10

A11

A12

A13

A0

A1

A2

A3

A4

A5

A6

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

48

47

46

45

44

43

57

56

54

53

52

49

65

64

63

62

61

58

140

72

71

70

67

66

T317

C9

0.1uF

VCCSYN

19

T81

T80

T79

T78

T77

T76

T75

T74

T73

T72

T71

T70

O PTO

T68

T67

T66

T65

T64

T318

T53

T322

T319

T320

T321

T63

T62

T61

T60

T59

T57

T56

T55

T54

XFC

CLOCK

XTAL

16

14

20

T186

T50

T52

A[0.. 29]

A24 A25 A26

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A 4

A 5

A 6

A 7

A 8

A 9

A 0

A 1

A 2

A 3

R141

4.7K

+5V

+5V

C1

C5

R142

4.7K

0.1uF

0.1uF

+5V

+5V

R143

4.7K

C 2

0.1uF

C 6

0.1uF

A24

A25

A26

A27

A28

A29

SPARE1

SPAR E1

EED ATA

D TR

D O NE/PROG*

(2D7)

(3B1)

(3B1,5A8)

(3C5)

T69

(7D1)

(7D1)

(7D7)

A27

R144

4.7K

+5V

+5V

OPTO

C O LOR

K Y 5

C3

0.1uF

C7

0.1uF

A28

R145

4.7K

+5V

+5V

A29

R146

4.7K

C4

0.1uF

C8

0.1uF

A[0..29]

+5V

C 77

10uF

10V

F AN

EECLK

EPLDCT RL

(8D4)

(2D7)

D R EQS*

EPLDCTRL

F L0CS*

F L1CS*

SIMM1CS*

SIMM2CS*

D S *

D S *

(3C8,5C6)

(3C8,5C3)

(3C8)

(3C8)

(3B8)

S IZ0

R 14

7 5

RW* (3C8,6A8)

(3C8)

(3B4)

(3C5)

C 11

0.01uF

+5V

R147

10K

+5V

C 10

0.1uF

A S* (3D8)

C LOCK (3C8,5A5)

R9

10M

EXTAL

18

R 13

10M

R 8

470K

ENCAD, Incorporated

X1

Title

C 92

10pF

4

32. 768KHz

C 15

22pF

C 14

22pF

3

C 93

10pF

Size

B

Date:

Enhanced Main Board (CPU.sch)

Document Number

205325

Monday, November 04, 2002

2

Sheet

(3D8,5B6,6D8)

2

1 o f 9

R e v

F

D

C

B

A

D

C

B

A

8 7

10V

C 78

1 0uF

C 17

0.1uF

C 18

0.1uF

C 19

0.1uF

C 20

0.1uF

C 21

0.1uF

C 94

0.1uF

A S*

A[0..29]

C 16

0.1uF

1

2

3

15

IN

NC

NC

NC

A[0.. 29]

A S*

A S*

P D6

P D5

P D2

P D1

T15

T30

C L OCK

F L0CS*

F L1CS*

SIMM1CS*

SIMM2CS*

S IZ0

H S KIN

BDMEN

RESET*

PBDMCLK

PBD MDATA

SERDATA

RW*

D S *

T185

T187

T188

D S *

R W *

D S *

RES ET*

T256

T257

C L OCK

+5V

A29

A28

A27

A26

A25

A24

A22

A 1

A 0

A[0.. 29]

8

A 5

A 6

A 7

A 8

A 9

+5V

A10

A11

A12

A13

U6

DS1010S-050

TAP1

TAP2

TAP3

TAP4

TAP5

TAP6

TAP7

TAP8

TAP9

TAP10

14

4

13

5

12

6

11

7

10

9

T15

T30

A14

A15

A16

A17

A18

A19

A20

A21

A23

7

6 5 4

R185

10K

R186

10K

R187

10K

3

+5V

2 1

+5V

53

54

55

31

32

45

46

47

48

50

A29

A28

A27

A26

A25

A24

A22

A1

A0

AS*

81

80

79

1

82

58

44

9

62

61

84

83

51

52

2

3

63

57

59

5

6

PD6

PD5

PD2

PD1

T10

T30

CLOCK

FL0CS*

FL1CS*

SIMM1CS*

SIMM2CS*

MSTRRST*

SIZ0

HSKIN

BDMEN*

RESET*

PBDMCLK

PBDMDATA

SERDATA

RW*

DS*

XC7372-10PC84C

U9

RAS0*

RAS1*

RAS2*

RAS3*

RAS4*

RAS5*

RAS6*

RAS7*

RAS8*

CAS0*

CAS1*

CAS2*

CAS3*

MUXSEL

DSACK0*

DSACK1*

GACS*

STLEDCS*

KYPARCS*

DRAMOE*

68

75

74

11

10

12

71

77

33

76

36

70

21

39

19

18

17

37

14

13

G ACS*

T193

T192

T191

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

BKPT*

RXDO

FLOE*

65

56

69

23

24

25

26

28

29

66

34

35

67

15

S P1

SPARE1

EPLDCT RL

RASB0*

RAS10*

RAS12*

RAS11*

RAS13*

RAS20*

RAS22*

RAS21*

RAS23*

C AS0*

C AS1*

C AS2*

C AS3*

T194

C 22

0.1uF

RAS23*

C AS0*

C AS1*

C AS2*

C AS3*

RASB0*

RAS10*

RAS12*

RAS11*

RAS13*

RAS20*

RAS22*

RAS21*

T205

T206

T207

T208

T209

R W *

R176

7 5

T197

T198

T199

T200

T201

T202

T203

T204

T307

6

8

17

2

4

15

13

11

1

19

IA0

IA1

IA2

IA3

IB0

IB1

IB2

IB3

OEA

OEB

U8

74F 244

YA0

YA1

YA2

YA3

YB0

YB1

YB2

YB3

VCC

GND

5

7

9

18

16

14

12

3

20

10

17

15

6

8

13

11

2

4

1

19

IA0

IA1

IA2

IA3

IB0

IB1

IB2

IB3

OEA

OEB

U7

74F 244

YA0

YA1

YA2

YA3

YB0

YB1

YB2

YB3

VCC

GND

7

9

18

16

3

5

14

12

20

10

6

T286

T287

T288

T289

T290

T291

T292

T293

C 23

0.1uF

C 28

0.1uF

T294

T295

T296

T297

T298

T299

C 29

0.1uF

5

+5V

C 24

0.1uF

R128

R129

R130

R131

R132

R133

R134

R135

R136

R137

R138

R139

R140

C 79

10uF

10V

R127

T223

75

75

75

75

75

75

75

75

+5V

75

75

75

75

75

75

C 25

0.1uF

B W E*

M0

M1

BRAS0*

S1RAS0*

S1RAS2*

S1RAS1*

S1RAS3*

S2RAS0*

S2RAS2*

S2RAS1*

S2RAS3*

BCAS0*

BCAS1*

BCAS2*

BCAS3*

4

C 26

0.1uF

M0

M1

+5V

R181

10K

SP2

D[0..15]

