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NJ PRO 36 NJ PRO 50 NJ 4 Service Manual

1. P1 NER P2 PIN25 7 1807 4 gt 7 LE PIN14 gt DIAGRAM MINI DIN 8 P1 P2 08 255 Pm FEMALE GND SHELL SHIELD SHELL GND RXD 5 2 TXD 3 3 RXD 2 4 RTS HSKO 1 5 CTS RXD Ba 5 6 DSR CND 4 7 CND TXD 6 8 DCD 7 20 DTR 22 RI P3 08 95 FEMALE SHELL GND 3 TXD 2 RXD 7 5 8 CTS L 6 DSR 5 GND 1 DCD 4 DIR 9 RI Figure Chapter 9 26 Cable 85422 Mini DIN8 P N 203977 Figure Chapter 9 27 Cable Trailing with bend in cable P N 205697 9 20 NOVAJET SERIES Replacement Parts List Figure Chapter 9 30 Caster Non Locking Twin P N 202512 NOVAJET SERIES 9 21 Replacement Parts List Figure Chapter 9 32 Foam Block Lower P N 204982 Figure Chapter 9 33 Foam Bottom Left P N 205452 9 22 NOVAJET SERIES Replacement Parts List Figure Chapter 9 35 Foam Top Left P N 205453 Figure Chapter 9 36 Foam Top Right P N 205524 NOVAJET SERIES 9 23 Replacement Parts List Figure Chapter 9 37 Frame Tensioner P N 203870 1
2. 5 37 11 5 4 Loaded Media Not Detected Media Size Not Detected or Plotter Has Incorrect PlotArea So nt A RI E Aer 5 38 11 5 5 Keypad Display Shows LOAD MEDIA Message When Rollfeed Media is ioco pb PCI 5 39 11 5 6 Loud Grinding Noise When Media 5 40 11 6 Media Cutting 5 42 11 7 Delivery System 5 43 5 51 11 9 Memory ce 5 52 11 10 Plotter Hesitates During Plotting 5 53 11 11 Plot Appearance is not as Expected 5 53 TIAA ORG sare ettet A Dt M LL TL A CL At ANE 5 54 11 13 Plotter is Noisy 5 55 11 14 User Parameters Not Saved When Power Is Cycled 5 55 11 15 Carriage Assembly Moves Erratically 5 56 11 16 Media Movement Erratic essen 5 58 11 17 LCD or LED 5 59 11 18 LCD ix 5 61 5 5 5 63 Troubleshooting Figure 5 1 Fig
3. P N 204916 9 6 Assy Carriage complete P N 204996 9 6 Assy Cover Left P N 205026 9 7 Assy Cover ad nan aded P N 203476 4 9 7 Assy Encoder w Flex P N 204999 9 7 cedes sene ns emia P N 203443 9 8 Assy Hardware Kit NOVAJET PRO Service P N 205440 9 8 PSSY Net inin URDU EU P N 203405 1 9 8 Assy Keypad P N 203488 1 9 9 Assy Legs and P N 203484 3 9 9 NOVAJET SERIES Figure 9 11 Figure 9 12 Figure 9 13 Figure 9 14 Figure 9 15 Figure 9 16 Table of Contents Assy Lower DIVE P N 204917 1 9 10 Assy MPOB uiuere P N 205853 9 10 Assy Pinch Roller P N 204773 9 10 Assy Rollguide P N 204969 3 9 11 Assy Rollguide P N 203477 6 9 11 Assy Service Station P N 204629 9 12 NOVAJET SERIES XXV Table of Contents CHAPTER 9 REPLACEMENT PARTS LIST continued Number
4. 9 16 Figure 9 19 Assy Stepper Motor Bracket Service P N 205350 right bracket 9 16 Figure 9 20 Assy Stepper Motor Service includes Gear P N 205128 9 17 Figure 9 21 Assy Top Cover NOVAJET PRO P N 204711 1 9 17 Figure 9 22 Assy Tubing Chain Support Service P N 205868 9 18 Figure 9 23 Belt 312 Wide E Size P N 205678 9 19 Figure 9 24 Bushing Carriage 2 P N 203228 9 19 NOVAJET SERIES 9 31 Replacement Parts List Figure 9 25 Figure 9 26 Figure 9 27 Figure 9 28 Figure 9 29 Figure 9 30 Figure 9 31 Figure 9 32 Figure 9 33 Figure 9 34 Figure 9 35 Figure 9 36 Figure 9 37 Figure 9 38 Figure 9 39 Figure 9 40 Figure 9 41 Figure 9 42 Figure 9 43 Figure 9 44 Figure 9 45 Figure 9 46 Figure 9 47 Figure 9 48 Figure 9 49 Figure 9 50 Figure 9 51 Figure 9 52 Figure 9 53 9 32 Cable Keypad P N 203457 acces 9 19 Cable RS422 Mini DIN8 P N 203977 9 20 Cable Trailing with bend in cable P N 205697 9 20 Carriage Board P N 204562 9 21 Caster Locking Twin P N 202513
5. ae 6 18 4 5 1 Extra Memory SIMM 6 18 4 5 2 Extra Memory SIMM 6 20 4 6 Reinstalling the Right Cover 6 21 21 9 Ns MM M ee 6 22 5 1 Removing the Servo iie IU eR CERE AA OU 6 22 5 2 Replacing the Servo 6 26 6 9 Display ASSO mbly udi r 6 28 6 1 Removing the Display Assembly 6 28 6 2 Reinstalling the Display 6 29 7 0 Left Cover Assembly Left Side Plate Carriage Assembly and components Trailing Cable Carriage Belt and NOVAJET PRO Tubing Chain Assembly 6 30 7 1 Removing the Left Cover Assembly and Left Side Plate 6 30 7 2 Removing the Carriage 6 31 7 3 Reinstalling the Carriage 6 35 7 4 Reinstalling the Left Side Plate and Left Cover Assembly 6 38 7 5 Removing the Trailing 020 6 39 7 6 Reinstalling the Trailing 6 41 6 88
6. P N 203999 9 24 Figure 9 48 Spring Compression Top Cover P N 202010 9 25 Figure 9 49 Spring Extension Service Station Bottom P N 204763 9 25 Figure 9 50 Stop Retracting a actes P N 204246 1 9 25 Figure 9 51 Support Drive Shaft middle support P N 203556 2 9 26 Figure 9 52 Support sooo iva e ee te eure s P N 204760 9 26 Figure 9 53 P N 204732 9 26 Number Title Page Figure A 1 Cable R8422 Mini DIN8 un t ca aln cC e ec ecc A 3 NOVAJET SERIES xxvii Table of Contents TABLES Number Title Page Table 1 1 Comparison of NOVAJET and 1 6 Table 1 2 Media Sizes and Maximum Plotting Areas for Rollfeed Media 1 9 Table 1 3 Media Sizes and Maximum Plotting Areas for Sheet Media 1 10 Number Title Page Table 4 1 Cartridge Jet Area Cleaning 4 10 Number Title Page Table 5 1 Decision Logic Table One 07 1 5 4 Table 5 2 Decision Logic Table Two 5 5 Table 5 3 Decision Logic Table Three DLT 3 5 6 Table 5 4 Decision Logic Table Four DET 4 tr tte totes 5 7 Table 5 5 Ink Delivery System Troubleshoo