MUXSEL

D SACK0*

D SACK1*

STPLED CS*

DRAMOE*

BKPT*

RXDO

FLOE*

SPARE1

EPLDCTRL

K Y P A RCS*

A CK

B U S Y

T195

XCHKC LK

R 184

0

XCHKCLK

D[0..15]

D 0

D 1

D 2

D 3

D 4

D 5

D 6

D 7

A[0.. 29]

STB

T250

T251

T252

RES ET*

PGAC LK

OPTO

CARRSTAT

D R EQS*

R W *

PGACLK

O PTO

CARR STAT

D R EQS*

D 8

D 9

D 10

D 11

D 12

D 13

D 14

D 15

A 2

A 3

A 4

EXA

EXB

TOUT2

T254

T255

T301

TOO_LOW_A

TOO_LOW_B

32

31

33

12

M0

M1

M2

PWRDN

U5

PWMP

PWMN

HA0

HA1

HA2

HA3

HEADSTB

SHIFT

59

60

9

7

5

6

83

84 23

24

28

27

40

38

41

44

D0

D1

D2

D3

D4

D5

D6

D7

RA0

RA1

RA2

RA3

RA4

RA5

80

81

78

82

79

73

46

72

4

67

A2

A3

A4

KYCSN

13

8

10

63

30

45

29

68

35

74

54

25

21

77

BUSY

ACK

STB

GACS

CCLK

RESET

PGACLK

PAPER_F

CARRSTAT

DREQSN

R/W

EXA

EXB

TOUT2

58

47

TOO_LOW_A

TOO_LOW_B

RD0

RD1

RD2

RD3

RD4

RD5

RD6

RD7

SRAMWR

SRAMOE

2

3

19

18

26

20

36

37

39

42

DREQHN

DREQPN

71

65

SELECT

DTR

DTRCLK

LED4

DONE/PROG

PTRRTS

TGATE2

PARCLK

PE

LEFTA

RIGHTA

LEFTB

RIGHTB

STPLTCHA

STPLTCHB

XC3042A-7PC84C

52

57

50

51

76

75

16

48

49

14

55

17

11

61

34

3

ENCAD, Incorported

Title

PWMP

P WMN

T280

T281

T282

T283

T284

T285

H A 0

H A 1

H A 2

H A 3

HSTB*

SHIFT

T224

T225

T226

T227

T228

T25

10

9

8

7

6

5

A0

A1

A2

A3

A4

A5

T229

T230

T231

T232

T233

T234

T235

T236

T237

T238

T239

T241

T249

T248

T243

T242

R 182

4.7K

+5V

D REQ1*

D REQ2*

SELECT

D TR

DTRCLK

LED4

D O NE/PROG*

PTRRTS

TGATE2*

P ARCLK

P E

LEFT_A

RIGH T_A

LEFT_B

RIGH T_B

STPLTCHA

STPLTCHB

11

12

13

15

16

17

18

19

27

22

D4

D5

D6

D7

D0

D1

D2

D3

WE

OE

C 83

0.001uF

Size

B

Date:

Enhanced Ma in Board (GLUE.sch)

Document Number

205325

Monday, November 04, 2002

2

Sheet

+5V

C 27

0.1uF

NC

U4

6264

1

A6

A7

A8

A9

A10

A11

A12

CS1

4

3

25

24

21

23

2

20

3

1 o f 9

R e v

F

D

C

B

A

D

C

MD[0. .15]

8

MD0

MD1

MD2

MD3

MD4

MD5

MD6

MD7

MD8

MD9

MD 10

MD 11

MD 12

MD 13

MD 14

MD 15

R150

75

MA[0..11]

MD[0. .15]

T124

7

MA0

MA1

MA2

MA3

MA4

MA5

MA6

MA7

MA8

MA9

BRAS0*

BCAS0*

B W E*

6

U 10

MT4C4001J

9

10

11

12

14

15

16

17

18

5

A0

A1

A2

A3

A4

A5

A6

A7

A8

A9

4

23

3

22

RAS

CAS

WE

OE

DQ0

DQ1

DQ2

DQ3

1

2

24

25

VSS

26

MD 15

MD 14

MD 13

MD 12

+5V

C 30

0.1uF

MA[0..11]

MD[0. .15]

B

MA[0..11]