7. 1 14 1 15 EE Na ee Saree 1 16 Acronyms arid AbbteviallOliS 1 18 al6SSaly LL 1 19 NOVAJET SERIES Table of Contents CHAPTER 2 THEORY OF OPERATION 1 0 2 0 3 0 Mechanical overview and electrical circuitry theory with block diagram visuals ae ee eee eet 2 1 2 2 2 1 Paper Media Axis 2 2 2 2 Carriage Axis DIVa bs oan toco 2 2 Electrical I pGranon sc avin uo oen epa eon n cono bn onu 2 3 3 1 CIICUIEASSOITiDIIGS cc ota roe aeo arsit ie taraen su 2 3 3 1 1 Main Printed Circuit Board 2 3 3 1 2 Front Panel ta abel 2 3 3 1 3 Carriage Printed Circuit Assembly Carriage 2 4 3 2 Block Dia tam ier EE ERE IM E 2 5 3 3 Power Supply Am 2 6 3 4 2 7 3 5 NONO 2 8 3 6 2 9 3 7 Flash EEPROM 2 10 3 8 DEAN 2 11 3 9 Seral EEPROM 2 11 9 10 Salo AN By aucto e e o M dd 2 12 3 11
8. STABILIZER BRACKE Figure Chapter 9 18 Assy Stabilizer Bracket Service P N 204699 Figure Chapter 9 19 Assy Stepper Motor Bracket Service P N 205350 right bracket w bushing NOVAJET SERIES Replacement Parts List Figure Chapter 9 20 Assy Stepper Motor Service includes Gear P N 205128 MPRESSION P N 2020 EPARATELY RACTING P N 204246 1 SEPARATELY Figure Chapter 9 21 2 Assy Top Cover NOVAJET PRO P N 204711 1 NOVAJET SERIES 9 17 Replacement Parts List NIGUS CHAIN WITH TUBING 252 NICS COUVER WITH NEEDLES CPC FITTINGS omae S Figure Chapter 9 22 Assy Tubing Chain NJP 36 P N 205023 Assy Tubing Chain NJP 50 P N 206541 9 18 NOVAJET SERIES Replacement Parts List Figure Chapter 9 23 Belt 312 Wide E Size P N 205678 E N B NN 27 f SEN NN NAT Figure Chapter 9 24 Bushing Carriage 2 203228 9 A Figure Chapter 9 25 Cable Keypad P N 203457 NOVAJET SERIES 9 19 Replacement Parts List
9. Figure Chapter 9 53 Wiper 4 P N 204732 NOVAJET SERIES 9 29 Replacement Parts List 9 30 If you are ordering the Assy Cover P N 204711 1 P N 204711 31 or P N 204711 61 the Stop Retracting P N 204246 1 or P N 205694 and the Spring Compression P N 202010 are not included They must be ordered separately These parts make up the entire Display Keypad The Assy Keypad Top P N 203488 1 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 203457 for NJ 4 or NJP 36 or P N 205111 for NJP 50 or the Keypad Label included in P N 204994 are needed they must be ordered in addition to P N 203488 1 The MPCB has the Flash EEPROM already mounted but it is not programmed The 10 Stand Screws P N 203485 2 are not included in the Assy Hardware Kit Service P N 205440 NOVAJET SERIES Replacement Parts List Chapter 9 REPLACEMENT PARTS LIST 9 1 S E 9 1 2 0 Numerical Listing as Am d d 9 2 3 0 Alphabetical EIGN oett 9 5 4 0 Alphabetical Listing with Drawings 000000000 9 9 Figure 9 1 Assy Bracket Drive Shaft P N 204916 left bracket w bushing 9 9 Figure 9 2 Assy Carriage complete P N 204996 9 9 Figure
10. RS 422 RS 232 Error er NOVAJET SERIES Table of Contents CHAPTER 5 TROUBLESHOOTING continued 11 0 Operation 5 25 11 1 Plotter Does Not Turn 5 25 11 2 Plotter slgwto InitlaliZEe codes 5 26 11 3 Plotter WIILNOBEEIOU ER ete tre 5 27 11 3 1 Parallel Interface and Serial Interface Tests 5 28 11 4 Movement in the Carriage Axis 5 31 11 5 Media PEODIGITIS va 5 34 11 5 1 Cut Sheet Media Won t 5 34 11 5 2 Media Feeds Out of Plotter When Plot is Completed 5 36 11 5 8 Media Skews or 5 36 11 5 4 Loaded Media Not Detected Media Size Not Detected or Plotter Has Incorrect Plot Area 5 37 11 5 5 Keypad Display Shows LOAD MEDIA Message When Rollfeed Media is 5 38 11 5 6 Loud Grinding Noise When Media Loads 5 39 11 6 M dia Cutting Problems ore meo d eme dere pes 5 41 11 7 Ink Delivery System 2 5 42 6 2 PRIME PIOE
11. Figure Chapter 3 10 Priming NJP Cartridge Prior to Installation in Carriage NOVAJET SERIES Assembly 3 13 Ink Delivery System 10 Install the Cartridge in its slot in the Carriage Assembly see Figure Chapter 3 11 Cartridge positions from left to right are Yellow Magenta Cyan and Black which is the same left to right sequence as the Ink Reservoirs PA A gt US Figure Chapter 3 11 Installing NJP Cartridge in Carriage 11 It is very important that the Ink Delivery Line is not twisted To prevent this from happening loosen the Needle s connector and lift the connector up away from the Cartridge slightly so that the Ink Delivery Line is completely relaxed do not remove the Needle from the Cartridge 12 Without allowing the connector to rest on the Cartridge turn the connector counter clockwise one full turn hold it in that position and lower it back down onto the Cartridge 13 Tighten the connector gently until it is just barely snug DO NOT OVERTIGHTEN 3 14 NOVAJET SERIES NOVAJET SERIES Ink Delivery System Repeat this entire procedure from the beginning of Section 2 2 through the end of Section 2 4 for the other Cartridges until all four of them are installed Be sure to thoroughly rinse the Priming Pump and the Suction Bulb between each color Once all four Cartridges are installed press the PRIME key to run the Prime plot Check the Prime plot to see if
12. 6 9 Inside View of Right Cover 6 11 MPCB GOnMGCIONS 6 14 locaton of SIMM k ea con oot ahaa obe 6 18 Closeup View of GI aot ht eta d e 6 18 Side View of SIMM ir EE Ret HER etate in 6 18 Side View of SIMM Installation 2 6 19 NOVAJET SERIES Table of Contents CHAPTER 6 DISASSEMBLY ASSEMBLY continued Number Figure 6 11 Figure 6 12 Figure 6 13 Figure 6 14 Figure 6 15 Figure 6 16 Figure 6 17 Figure 6 18 Figure 6 19 Figure 6 20 Figure 6 21 Figure 6 22 Figure 6 23 Figure 6 24 Figure 6 25 Figure 6 26 Figure 6 27 Figure 6 28 Figure 6 29 Figure 6 30 Figure 6 31 Figure 6 32 Title Page Compression of Frame 6 21 spare sc E E MM 6 22 Trailing Cable Support 6 23 Display ASSBIHDIV ii 6 27 6 28 Strain Relief and Trailing Cable on Carriage Assembly 6 31 left End of Y AIT petto tide 6 32 Carriage Belt and Belt 6 41 Removing the Carriage