MA0

MA1

MA2

MA3

MA4

MA5

MA6

MA7

MA8

MA9

M A10

M A11

B W E*

BRAS0*

BCAS0*

BCAS1*

BCAS2*

BCAS3*

B W E*

BRAS0*

BCAS0*

BCAS1*

BCAS2*

BCAS3*

R 151

7 5

T125

MA0

MA1

MA2

MA3

MA4

MA5

MA6

MA7

MA8

MA9

BRAS0*

BCAS2*

B W E*

U 17

MT4C4001J

9

10

11

12

14

15

16

17

18

5

A0

A1

A2

A3

A4

A5

A6

A7

A8

A9

4

23

3

22

RAS

CAS

WE

OE

DQ0

DQ1

DQ2

DQ3

1

2

24

25

VSS

26

MD 15

MD 14

MD 13

MD 12

+5V

C 37

0.1uF

C 80

10uF

10V

A

MA0

MA1

MA2

MA3

MA4

MA5

MA6

MA7

MA8

MA9

BRAS0*

BCAS0*

B W E*

5

U 11

MT4C4001J

A0

A1

A2

A3

A4

A5

A6

A7

A8

A9

RAS

CAS

WE

OE

9

10

11

12

14

15

16

17

18

5

4

23

3

22

DQ0

DQ1

DQ2

DQ3

1

2

24

25

VSS

26

MD 11

MD 10

MD9

MD8

4

+5V

C 31

0.1uF

MA0

MA1

MA2

MA3

MA4

MA5

MA6

MA7

MA8

MA9

BRAS0*

BCAS1*

B W E*

3

U 12

MT4C4001J

A0

A1

A2

A3

A4

A5

A6

A7

A8

A9

RAS

CAS

WE

OE

9

10

11

12

14

15

16

17

18

5

4

23

3

22

DQ0

DQ1

DQ2

DQ3

1

2

24

25

VSS

26

MD7

MD6

MD5

MD4

+5V

C 32

0.1uF

MA0

MA1

MA2

MA3

MA4

MA5

MA6

MA7

MA8

MA9

BRAS0*

BCAS2*

B W E*

U 16

MT4C4001J

A0

A1

A2

A3

A4

A5

A6

A7

A8

A9

RAS

CAS

WE

OE

9

10

11

12

14

15

16

17

18

5

4

23

3

22

DQ0

DQ1

DQ2

DQ3

1

2

24

25

VSS

26

+5V

C 36

0.1uF

MD 11

MD 10

MD9

MD8

MA0

MA1

MA2

MA3

MA4

MA5

MA6

MA7

MA8

MA9

BRAS0*

BCAS3*

B W E*

U 15

MT4C4001J

A0

A1

A2

A3

A4

A5

A6

A7

A8

A9

RAS

CAS

WE

OE

9

10

11

12

14

15

16

17

18

5

4

23

3

22

DQ0

DQ1

DQ2

DQ3

1

2

24

25

VSS

26

+5V

C 35

0.1uF

MD7

MD6

MD5

MD4

8 7 6 5 4 3

2

MA0

MA1

MA2

MA3

MA4

MA5

MA6

MA7

MA8

MA9

BRAS0*

BCAS1*

B W E*

1

U 13

MT4C4001J

A0

A1

A2

A3

A4

A5

A6

A7

A8

A9

RAS

CAS

WE

OE

9

10

11

12

14

15

16

17

18

5

4

23

3

22

DQ0

DQ1

DQ2

DQ3

1

2

24

25

VSS

26

MD3

MD2

MD1

MD0

+5V

C 33

0.1uF

MA0

MA1

MA2

MA3

MA4

MA5

MA6

MA7

MA8

MA9

BRAS0*

BCAS3*

B W E*

U 14

MT4C4001J

A0

A1

A2

A3

A4

A5

A6

A7

A8

A9

RAS

CAS

WE

OE

9

10

11

12

14

15

16

17

18

5

4

23

3

22

DQ0

DQ1

DQ2

DQ3

1

2

24

25

VSS

26

MD3

MD2

MD1

MD0

+5V

C 34

0.1uF

D

C

B

ENCAD, Incorporated

Title

Size

B

Date:

Enhanced Main Board (DRAM.sch)

Document Number

205325

Monday, November 04, 2002

2

Sheet 4

1 o f 9

R e v

F

A

8 7 6 5 4 3 2 1

D

C

B

A

XCHKCLK

PE

D O NE/PROG*

RESET*

8

F L0CS*

F L0CS*

XCHKCLK

D O NE/PROG*

P E

RES ET*

A 3

T350

+5V

7

+5V

E 1

E 3

E 7

E 9

E11

E15

E17

+5V

R188

1 0k

FL0CSA*

J P7

JUMPER

B W E*

FLOE*

C 39

0.1uF

A 0

A 1

A 2

A 3

A 4

A 5

A 6

A 7

A 8

A 9

A10

A11

A12

A13

A14

A15

A16

A17

A18

27

26

23

7

6

5

12

11

10

9

8

30

1

3

2

25

4

28

29

31

24

22

A0

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

VPP/A18

WE

OE

CE

E 2

E 4

E 6

E16

E18

J P6

1

2

J UMPER

M0

M1

XCH KTRIG

C L OCK

PGACLK

A[0..29]

A[0.. 29]

D[0..15]

M0

M1

XCHKTRIG

C L OCK

PGACLK

D 0

D 1

D 2

D 3

D 4

D 5

D 6

D 7

D[0..15]

F LOE*

A19

A20

A21

A22

A23

A24

A25

A26

A27

A28

A29

D0

D1

D2

D3

D4

D5

D6

D7

U 20

13

14

15

17

18

19

20

21

D 8

D 9

D 10

D 11

D 12

D 13

D 14

D 15

28F020/ 29F040

F L1CS*

F L1CS* FL1CSA*

J P8

JUMPER

C 38

0.1uF

A 0

A 1

A 2

A 3

A 4

A 5

A 6

A 7

A 8

A 9

A10

A11

A12

A13

A14

A15

A16

A17

A18

A7

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A18

A0

A1

A2

A3

A4

A5

A6

31

WE

24

22

OE

CE

27

26

23

7

6

5

12

11

10

9

8

30

1

3

2

25

4

28

29

29F 040

D0

D1

D2

D3

D4

D5

D6

D7

U 19

13

14

15

17

18

19

20

21

D 8

D 9

D 10

D 11

D 12

D 13

D 14

D 15

R189

10K

+5V

6 5 4 3

D

C

B

ENCAD, Incorporated

Title

Size

B

Date:

Enhanced Main Board (FLASH.sch)

Document Number

205325

Monday, November 04, 2002

2

Sheet 5

1 o f 9

R e v

F

A

D

C

B

A

8 7 6 5

+5V

C 4 5

0.1uF

+5V

C 46

0.1uF

A[0..29]

MUXSEL

ICT

T308

D[0..15]

D 0

D 1

D 2

D 3

D 4

D 5

D 6

D 7

D 8

D 9

D 10

D 11

D 12

D 13

D 14

D 15

R177

75

A[0.. 29]