13. A 1 APPENDIXB PRINTER FIRMWARE UPGRADE PROCEDURE B 1 APPENDIX SCHEMATICS s ascen davis ee arc E ex ara E A RV eR REIR C 1 NOVAJET SERIES vii Table of Contents CHAPTER1 GENERAL INFORMATION 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 12 0 viii Overview Technical Support comparison of NOVAJET Ill NOVAJET PRO media sizes and plot areas general product notes plotter features and specifications Line Length Accuracy and Skew information acronyms and abbreviations and glossary RE E E 1 1 1 2 2 1 Related 1 2 2 2 Features of this Service 1 3 2 2 1 Subject 5 00 4 0000 1 3 2 2 2 Figures ANG T ableS oro i tese ge 1 3 2 2 3 Manual 1 4 ENCAD Technical Support amp 1 5 Comparison of NOVAJET and NOVAJET 1 6 Media Sizes and 1 8 te ee ee 1 11 Plotter M Oh St 1 12 Plotter SDOCITOSHOFiS 2
14. B OOOOOEH lt 5 i FAN 7N a i PEE CHANGECHRTEIBGE mL LEN O 5 55 i 7 go Fleas Hd EM C To assy P N I REV sma AO 1 ua us us ue ae ee a n 66588605 p nnnnnnnnnnnnnnnnnnnnn 9 ie val 1 d E uuu COUT UUUUUUUU 8 E 8372 w 8 un q Bd 3 S w B 8 B 8 N B S 4 N MADE IN USA 5 E CD Be GI P UUUUUUUUUUUUUUUUUUUUG d Him Figure Chapter 9 13 Assy Pinch Roller 8 P N 204773 NOVAJET SERIES 9 13 Replacement Parts List y ASSY ROLLGUIDE LEFT N ___ SPRING ROLL HOLDER Figure Chapter 9 14 Assy Rollguide Left P N 204969 3 SPRING ROLL HOLDER 4 ROLLGUIDE RIGHT Figure Chapter 9 15 Assy Rollguide Right P N 203477 6 9 14 NOVAJET SERIES Replacement Parts List Figure Chapter 9 17 Assy Servo Motor P N 203496 1 NOVAJET SERIES 9 15 Replacement Parts List ODER ODER STRIP
15. 7 27 NOVAJET SERIES xxiii Table of Contents CHAPTER 7 CALIBRATION continued Number Figure 7 5 Figure 7 6 Figure 7 7 Figure 7 8 Figure 7 9 Figure 7 10 Figure 7 11 Figure 7 12 Figure 7 13 Figure 7 14 CHAPTER 8 Number Figure 8 1 Figure 8 2 Title Page Correct Positioning of the Spring in the Upper Roller Support 7 29 Test for Minimum Acceptable 7 30 Visual Verification of Gap between Roller and Y Arm 7 31 Paper Skew Acceptance Range for Rear Media Alignment Mark 7 33 Paper Skew Acceptance Range for Front Media Alignment Mark 7 34 Motion of Rollers and Adjustment of Mounting Screws 7 35 Deadband 2 44404444000 7 45 All EE 7 49 Vertical Lines One sant eta uaa atu cont 7 50 NOVAJET PRO Calibration 7 61 Media Feeder Takeup Mechanism Title Page U 8 SE tetas eter 8 9 REPLACEMENT PARTS LIST Number Figure 9 1 Figure 9 2 Figure 9 3 Figure 9 4 Figure 9 5 Figure 9 6 Figure 9 7 Figure 9 8 Figure 9 9 Figure 9 10 Title Part Page Assy Bracket Drive Shaft left bracket
16. Motor 452 2 13 3 12 Servo Motor p oa 2 15 3 13 Parallel and Serlal POF S i c SREE 2 16 314 abend a 2 17 3 15 Carriage Assembly Circuits 2 18 3 16 LEDs ee 2 19 3 17 BotFiring 5 rain nace adeo qaare ceca eta seca ture 2 19 3 18 Schematic p ERE ERE ER PE REB 2 19 NOVAJET SERIES ix Table of Contents CHAPTER 3 INK DELIVERY SYSTEM 1 0 2 0 3 0 Instructions for Loading and Unloading the NOVAJET PRO Ink Delivery System and for preparing the Plotter for shipment to ENCAD or for storage or transporting 3 1 Leading the Ink Delivery Systelri ui ero e ERE ER ER ER ERE 3 3 2 1 Filling the Ink ReSprVOll esie p e Eo 3 3 2 2 Priming the Ink Delivery 3 6 2 3 Filling the to ee tiet to 3 9 2 4 Installing and Priming the 3 11 Unloading the Ink Delivery 3 16 3 1 Removing the Ink 3 16 3 2 Purging the Ink Delivery 3
17. 3 24 Removing Black Foam 3 26 Refilling the NOVAJET 4 Ink 3 29 NOVAJET SERIES Chapter 4 MAINTENANCE 1 00 Introduction This chapter contains general maintenance and cleaning instructions for the NOVAJET PRO 36 NOVAJET PRO 50 and NOVAJET 4 D and E Size plotters Refer to Chapter5 for troubleshooting information Always disconnect the power cord and the interface cable before cleaning the plotter An electrical shock hazard may result if these procedures are not followed 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 Never allow any type of liquid including ink to enter the last vacuum hole on the left end of the Platen It will drip down onto the internal Power Supply and cause damage Liquid spills into the other vacuum holes should also be avoided to prevent damage to internal parts If any liquid spills onto the Platen immediately blot it up with a dry cloth Do not wipe across the vacuum holes wipe away from them NOVAJET SERIES 4 1 Maintenance 20 External Never allow type of liquid including ink to enter the last vacuum hole on the left end of the Platen It will drip down onto the internal Power Supply and cause damage Liquid
18. 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 NOVAJET SERIES A 5 PIN pint 12761 07 4 184 ND LO a PINTA PING PINS PINS 3 R DTR lt SHELL i Enea CN PO 10 CO 00 pA CN P 00 10 NN i l DIAG HIELD cy P SHELL IN 00 x MINI c H Figure Appendix A 1 Cable RS422 Mini DIN8 P N 203977 NOVAJET SERIES PRINTER FIRMWARE UPGRADE PROCEDURE RS422 Serial Cable parallel is faster The RS422 Serial nore Note 1 This procedure can be performed with a parallel cable or a Cable is available from ENCAD The Part Number is 203977 See Chapter 9 of this manual If you prefer to make your own cable see Figure A 1 at the end of Appendix A This procedure cannot be used if the Flash EEPROM is blank or corrupt See Appendix A
19. 4 5 5 0 Encoder Strip Maintenance se a ee Cubs oer 4 7 6 0 Ink Delivery System Maintenance 2 20 000000 4 8 6 1 Cleaning the Cartridges NUP and 4 4 8 6 1 Flex Contact Areg rix Ph ir thee bicho nett 4 8 DTP Jet ATOS cete ite oM uto 4 8 6 2 Extended Periods 4 12 6 3 Reservoirs and Delivery Lines NUP 4 13 7 0 Upper and Lower 00 4 14 Figure 4 1 Removal of Service bo i ie atc 4 6 Table 4 1 NOVAJET PRO Cartridge Jet Area Cleaning Procedures 4 10 Table 4 2 NOVAJET 4 Cartridge Jet Area Cleaning Procedures 4 10 NOVAJET SERIES 4 15 Chapter 5 TROUBLESHOOTING 1 0 Introduction 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 Be aware that liquid which enters the last vacuum hole on the top left sid
20. 5 46 9 5 47 11 10 Plotter Hesitates During 5 48 11 11 Plot Appearance is not as 5 48 11 12 rate 5 49 11134 gt Plotter iS NOISY Eai 5 50 11 14 User Parameters Not Saved When Power Is Cycled 5 50 11 15 Carriage Assembly Moves 5 51 11 16 Media Movement Erratic iit oo e E o enn 5 53 11 17 LCD or LED Key s 5 54 11 18 LCD Keypad Display Inoperative 5 56 NOVAJET SERIES xiii Table of Contents CHAPTER6 DISASSEMBLY ASSEMBLY 1 0 2 0 3 0 4 0 4 6 5 0 6 0 7 0 Detailed procedures for removing and installing field replaceable parts and assemblies fep 6 1 Tools and Equipment RSquit Cie 6 4 6 6 3 1 Removing the Plotter from the 6 6 3 2 Placing th
21. The NJ Pro 50 has two turnbuckles so these need to be adjusted together for the center position Measure Measure First Second Adjust if Measure required Last 5 For example If the Left 0 Right 0 004 then the Center should be adjusted to 0 002 This will ensure a smooth plane of travel for the carriage assembly There are no adjustments on either end of the shaft in all models NOVAJET SERIES 7 17 Calibration Record on the Calibration Worksheet the readings at the following positions Right position in front of the Platen s Front Media Alignment Mark see Chapter 1 Figure 1 1 Center position directly in line with the center of the turnbuckle screw see Figure 7 2 Left position in front of the inner screw which is to the right of the left Support Bracket see Figure 7 2 E TURNBUCKLE OSITION GAUGE N LINE WITH e J THIS 15 THE INNER SCREW POSITION GAUGE DIRECTLY IN FRONT Figure Chapter 7 2 Center and Left Positions for Slide Shaft Profile Adjustment 7 18 NOVAJET SERIES Calibration Calibration Worksheet Slide Shaft Profile Adjustment LEFT CENTER RIGHT Relative difference Shaft Height Values LEFT RIGHT SUM DIVIDED BY 2 NOVAJET SERIES 7 19 Calibration 7 0 Cartridge Head Height Adjustment Use extreme
22. OPTICAL SENSOR PAPER SENSOR Figure Chapter 2 7 Carriage Assembly Circuits The Carriage Assembly contains the optical encoder sensor for horizontal position sensing a Paper Sensor and the logic and drive circuitry for firing the ink jets NOVAJET SERIES 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 Ink Low feature is not functional for the NOVAJET PRO 36 NOVAJET PRO 50 The beeper contains built in driver circuitry so that it beeps under firmware control The beeper alerts the user to error conditions The Fan provides suction on the platen bed and holds the paper media flat during the plot process 3 17 Dot Firing Sequence The following sequence of events occurs for every swath printed 1 A buffer in RAM is filled with all the firing data for the whole swath 2 DMA controller is initialized INIT DMA is set in the gate array This causes the gate array to initiate the DMA transfer of 32 bytes of firing data for the first position into the buffer SRAM The last byte of data is the quadrature counter value at which to fire the jets 4 15 set in the gate array to enable the hardware position comparator 5 When the Carriage Assembly reaches the firing position the gate array sequences through the fourteen jet positions in the cartridge quadrants The dat
23. and NJ 4 6 1 1 Flex Contact Area Acetone or any other harsh cleaner may damage the Flex Contacts Do not touch the Flex Contacts with your fingers when handling the Cartridges The Flex Contact area of the Cartridges and the Flex Cables on the Carriage Assembly should be clean and dry free from any ink Use a cotton swab moistened with alcohol to clean them 6 1 2 Jet Area Clean the jet area on the Cartridges only if the plot quality is unsatisfactory and the troubleshooting information in Chapter 5 indicates that the jet area should be cleaned Whenever you clean the jet area of the Cartridges you should also clean the Wipers and Seals on the Service Station so that no ink buildup on them is transferred to the clean jet area See Section 4 0 of this chapter There are three methods for cleaning the jet area of the Cartridge The sequence in which these methods should be tried is as follows 1 use the Suction Bulb NOVAJET PRO only 2 blot the jet area and 3 use ultrasonic cleaner The details for each of these methods are described below in Table Chapter 4 1 NOVAJET PRO and Table Chapter 4 2 NOVAJET 4 4 8 NOVAJET SERIES NOVAJET SERIES Maintenance Tapping the Cartridge on any hard surface may cause damage Blot the jet area by pressing lightly against the jets Use a lint free non paper cloth that has been moistened with distilled water or R O water Reverse Osmosis Do not use
24. size Architectural media Paper Axis Calibration is out Perform the Paper Axis Calibration in Chapter 7 Section 13 2 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 b NOVAJET SERIES The media was not loaded properly Remove the media and carefully load it again The Upper Roller Supports which hold the media have become dirty misaligned or excessively worn Refer to the alignment procedures in Chapter 7 Section 10 0 and or to the removal and replacement procedures in Chapter 6 Section 11 0 of this manual 5 37 Troubleshooting 5 38 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 plotter 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 NOVAJET Series User s Guide for the procedure The optical sensor circuit Paper Sensor may be defective or the flex cable may not be properly seated in the connector on the Carriage Board J6 See Chapter 6 Figure 6 19 Go to the SERVICE D