A10

A11

A 2

A12

A 3

A13

A 4

A14

A 5

A15

A 6

A16

A 7

A17

A 8

A18

A 9

A19

A20

A21

A23

A22

A24

A25

18

17

16

15

14

13

12

11

20

10

D[0..15]

U 24

B1

B2

B3

B4

B5

B6

B7

B8

A1

A2

A3

A4

A5

A6

A7

A8

VCC

GND

74F245

G

DR

2

3

4

5

6

7

8

9

19

1

18

17

16

15

14

13

12

11

20

10

U 25

B1

B2

B3

B4

B5

B6

B7

B8

VCC

GND

74F245

G

DR

A1

A2

A3

A4

A5

A6

A7

A8

4

5

2

3

6

7

8

9

19

1

+5V

C 42

0.1uF

2

3

5

6

11

10

14

13

1

15

U 21

1A

1B

2A

2B

3A

3B

4A

4B

4Y

2

3

5

6

11

10

14

13

1

15

A/B

G

74F157

U 22

1A

1B

2A

2B

3A

3B

4A

4B

1Y

2Y

3Y

4Y

2

3

5

6

11

10

14

13

1

15

A/B

G

74F157

A/B

G

74F157

U 23

1A

1B

2A

2B

3A

3B

4A

4B

1Y

2Y

3Y

4Y

1Y

2Y

3Y

4

7

9

12

+5V

4

7

9

12

+5V

4

7

9

12

C 44

0.1uF

C 43

0.1uF

T167

T168

T169

T170

T171

T172

T173

T174

T175

T176

T177

T178

R 158

R 157

R 167

R 168

R 169

R 170

R 171

R 172

R 159

R 160

R 161

R 162

R 163

R 164

R 165

R 166

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

R 20

R 18

R 17

R 19

0

0

0

0

R 24

R 22

R 21

R 23

0

0

0

0

MA0

MA1

MA2

MA3

MA4

MA5

MA6

MA7

R 27

R 26

R 25

R 28

0

0

MA8

0

0

MA9

M A10

M A11

MD0

MD1

MD2

MD3

MD4

MD5

MD6

MD7

MD8

MD9

MD 10

MD 11

MD 12

MD 13

MD 14

MD 15

MD[0. .15]

MA[0..11]

S1RAS0*

S1RAS2*

S1RAS1*

S1RAS3*

BCAS0*

BCAS1*

BCAS2*

BCAS3*

B W E*

MA[0..11]

S2RAS0*

S2RAS2*

S2RAS1*

S2RAS3*

MD[0. .15]

R W *

DRAMOE*

8 7 6 5

43

40

42

41

47

44

34

45

33

+5V

43

40

42

41

47

44

34

45

33

RAS0

RAS2

RAS1

RAS3

CAS0

CAS1

CAS2

CAS3

WE

+5V

RAS0

RAS2

RAS1

RAS3

CAS0

CAS1

CAS2

CAS3

WE

A[0.. 29]

4

4

A 0

A 1

A26

A27

A28

A29

C 82

10uF

10V U 26

SIMM72

C 81

10uF

10V U 27

SIMM72

3

3

2 1

PRD1

PRD2

PRD3

PRD4

67

68

69

70

4 0DEG

R 30

10K

R 31

10K

+5V

P D 1

P D 2

D

PRD1

PRD2

PRD3

PRD4

67

68

69

70

+5V

R 33

10K

R 34

10K

P D 5

P D 6

C

B

ENCAD, Incorporated

Title

Size

B

Date:

Enhanced Main Board (SIMM.sch)

Document Number

205325

Monday, November 04, 2002

2

Sheet 6

1 o f 9

R e v

F

A

D

C

B

A

S7

8

S6

S2

S3

S4

S5

S1

+5V

R 41

4.7K

T107

7 6

T101 +5V

+5V

4.7K

K Y 0

K Y 1

K Y 2

K Y 3

K Y 4

K Y 5

R 43

BDMEN

K Y 5

R 46

4.7K

4.7K

R 44

T102

T103

T104

T105

R 47

4.7K

R 45

4.7K

R 42

4.7K

C 51

0.1uF

AUTOFD

IN IT

SLCT IN

K Y P A RCS*

15

17

8

6

4

2

11

13

U 28

I1

I2

I3

I4

I5

I6

I7

I8

1

19

G1

G2

74HCT244

K Y P A RCS*

O1

O2

O3

O4

O5

O6

O7

O8

9

7

16

18

5

3

12

14

C O LORUB

C 52

0.1uF

+5V

C 49

0.1uF

D 8

D 9

D 10

D 11

D 12

D 13

D 14

D 15

6

9

12

2

5

15

16

19

U 32

Q0

Q1

Q2

Q3

Q4

Q5

Q6

Q7

D0

D1

D2

D3

D4

D5

D6

D7

OE

CLK

74HCT374

3

4

7

8

13

14

17

18

1

11

P ARCLK

K Y P A RCS*

D 0

D 1

D 2

D 3

D 4

D 5

D 6

D 7

T108

T109

T110

T111

T112

T113

T114

T115

5

D[0..15]

R 54

R 55

R 56

R 57

R 58

R 59

R 60

R 61

A CKB

B U S Y B

1 K

1 K

PEB

SEL ECTB

1 K

1 K

1 K

1 K

1 K

1 K

D[0..15]