25. 5 18 D0 LEDKEYS 5 19 6 0 LCD 42118 5 20 7 0 Keypad Messages 5 21 du RE DM UU 5 21 5 21 To laset M dia 5 21 ttc E 5 21 PARAM ecc 5 22 7 6 Checks m Err cM MIN US 5 22 a Es 5 22 Voobeady to HODIOL c 5 22 8 0 Initialization Sequence ood bande Mx EM EM AM UE PME 5 23 9 0 RS 422 RS 232 Error Messages 40004 0000001 1 5 24 TOO ROA Error ced ec adii soda ua ecd ae Ese ose 5 25 11 0 Operation 5 26 11 1 Plotter Does Not 5 26 11 2 Plotter SIOW ZG i 5 27 11 3 Plotter Will NOE PlOls cows cei eit eae aie 5 28 11 3 1 Parallel Interface and Serial Interface 5 29 11 4 No Movement in the Carriage 5 32 5 62 NOVAJET SERIES Troubleshooting 11 5 Media 5 35 11 5 1 Cut Sheet Media 1 5 35 11 5 2 Media Feeds Out of Plotter When Plot is Completed 5 37 11 5 3 Media Skews or
26. 4 2222 44 7 56 15 1 Adjusting the Horizontal Head to Head Calibration 7 59 15 2 Adjusting the Vertical Head to Head Calibration 7 60 16 0 Color Deadband Calibration ERR ER EU 7 61 16 1 Color Deadband 7 62 17 0 Line Quality Plot Computer 7 63 18 0 Production Gold Standard Computer 7 65 NOVAJET SERIES xvii Table of Contents 8 MEDIA FEEDER TAKEUP MECHANISM Installation and parts required for the automatic Media Feeder Takeup Mechanism 1 0 IATHOCUGTION 8 1 2 0 Installation c eot ene hei 8 2 3 0 eee aa 8 9 xviii NOVAJET SERIES Table of Contents CHAPTER9 REPLACEMENT PARTS LIST 1 0 2 0 3 0 4 0 A complete listing numerical alphabetical and illustrated alphabetical of all field replaceable parts and assemblies for the NOVAJET PRO 36 NOVAJET PRO 50 and NOVAJET 4 Color Inkjet Plotters igit fere Wo GIN rcc 9 1 N mencal ISI s e oo ERREUR 9 2 Alphabetical 6 E 9 4 Alphabetical Listing with Drawings 022220 9 6 NOVAJET SERIES xix Table of Contents APPEN
27. 6 8 Inside View of Right Cover 6 10 MEGB GODRSDIDISLO S cod ect Su pu ctu Mt 6 14 Boeziinugm 6 18 Closeup View 4 4 444 0 000 nennen nnne 6 18 Side View of SIMM 6 19 Side View of SIMM 000 0 6 20 Compression of Frame 6 22 vite f 6 23 Trailing Cable Support 6 24 Display ASSGMDIY 6 28 Keypad POB 1s 6 29 Trailing Cable Support Assembly 6 32 Strain Relief and Trailing Cable on Carriage Assembly 6 33 moo diri TP 6 34 Carriage Belt and Belt 004 6 44 Removing the Carriage oiu e ad e t UR died 6 46 Removing Paper Sensor and Encoder 6 49 Installing Paper Sensor and 6 51 Replacing the Carriage 0 5 6 53 Trailng Cable Support and Tubing Chain Assembly 6 54 Stabilizer Bracket with Encoder 6 60 Inner Platen
28. Figure Chapter 3 14 Removal of NOVAJET PRO Left Cover Assembly NOVAJET SERIES 3 23 Ink Delivery System Figure Chapter 3 15 NJP Left Cover Assembly with Ink Reservoirs in Packing 3 24 5 10 If you shipping the plotter to ENCAD DO NOT return the Left Cover Assembly and the Ink Reservoirs See Note 3 at the beginning of this section You will not need to empty the ink out of the Ink Reservoirs because you will be keeping them Once the replacement plotter is set up remove its Left Cover Assembly and attach it to the plotter you are shipping to ENCAD Be sure to open the Tubing Clamps on the Ink Delivery Lines before packing the plotter in the shipping box At this point you should also turn to Chapter 6 Section 3 0 for further shipping instructions Have someone help you attach your Left Cover Assembly with the Ink Reservoirs to the replacement plotter Do not overtighten the SCrews Install the Top Cover Attach the connectors to the back of the Ink Reservoirs You will need to perform the entire procedure for loading the Extended Ink Supply given in Section 2 0 except for Section 2 1 NOVAJET SERIES Ink Delivery System 3 3 2 Preparing the NOVAJET PRO for Storage or Transporting This procedure is to be followed if you plan to store the plotter or not use it for a prolonged period of time approximately more than 30 days see Chapter 4 Section 6 2 This will prevent the ink fro
29. P N 202513 9 18 Caster Non Locking Twin P N 202512 9 18 2 eter iere P N 204976 9 19 Foam Block P N 204982 9 19 Foam Bottom P N 205452 9 19 Foam Bottom P N 205523 9 20 Foam T p eara P N 205453 9 20 Foam Top FGM PPP P N 205524 9 20 Frame Tensioner sect bete P N 203870 1 9 21 Keypad P N 203440 3 9 21 ON OFF Switch Power Entry Module P N 204599 9 21 Paper Sensor w Flex P N 204559 9 22 Platen Machined NOVAJET P N 204972 1 9 22 Power Supply 24V DG s io its P N 204849 9 23 IGM SUDDO eoi P N 203868 2 9 23 Screws Stand 10 P N 203485 2 9 23 NOVAJET SERIES Table of Contents CHAPTER 9 REPLACEMENT PARTS LIST continued Number Title Part Page Figure 948 eal 4 oisi eb re heres P N 204731 9 24 Figure 9 46 Slide Shialb iios tie eee eee a ien te P N 204774 9 24 Figure 9 47 Spring Compression Idler