4

+5V

R 66

1 K

R 6 2

1 K

R 67

1K

R 63

1K

R 68

1 K

R 6 9

R 64

1 K 1 K

R 65

1K

8

TXD0

DTRCLK

1 uF

10V

T189

C 91

+5V

T122

H S KIN

SERDATA

T123

11

RXD

4

TXD

5

10

9

7

8

6

3

DTR

HSKI.R

GPI

SHDN

RXEN

TXEN

CPEN

1

C1+

2

C1-

T154

C 73

1 uF

10V

+5V C 50

1 uF

10V

RXD+

RXD-

14

15

TXD+

19

TXD-

20

HSKO

18

HSKI

16

GPI

17

C2+

23

C2-

22

U 29

LTC1323CS

T196

T121

C 86

1 uF

10V

7 6

G18 G19

5

G20 G21 G22

G 1 G8 G 2 G 7 G 3 G 6 G4 G 5 G 9

G10

G11

G12

R 183

20K

1

2

7

4

8

5

6

3

J3

2

1

5

4

3

MINI_DIN_8

8

7

6

G23 G24

4

A C K

B U S Y

P E

3

SELECT

PTRRTS

OPT OUB

C O LORUB

T259

+5V

R 48

1K

R154

1K

G17

P D0

P D1

P D2

P D3

P D4

P D5

P D6

P D7

10

11

12

7

8

9

3

4

5

6

1

2

13

14

15

16

17

18

25

26

27

28

29

30

19

20

21

22

23

24

31

32

33

34

35

36

R 53

1 K

IEEE1284

J2

PT RRTSB

+5V

+5V

R 35

1 K

R153

1K

+5V

R152

1K

R 51

1 K

R 52

1 K

IN IT

SLCT IN

PBDMCLK

PBD MDATA

AUTOFD

G13

3

R 50

1K

15

17

8

6

4

2

11

13

1

19

U 31

I4

I5

I6

I1

I2

I3

I7

I8

G1

G2

74LS244

O1

O2

O3

O4

O5

O6

O7

O8

5

3

12

14

16

18

9

7

R 49

1K

2

+5V

ENCAD, Incorporated

G14

T116

T117

T118

T119

T120

R 36

R 37

R 38

R 39

R 40

G15 G16

Title

Size

B

Date:

Enhanced Main Board (IO.sch)

Document Number

205325

Monday, November 04, 2002

2

T309

ICT

R178

75

33

33

33

33

33

C O LOR

Sheet

STB

OPTO

1

A CKB

B U S Y B

PEB

SEL ECTB

PT RRTSB

7

1 o f 9

R e v

F

D

C

B

A

D

C

B

A

8 7 6 5 4 3 2 1

8

RES ET*

PWMP

P WMN

7

D[0..15]

6

D[0..15]

+24V

11

ENBL

5

IN1

7

IN2

+24V

U 36

L6203

BOOT1

4

OUT1

3

OUT2

1

BOOT2

8

C 65

0.1uF

C 62

0.01uF

C 63

0.01uF

C 95

.033uF

R 88

T1

1 2

C 66

0.01uF

J 6

1

2

3

C 96

.033uF

D 0

D 1

D 2

D 3

D 4

D 5

D 6

D 7

STPLEDCS*

RESET*

D 8

D 9

D 10

D 11

D 12

D 13

D 14

D 15

C 64

0.1uF

+5V

HST B*

SHIFT

H A0

H A1

H A2

H A3

C 57

0.1uF

+5V

R 76

47K

T8

11

13

4

2

15

17

8

6

1

19

U 34

I1

I2

I3

I4

I5

I6

I7

I8

G1

G2

74HCT244

O1

O2

O3

O4

O5

O6

O7

O8

9

7

16

18

5

3

12

14

+5V

R 86

2 K

T9

R 84

1K R 85

1K

0.001uF

C 60

EXA

EXB

T2

T3

T4

T5

T6

T7

R 87

2K

C 59

0.001uF

3

4

7

8

13

14

17

18

11

1

U 35

D1

D2

D3

D4

D5

D6

D7

D8

Q1

Q2

Q3

Q4

Q5

Q6

Q7

Q8

CLK

CLR

74HCT273

RES ET*

2

5

6

9

12

15

16

19

XCH KTRIG

BEEPER

L ED0

L ED1

L ED2

L ED3

OPT OUB

T253

R 77

33

R 79

33

R 81

33

C 61

0.01uF

R 78

3 3

R 80

3 3

R 82

3 3

1

1

1

1

1

1

1

L4

L3

L2

L1

L7

L6

L5

C 58

0.1uF

2

2

2

2

2

2

2

+5V

XCHKTRIG

T10

T11

T12

T13

LED4

F AN

+24V

C ARIGE1

C ARIGE2

C ARIGE3

C ARIGE4

C ARIGE5

C ARIGE6

C ARIGE7

C ARIGE8

C ARIGE9

CARIGE10

CARIGE11

CARIGE12

CARIGE13

CARIGE14

CARIGE15

CARIGE16

CARRSTAT

5

6

7

1

2

3

4

I5

I6

I7

I1

I2

I3

I4

O1

O2

O3

O4

O5

O6

O7

U 33

MC1413

16

15

14

13

12

11

10

JP3

6

7

8

9

10

11

12

13

14

3

4

5

1

2

15

16

17

18

19

20

C O NN20

5 4 3

+24V

C 56

0.1uF

3

1

1

1

D 2B

4

R 7 3

GR EEN

D4

2

R 7 1

Y E L L OW

D3

2

R 7 2

Y E L L OW

D 2A

2

R 7 4

1

GR EEN

D 13

2

R173

150

150

150

150

150

GR EEN

+24V

J 5

1

2

3

+5V

C ARIGE1

C ARIGE2

C ARIGE3

C ARIGE4

C ARIGE5

C ARIGE6

C ARIGE7

C ARIGE8

C ARIGE9

CARIGE10

CARIGE11

CARIGE12

CARIGE13

CARIGE14

CARIGE15

CARIGE16

+5V

1

LS1

+

2 -

HMB-06

JP4

8

9

10

11

12

13

5

6

7

1

2

3

4

14

15

16

C O NN16

D

C

B

ENCAD, Incorported

Title

Size

B

Date:

Enhanced Main Board (IO2.sch)

Document Number

205325

Monday, November 04, 2002

2

Sheet 8

1 o f 9

R e v

F

A

D

C

B

A

8 7 6

LEFT_A

RIGHT_A

D[0..15]

D[0..15]

STPLTCHA

RESET*

D 7

D 6

D 5

D 4

D 3

D 2

D 1

D 0

D 15

D 14

D 13

D 12

D 11

D 10

D 9

D 8

13

14

17

18

3

4

7

8

11

1

U 40

D1

D2

D3

D4

D5

D6

D7

D8

CLK

CLR

74HCT273

Q1

Q2

Q3

Q4

Q5

Q6

Q7

Q8

12

15

16

19

2

5

6

9

R 106

U N U SED

T274

T275

T276

R 105

2.49K

1 %

R 104

4.99K

1 %

T277

10K

R 103

1 %

R 102

20K 1 %

T272

T271

T273

R 101

4.99K

1 %

10K

R 100

1 %

R 99

20K

1 %

LEFT_B

RIGHT_B

STPLTCHB

D 15

D 14

D 13

D 12

D 11

D 10

D 9

D 8

3

4

7

8

13

14

17

18

11

1

U 41

D1

D2

D3

D4

D5

D6

D7

D8

CLK

CLR

74HCT273

Q1

Q2

Q3

Q4

Q5

Q6

Q7

Q8

2

5

6

9

12

15

16

19

R 124

U N U S ED

T267

T268

T269

R 123

2.49K

R 122

1 %

4.99K

R 121

1 %

10K 1 %

T270

20K

R 120

1 %

8 7

T265

T264

T266

R 119

4.99K

1 %

10K

R 118

1 %

20K

R 117

1 %

6

5

+5V +24V

T160

C 70

0.1uF

C 67

0.1uF

+5V

5

7

IN1

IN2

6

EN

R 98

1 %

2.49K

+24V

OUT1

2

OUT2

3

U39A

L298

4

R125

20K

1 %

+5V

MC34074

U 38A

2

3

+24V

C 68

0.01uF

-

+

1

T159

3 2

D5

1N5818

D 8

1N5818

D6

1N5818

+5V

R 91

0.5

1 %

1W

D7

1N5818

R 89

10K

0.1%

R 93

2 K

1 %

R 96

2 K

0.1%

R 97

2K

0.1%

R 90

T156

6

10K

0.1%

T155

MC34074

U 38B

5

-

+

7

T157

R 94

2 K

1 %

T158

+5V

C 69

0.001uF

R 95

1K

1 %

2

3

+24V

-

+

1

U37A

LM393

+5V

R 92

1 K

T278

TOO_LOW_A

1

J P5

1

2

3

4

5

6

T261 +24V

T165

R126

20K

1 %

13

+5V

MC34074

U 3 8D

12

R 116

1 %

2.49K

C 71

0.01uF

-

+

14

10

IN1

12

IN2

11

EN

OUT1

13

OUT2

14

U39B

L298

D9

1N5818

D 10

1N5818

D 12

1N5818

+5V

T164

R109

0.5

1 %

1W

D 11

1N5818

R107

10K

0.1%

R111

2 K

1 %

R114

2 K

0.1%

R115

2K

0.1%

R 108

T162

9

T161

MC34074

U 3 8C

10

10K

0.1%

-

+

8

R112

2 K

1 %

T166

+5V

0.001uF

C 72

T163

R113

1K

1 %

6

5

-

+

7

U37B

LM393

+5V

R 110

1 K

T279

TOO_LOW_B

T263

5 4 3

D

C

B

ENCAD, Incorporated

Title

Size

B

Date:

Enhanced Main Board (STEPPER.sch)

Document Number

205325

Monday, November 04, 2002

2

Sheet 9

1 o f 9

R e v

F

A

D

C

B

A

8

PAPER SENSOR

OPTO

PPRSNRC

J1

5

6

7

8

9

10

1

2

3

4

11

12

13

14

15

16

HEADER 16

OPTO

+5V

C12

0.1uF

20%

J3

4

3

2

1

HEADER 4

+5V

+24V

1000uF

C2

80%

+5V

C3

10uF

8

(2C1)

+24V

EXB

EXA

HSTB*

+5V

1

U6

LM2576T-ADJ

VI VO

2

FB

4

7

+5V

VCC

6 5 4 3 2 1

7

R1

1K

R2

1K

R3

1K

R4

1K

R5

1K

R6

1K

HA0

HA1

HA2

HA3

(1A5,1B6,1D4)

(1A5,1B6,1D6)

(1A5,1B6,1D4)

(1A5,1B6,1D4)

+24V

(1C7)

+5V

C11

0.1uF

20%

SHIFT

HA2

HA1

HSTB*

HA0

PSEL4

PSEL1

PSEL3

PSEL6

PSEL7

PSEL5

+5V

1

2

3

4

5

6

7

9

10

11

12

13

14

15

(1B4)

(1C4)

(1C4)

(1B4)

(1D4)

(1D4)

U1

VCC

I/CLK

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

GND

GND

PA7024-PLCC

VCC

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/CLK2

NC

NC

28

27

26

25

24

23

21

20

19

18

17

16

22

8

+5V

HA3

PSEL2

PSEL8

QP9*

QP10*

QP11*

QP12*

+5V

(1C7)

(1C4)

(1B4)

(1B6)

(1B6)

(1B6)

(1B6)

L1

220uH

D1

MUR410

R7

23.2

PQ1

R15

10K

1%

R16

1.13K

1%

R8

23.2

PQ2

R9

23.2

PQ3

R10

23.2

(1C4)

(1C4)

PQ4

(1C4)

(1C7)

(1C7)

(1C7)

(1C7)

(1C5)

C1

1000uF

80%

25V

+12.1V

6

+5V

QP11*

QP12*

QP10*

HA3

HA2

HA1

HA0

QP9*

J2

7

8

9

4

5

6

1

2

3

10

11

12

13

14

15

16

HEADER 16

TRICOLOR CARTRIDGE

(1C7)

(1C7)

(1C7)

(1C7)

HA0

HA1

HA2

HA3

5

1

5

2

U4A

7406

9

6

U4C

7406

3

U4D

7406

U4B

7406

8

4

4

(1C6)

(1C6)

(1C6)

(1C6)

(1D4)

(1C6)

(1C6)

(1C4)