30. inks other than those supplied ENCAD Inc will void the warranty The NOVAJET 4 is designed to use only specific ENCAD cartridges The NOVAJET 4 Carriage Assembly has removable lock outs which prevent the use of any other cartridges Intentional modification of the lock out feature will void the warranty When the power is turned on always use the ACCESS CARTRIDGES key on the Right Cover Assembly to move the Carriage Assembly out of the Service Station The plotter may be damaged if you move the Carriage Assembly by hand when the power is turned on When you handle the Cartridge do not touch the Flex Contact area of the Cartridge See Figure Chapter 3 1 Do not fill a used Cartridge with a different type of ink or a different color of ink There will still be some of the previous ink left in the Cartridge and if it mixes with the new ink plotting quality may be affected Leave the blue tape on the jet area on the bottom of the Cartridge until you are ready to install the cartridge on the Carriage Assembly and hold the Cartridge upright once you have put ink in it This will prevent ink from coming out of the jet area or out of the opening in the top of the Cartridge If you remove a Cartridge and plan to store it place it in a plastic bag and seal the bag tightly to prevent the ink from drying out Prime the Cartridges and do the Color Calibration Chapter 7 Section 15 0 of this Service Manual This w
31. only NOVAJET SERIES Ink Delivery System Chapter 3 INK DELIVERY SYSTEM 3 1 3 1 2 0 Loading the NOVAJET PRO Extended Ink 3 3 2 1 Filling the Ink Reservoirs 6 3 3 2 2 Priming the Ink Delivery 3 6 2 3 Filling the NOVAJET PRO 2 3 9 2 4 Installing and Priming NOVAJET 3 11 3 0 Unloading the NOVAJET PRO Extended Ink Supply 3 16 3 1 Removing the NOVAJET PRO Ink 3 16 3 2 Purging the Ink Delivery 3 18 3 3 Removing the NOVAJET PRO Left Cover 3 22 3 3 1 Preparing the NOVAJET PRO for Shipment to ENCAD 3 22 3 3 2 Preparing the NOVAJET PRO for Storage or Transporting 3 25 4 0 NOVAJET 4 Refillable Cartridges erento torret err 3 27 4 1 Installing and Refilling NOVAJET 4 3 27 4 1 1 Installing a New NOVAJET 4 Cartridge 3 28 4 1 2 Refilling a Used NOVAJET 4 3 29 4 2
32. 2 2 22 6 43 Removing Paper Sensor and 6 46 Installing Paper Sensor and 6 48 Replacing the Carriage 65 2 6 49 Stabilizer Bracket with Encoder 6 54 Inner Platen EE 6 57 Details of Figure dic ee 6 58 Removing the Lower Drive Shaft 6 61 Removing the Foam 24 444 1 6 62 Lower Drive Assembly and Stepper Motor Assembly 6 65 Alignment of Foam Block Lower 2 222222 6 68 Ground for Left End of Power Cable and ON OFF Switch 6 70 Routing of Wires and Cables on Right Side Plate and MPCB 6 71 Positioning Upper Roller 6 75 7 CALIBRATION Number Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Title Page Upper Roller Supports Numbering Sequence 7 12 Center and Left Positions for Slide Shaft Profile Adjustment 7 15 Paper Sensor Voltage 7 22 Upper Roller Support and Mounting Screws
33. 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 the back of the Platen is within one line width 0 08 See Figure Chapter 7 8 P US A MEDIA ALIGNMENT MARK CLOCATED N THE BAC SIDE THE PLATEN A L 4 LEE T 000 0 087 RIGHT PAPER SKEW ACCEPTANCE RANGE MUST BE WITHIN NE LINE WIDTH 00895 CONE LINE WIDTH WIDTH OF THE EDIA ALIGNMENT MARK Figure Chapter 7 8 Paper Skew Acceptance Range for Rear Media Alignment Mark NOVAJET SERIES 7 39 Calibration 10 4 3 Observation of Paper Skew at Front Media Alignment Mark 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 The paper should be returning to its pre loading location preferably without any skewing Engineering specification requires the skew to be within 0 00 0 06 approximately one width of Platen s Media Alignment Mark See Figure Chapter 7 9 FRONT MEDIA ALIGNMENT MARK LOCATED DN THE FRONT SIDE OF THE PLATEND P
34. HANDSHAKE HARDCLIP LIMIT HEIGHT ADJUSTMENT INITIALIZE INKJET INK RECEPTIVITY INTERFACE CABLE ERROR NOVAJET SERIES General Information A set of firmware instructions for the detection and isolation of plotter malfunctions A change in position Dots per inch the number of dots the plotter lays down in an inch One complete cycle of time to complete a printing command ratio of printing to idling To equal in quality or quantity Electronically erasable and programmable memory Used to indicate the force to which two bodies are subjected 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 Height Adjustment refers to the adjustment of the gap between the Platen and the Cartridge head The menu driven instruction set which brings the plotter to the factory default conditions 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 NOVAJET plotters use a serial or parallel interface cable A data transmission error between the computer
35. NOVAJET SERIES 5 55 Troubleshooting 11 15 Carriage Assembly Moves Erratically 5 56 If the Carriage Assembly 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 4 Section 3 0 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 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 6 Sections 7 7 and 7 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 Run the Servo Motor Test SERVO MOTOR Select FAST or SLOW speed to cycle the Servo Motor Display message will be either RESULT OK or RESULT ERROR f ERROR appears the Servo Motor or driver circuits