PSEL5

PSEL7

PSEL3

PSEL1

PSEL2

PSEL4

PSEL6

PSEL8

13

13

9

3

1

5

11

11

U3F

7406

U4F

7406

U3D

7406

U3B

7406

U3A

7406

U3C

7406

U4E

7406

U3E

7406

12

12

8

4

2

6

10

10

R48

620

R49

620

R42

620

R43

620

R54

620

R55

620

R36

620

R37

620

R39

620

R40

620

R45

620

R46

620

R51

620

R52

620

R57

620

R58

620

R44

+12.1V

R50

47

1

R56

47

1

Q6

2907A

POWER5

+12.1V

Q8

2907A

POWER7

+12.1V

47

1

R38

Q4

2907A

POWER3

+12.1V

47

1

R41

Q2

2907A

POWER1

+12.1V

47

1

R53

Q3

2907A

POWER2

R47

47

1

+12.1V

Q5

2907A

POWER4

+12.1V

47

1

R59

47

1

Q7

2907A

POWER6

+12.1V

Q9

2907A

POWER8

+12.1V

(1A3)

(1A3)

(1A3)

(1A3)

POWER5

POWER7

POWER3

CHA3*

CHA2*

POWER1

POWER2

POWER4

CHA1*

CHA0*

POWER6

POWER8

HEADER 16

104 CARTRIDGE

J4

7

6

5

10

9

8

4

3

2

1

16

15

14

13

12

11

D

C

B

R11

4.7K

R12

4.7K

R13

4.7K

+12.1V

R14

4.7K

CHA0*

CHA1*

CHA2*

CHA3*

(1B1)

(1B1)

(1B1)

(1B1)

3

Encad, Inc.

6059 Cornerstone Court

San Diego, CA 92121

Title

SCH, CADJET CARRIAGE BOARD

Size

B

Date:

Document Number

204937

Thursday, November 09, 2000

2

Sheet 1

1 of 2

Rev

D

A

D

C

8

J5

1

2

3

4

HEADER 4

+24V

7

2

CCW

R30

20K

CW

2

+24V

3

Q1

SFH309F

3

+

2

-

+24V

U8A

LM324

1

R31

100K

R19

10K

R20

10K

C5

0.1uF

+5V

R28

150

1/8W

R29

150

1/8W

D4

SFH409

3

6

+24V

C6

0.1uF

BRIGHTNESS

5

+

6

-

2

U8B

LM324

7 1

D2

BAV99

3

10

+

9

-

U8C

LM324

8 3

D3

BAV99

2

1

TP1

5

PEAK+

C9

22uF

35V

PEAK-

C10

22uF

35V

B

A

NOTES:

UNLESS OTHERWISE SPECIFIED

1. ALL RESISTORS ARE IN OHMS, 5%, 1/10W.

ALL CAPACITORS ARE IN MICROFARADS, 10%, 50V.

2 ADJUST R30 TO PRODUCE 18-20V AT U1 PIN 1 LOOKING

AT WHITE BOND AT A DISTANCE OF 0.200".

3 D4 AND Q1 ARE ATTACHED THROUGH A CABLE.

THE PIN NUMBERS REFER TO THE CONNECTOR PIN NUMBERS.

3

+

2

-

+24V

U10A

LM324

1

12

+

13

-

U10D

LM324

14

R22

10K

R23

10K

R18

10K

10

+

9

-

R17

10K

U10C

LM324

8

(PEAK+) - (PEAK-)

4 3

13

12

-

+

U8D

LM324

14

R32

200K

THRESHOLD

R33

200K

R34

30K

+5V

R35

30K

R24

10K

R21

1M

5

+

6

-

U10B

LM324

7

LATCH_ENABLE

R25

10K

12

13

11

U9D

74HC00

R26

10K

+24V

C7

0.1uF

9

10

4

5

8 7 6 5 4 3

U9C

74HC00

8

6

U9B

74HC00

2

+5V

1

2

+5V

U9A

74HC00

3

C8

0.1uF

R27

1K

1

OPTO

(1D8)

D

C

B

Encad, Inc.

6059 Cornerstone Court

San Diego, CA 92121

Title

SELF CALIBRATING PAPER EDGE DETECTOR

Size

B

Date:

Document Number

204937

Thursday, November 09, 2000

2

Sheet 2

1 of 2

Rev

D

A

MAIN MENU

PRINT MODE press DOWN ARROW

MAIN MENU

UTILITIES press SELECT

UTILITIES

CALIBRATION

→ press DOWN ARROW

UTILITIES

OPTIONS=EASY

OPTIONS=EASY

OPTIONS=ADVANCED

If MENU=EASY, press SELECT, press UP ARROW once, then press SELECT.

press UP ARROW twice

UTILITIES

SERVICE

→ press SELECT

SERVICE

INFORMATION

→ press SELECT press DOWN ARROW once to go to “SERVICE DIAGNOSTICS,” or twice to go to “SERVICE CALIBRATION”

INFORMATION

DISPLAY SETTINGS press DOWN ARROW

DATE:

TIME: press SELECT to display the current user’s User Settings (go to “MAIN MENU

USER SETTINGS” to change the User Settings)

XX-XX-XX

XX:XX:XX press DOWN ARROW

ROM REVISION

CADJET 2 V1.50

press DOWN ARROW

PRINT DIRECTION

BI press DOWN ARROW

RELEASE INFO

REV 1.50 ROM press DOWN ARROW

TOTAL MEMORY

XXXXXXXX BYTES press DOWN ARROW

MEMORY CONFIG

I

/O=128K RAS=3M press DOWN ARROW

EMULATE LANGUAGE

HPGL2 press DOWN ARROW

BAUD RATE

9600 press DOWN ARROW

PARITY

EVEN,7BITS press DOWN ARROW

HANDSHAKE

HARDWIRE press DOWN ARROW

DTR

NORMAL press DOWN ARROW

PRINT MODE

NORMAL press DOWN ARROW

PRINT COLOR

COLOR press DOWN ARROW

FIRING RATE

5000 press DOWN ARROW

MAX PWM/POSITION

14 84 0 press DOWN ARROW

PWM/SATURATION

0 245 0 -1 press DOWN ARROW

STOP/MAX/DISABLE

0 50 0 press DOWN ARROW

ERROR/CMD/POS

0 0 0 press DOWN ARROW

PLOT TIME

XX:XX:XX press MENU to return to

“INFORMATION

DISPLAY SETTINGS”

Service Menu

INFORMATION

PRINT SETTINGS press SELECT to print all 8 stored User Settings

If media is already loaded, all 8 User Settings will print.

press MENU to return to “SERVICE INFORMATION”

If no media is loaded, the following will be displayed:

INSERT MEDIA

PRESS LOAD KEY

After media is loaded, all 8 User Settings will print.

press MENU to return to “SERVICE INFORMATION”

SERVICE

DIAGNOSTICS → press SELECT

DIAGNOSTICS

PAPER SENSOR press DOWN ARROW press SELECT

(reads paper size & displays information) press DOWN ARROW twice

DIAGNOSTICS

SERIAL PORT press SELECT

SERIAL PORT

RESULT=OK

RESULT=OK

RESULT=ERROR press SELECT press DOWN ARROW

DIAGNOSTICS

PARALLEL PORT press SELECT

PARALLEL PORT

RESULT=OK

RESULT=OK

RESULT=ERROR press DOWN ARROW twice

DIAGNOSTICS

CARTRIDGE press SELECT

(draws PRIME pattern) press DOWN ARROW

DIAGNOSTICS

CARRIAGE VIBRATE press SELECT

(draws 5 sets of 3 parallel lines) press DOWN ARROW

DIAGNOSTICS

COLOR TEST=35%

COLOR TEST=10%, 25%, 35%, 50%, 65%, 75%, 100% press SELECT press UP or DOWN ARROWS to change value press SELECT to enter the value

(four 1” bands of each color will be drawn) press DOWN ARROW

DIAGNOSTICS

KEYPAD press SELECT (“beep” will sound if OK) press all other keys to test ( “beep” will sound if OK) press SELECT press DOWN ARROW

DIAGNOSTICS

LCD press SELECT

(2 rows of 16 eights should display briefly)

8888888888888888

8888888888888888 press DOWN ARROW

DIAGNOSTICS

LED press SELECT

(all lights flash on, unless they are already on) press DOWN ARROW

DIAGNOSTICS

ROM press SELECT

ROM

RESULT=OK

DIAGNOSTICS

RAM press SELECT

RAM

RESULT=OK

RESULT=OK

RESULT=ERROR press DOWN ARROW twice

RESULT=OK

RESULT=ERROR press DOWN ARROW twice

DIAGNOSTICS

SPEAKER press SELECT

(beeps once if OK) press DOWN ARROW

DIAGNOSTICS

SERVO MOTOR

→ press SELECT

SERVO MOTOR

SPEED=FAST

SPEED=SLOW

SPEED=FAST press SELECT press UP or DOWN ARROWS to change value press SELECT, then DOWN ARROW

SERVO MOTOR

CYCLES=1

0 to 1,000,000 (500 recommended) press SELECT press UP or DOWN ARROWS to change value press SELECT to run test press MENU, then DOWN ARROW after test

DIAGNOSTICS

PAPER MOTOR → press SELECT

PAPER MOTOR

SPEED=FAST

SPEED=SLOW

SPEED=FAST press SELECT press UP or DOWN ARROWS to change value press SELECT, then DOWN ARROW

PAPER MOTOR

INCHES=1

DIAGNOSTICS

FAN

0 to 1 inches press SELECT press UP or DOWN ARROWS to change value press SELECT to do Stepper Motor quality test press MENU, then DOWN ARROW press SELECT to test Fan press SELECT to end test press MENU to return to “SERVICE DIAGNOSTICS”

SERVICE

CALIBRATION → press SELECT

CALIBRATION

DEADBAND=XX

XX = 52 to 69 (do not exceed this range of values; 52 & 61 work best) press SELECT to draw 2 lines of 16 regions of deadband at XX

(The “=“ will blink while deadband is drawn.)

(press UP or DOWN ARROWS to change value press SELECT twice to draw deadband at new value) press SELECT to stop “=“ from blinking press DOWN ARROW

CALIBRATION

VERT LINES (ONE) press SELECT to draw 16 regions of vertical lines uni-directional press DOWN ARROW

CALIBRATION

VERT LINES (ALL) press SELECT to draw 16 regions of vertical lines bi-directional press DOWN ARROW

CALIBRATION

SLOW DEADBAND=0

SLOW DEADBAND=0 or 1 press SELECT to draw 1 line of 16 regions of deadband

(The “=“ will blink while deadband is drawn.)

(press UP or DOWN ARROWS to change value and press SELECT twice to draw deadband at new value) press SELECT to stop “=“ from blinking press MENU three times to return to “MAIN MENU UTILITIES” press UP ARROW to return to ‘MAIN MENU PRINT MODE”

4.

5.

2.

3.

NAVIGATING THE MENU

1.

6.

Press any of the four LCD keys to wake up the plotter. The plotter will wake up at the MAIN

MENU level and at the first MAIN MENU (PRINT MODE).

Press the arrow keys to scroll through the MAIN MENUs (either forward or backward).

Press SELECT to enter the desired menu.

Press the arrow keys to scroll through the selected menu.

To change a value or parameter, press SELECT. The equal sign (=) will blink, indicating that you are now in change mode. Press the arrow keys to scroll through the available values or parameters. The new value or parameter will blink , indicating that it is different from the currently saved value or parameter. Press SELECT again to save the changed value or parameter and leave the change mode.

Press the MENU key to move back up to the previous level of the menu tree.

KEY

DIAGNOSTICS

COLOR TEST=35%

COLOR TEST=10%, 25%, 35%, 50%, 65%, 75%, 100% press SELECT press UP or DOWN ARROWS to change value press SELECT to enter the value

(four 1” bands of each color will be drawn) press DOWN ARROW

Submenu items with an arrow (

) have additional submenus.

The values shown in the boxes are the default values for each option.

The text below the boxes shows any additional values for each option, indicates steps to be followed, and gives other information.

A color version of this menu is available on our BBS, filename: C2SVCMNU.ZIP

It may be printed on any of our inkjet plotters.

Encad, Inc.

6059 Cornerstone Court West

San Diego, CA 92121

Technical Support: 619-452-4350

Technical Support FAX: 619-546-0659

Technical Support BBS: 619-452-2653 or 619-452-3768

Technical Support Internet WEB Address: http://www.thegroup.net/encad/

09/18/95

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