36. 11 6 x 16 6 166 x 21 6 21 00 x 33 6 33 6 x 43 6 287 x 410mm 410 x 584mm 584 x 830mm 615 x 870mm 831 x 1179 mm 327 x 450mm 450 x 624mm 600 x 850mm 624 x 871mm 850 x 1210mm 871 x 1219 mm 990 x 1404 mm 1179 x 1672mm 240 x 343mm 343 x 490mm 490 x 697 mm 697 x 990 NOVAJET SERIES General Information Table Chapter 1 3 Media Sizes and Maximum Plotting Areas for Sheet Media Paper Size Normal Plot Area Expanded Plot Area GRAPHICS U S OFFSET 11 00 x 14 0 9 8 x 10 6 10 6 x 11 0 11 00 x 17 0 9 8 x 13 6 10 60 x 14 0 17 0 x 22 0 15 8 18 6 16 6 x 19 0 19 0 x 25 0 17 8 x 216 186 x 22 0 20 00 x 28 0 18 8 x 24 6 19 60 x 25 0 22 0 x 26 0 20 8 x 22 6 21 0 x 23 0 22 0 x 340 20 8 x 306 21 6 x 31 0 23 0 x 35 0 21 8 x 31 6 22 0 x 320 24 0 x 29 0 228 x 25 6 23 6 260 25 0 38 0 23 8 x 34 6 24 6 x 350 26 0 x 38 0 24 8 x 34 6 25 6 x 35 0 27 0 x 39 0 25 8 35 6 26 6 x 36 0 30 0 x 42 0 28 8 x 38 6 29 6 x 390 32 0 x 44 0 30 8 x 40 6 31 0 x 41 0 34 0 x 44 0 32 8 x 40 6 33 6 x 41 0 35 0 x 45 0 33 8 x 41 6 34 6 x 420 36 0 x 45 0 34 8 x 41 6 35 6 x 42 0 40 0 x 50 0 38 8 x 46 6 396 x 470 48 0 65 0 46 8 x 61 6 47 6 x 620 50 0 x 65 0 48 8 x 61 6 49 6 x 620 U S ARCHITECTURAL A 9 0 x 12 0
37. 42020 6 65 Details of Figure 6 25 edet didicit pta 6 66 Removing the Lower Drive Shaft Screws 6 69 Removing the Foam i ott rre teretes 6 70 Lower Drive Assembly and Stepper Motor Assembly 6 73 Alignment of Foam Block 6 77 Ground for Left End of Power Cable and ON OFF Switch 6 79 Routing of Wires and Cables on Right Side Plate and MPCB 6 80 NOVAJET SERIES Disassembly Assembly Figure 6 33 Positioning Upper Roller 6 85 NOVAJET SERIES 6 91 7 CALIBRATION 1 0 Introduction Every time Cartridges are installed in the NOVAJET PRO the Color Horizontal and Vertical Calibration Section 15 0 must be performed See Chapter 6 Section 1 0 for a list of the Calibrations necessary after other the installation of other parts 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 NOTE Note 1 The procedures in this chapter should be performed in the order in which they are presented For your convenience in recording the readings during procedures in this chapter photocopy the NOVAJET PRO Calibration Worksh
38. 6 53 8 2 Installing the Power Supply and ON OFF Switch 6 55 9 0 Stabilizer Bracket and Encoder Strip 6 56 9 1 Removing the Stabilizer 6 57 9 2 Reinstalling the Stabilizer 6 58 10 0 Lower Drive Assembly Fan Assembly and Stepper Motor Assembly Inner Platen roca oc Eee pk boa condunt 6 60 10 1 Disassembly of Plotter Before Removing the Inner Platen Parts 6 62 10 2 Removing the Inner Platen 6 63 10 3 Stepper Motor eoe al tle ua ope Un uenire Ud 6 67 10 3 1 Removing the Stepper 6 67 10 3 2 Reinstalling the Stepper 6 69 10 4 Reinstalling the Inner Platen 6 70 10 5 Reassembly of Plotter After Reinstalling the Inner Platen Parts 6 74 11 0 Upper Roller SUppOFts niei te etes 6 77 11 1 Removing the Upper Roller Supports 6 77 11 2 Installing the Upper Roller Supports 6 79 NOVAJET SERIES XV Table of Contents CHAPTER7 CALIBRATION 1 0 2 0 3 0 4 0 5 0
39. ASSEMBLY CKING CAS CKING CASTERS Figure Chapter 1 1 Front View of Plotter NOVAJET SERIES 1 13 General Information Figure Chapter 1 3 Back View of NOVAJET 4 1 14 NOVAJET SERIES General Information Key for Figure Chapter 1 2 and Figure Chapter 1 3 1 2 3 NOVAJET SERIES Centronics Parallel Port J2 RS 422 423 Serial Port Apple Talk J3 Power Input Plug and ON OFF Switch ID Label Left Rollguide NOVAJET PRO 36 and NOVAJET 4 only Right Rollguide NOVAJET PRO 36 NOVAJET 4 only Rear Media Alignment Mark Roll Supports NOVAJET PRO 36 and NOVAJET 4 only General Information 8 0 Plotter Specifications Standard Features Four 500 ml Ink Delivery Systems only Refillable Ink Cartridges NJ 4 only Power Media Feed amp Take Up System 50 only optional for NJP 36 and 4 E Size Cut sheet or roll feed with automatic cutter 8 user settings to save custom settings for multiple users Five modes for selecting speed and quality Selectable dry time Save Media advances media only as far as needed to print the image Automatic cutter on off Memory configuration to control raster buffer memory allocation Available as a function of HP GL and HP GL 2 Replot and multiple copies Long plot up to 50 feet 15 24m Merged vector raster images Plot nesting Auto rotation Cut Sheet Maximum Plo
40. tissues tap water or alcohol and do not wipe across the jet area Do not allow the Cartridge to rest on the bottom of the ultrasonic cleaner Use only distilled water or R O water Reverse Osmosis in the ultrasonic cleaner Tap water may contain minerals which can contaminate the ink and corrode the jet plate Do not touch the Flex Contacts with your fingers when handling the Cartridges Use the type of ultrasonic cleaner used to clean technical pens or jewelry typically found in drafting supply stores or department stores It may be necessary to run the PRIME plot several times in order to obtain a satisfactory plot The bands should be smooth without dark streaks or white lines The diagonal lines should not look fuzzy or contain gaps After a satisfactory PRIME plot is obtained perform the Cartridge Calibration See Chapter 7 Section 15 0 of this service manual NOVAJET 4 only these procedures fail to improve performance you may need to replace the Cartridge or the Cartridge may not be the source of the problem Refer to Chapter 5 for the troubleshooting information for the Ink Delivery System NOVAJET PRO only If these procedures fail to improve performance the Ink Reservoir may empty you may need to replace the Cartridge or the Cartridge may not be the source of the problem Refer to Chapter 5 for the troubleshooting information for the Ink Delivery System 4 9 Maintenance Table Chapte
41. 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 NOVAJET SERIES 2 7 Theory of Operation 2 8 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 All LEDs are turned on and off The fan is turned off The display is initialized and the copyright message is displayed A checksum of the EEPROM is performed The first four kilobytes of DRAM are tested to make sure enough RAM is working to run the compiled C code Execution of the compiled C code begins DRAM size is determined and all DRAM is tested Status information is shown on the display during the test Memory OK is displayed at the end of the test The code in the EEPROM is copied to DRAM and the program begins executing out of DRAM NOVAJET SERIES 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 EEPROM DRAM and EEPROM Flash EEPROM is Electrically Erasable Programmable Read Only Memory used to sto
42. 6 0 7 0 8 0 9 0 10 0 xvi Procedures to mechanically and electrically align the plotter following repairs or when plotter performance has been affected isis A 7 1 Hequired Supplies AMO 0016 iioi i o entren 7 2 Required Documentation and Files essen 7 4 Downloading Files From the 5 2 22 1 7 5 4 1 BBS Logon Procedure iate onte uer vue 7 5 4 2 Using the Downloaded Files NJPRO101 EXE and NUPTEST EXE 7 10 Numbering Sequence of Upper Roller 7 12 Slide Shaft Profile Eo 7 13 Cartridge Head Height 7 18 7 1 Initial Adjustment Procedure err ets 7 19 7 2 Fine Adjustment and Torque sssssseeenn 7 22 7 3 Encoder Strip is a etia 7 23 7 4 Frame Tensioner and Carriage Belt Position 7 23 7 5 Trailing Cable Strain Relief 7 23 Paper Sensor aiti EEKE aote ts 7 24 Paper Skew 7 28 Paper Skew 7 09 10 1 Paper Skew Adjustment Sequence 7 30 1
43. Calibration To download the NOVAJET PRO DOS Utilities Disk select NJPRO101 EXE this is a self extracting file To download the Line Quality Acceptance Standards file select NJPTEST EXE this is a self extracting file To download the file GO EXE which is needed to send NJPTEST PLT to the plotter select GO EXE 4 2 Using the Downloaded Files NJPRO101 EXE and NJPTEST EXE 1 After the files have been downloaded and communications have been ended the NOVAJET PRO 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 NJPRO101 B or NJPRO101 and press ENTER The file will decompress Type DIR B or DIR A to make certain that you have the files listed below DISK ID INSTALL DAT INSTALL EXE USERGUID TXT NJPRO 001 Files marked with will not be transferred to your hard drive NOVAJET SERIES 3 NOVAJET SERIES Calibration If all the above files are present your floppy disk at the C prompt type BNNNSTALL or A INSTALL to install the Utilities Disk files onto your hard disk You will be given the choice to install one of the following 1 Utility Program files only 2 Menu Tree files only 3 All ENCAD DOS UTILITY files Once the files are installed type DIR to make certain that you have the files listed below Select 1 or 3 to ins
44. Figure Chapter 9 38 Keypad Bottom P N 203440 3 Figure Chapter 9 39 ON OFF Switch Power Entry Module P N 204599 9 24 NOVAJET SERIES Replacement Parts List Figure Chapter 9 40 Paper Sensor w Flex P N 204559 Figure Chapter 9 41 Platen Machined NOVAJET PRO P N 204972 1 NOVAJET SERIES 9 25 Replacement Parts List Figure Chapter 9 42 Power Supply 24V DC P N 204849 Figure Chapter 9 44 Screws Stand 10 P N 203485 2 9 26 NOVAJET SERIES Figure Chapter 9 45 Seal 4 P N 204731 Replacement Parts List Figure Chapter 9 46 Slide Shaft P N 204774 G MPRE 55 I SPRING ADL ER Figure Chapter 9 47 Spring Compression Idler P N 203999 NOVAJET SERIES 9 27 Replacement Parts List 9 28 a ASSY COVER P N 204711 1 ORDER SEPARATELY SPRING COMPRESSION P N 202010 L 23 STOP RETRACTING P N 204246 1 a ORDER SEPARATELY a ASSY COVER P N 204711 1 ORDER SEPARATELY SPRING COMPRESSION P N 202010 CORDER SEPARATELY RACTING P N 204246 1 STOP RE Figure Chapter 9 50 Stop Retracting P N 204246 1 NOVAJET SERIES Replacement Parts List
45. NOVAJET PRO and NOVAJET 4 plotters Sections 2 0 3 0 of this chapter provide the instructions for loading and unloading the NOVAJET PRO Extended Ink System as well as information concerning the storage and shipment of the plotter We recommend that you read the procedures prior to loading or unloading the system Section 4 0 of this chapter provides information about the NOVAJET 4 Refillable Cartridges and some information about preparing the plotter for shipment See Chapter4 for Maintenance information and Chapter5 for Troubleshooting information Chapter 6 Section 3 0 contains additional shipping instructions which should be followed if a plotter is being returned to ENCAD NOVAJET QIS ink is nonhazardous requiring no special disposal handling It can be harmful if swallowed and should be kept away from children Do not touch the Flex Contact area of the Cartridge when you handle the Cartridges See Figure Chapter 3 1 NOVAJET PRO only Before beginning to load or unload the Extended Ink Supply load a D size or E size sheet of paper to protect the Platen from any ink spills It should hang over both the front and the back of the Platen NOVAJET SERIES 3 1 Ink Delivery System NOVAJET PRO only When loading or unloading the Extended Ink Supply you may want to have paper towels readily available wear disposable gloves and place a plastic drop cloth or newspaper on the floor to prevent any ink from being spi
46. NOVAJET SERIES Connect the Parallel Cable or the RS422 Serial Cable to the computer and the plotter Insert the Utilities Disk provided with your plotter You should use the most current version of the firmware which is 205727 ZIP as of the date of publication of this manual It is also available on ENCAD s BBS see Chapter 7 Section 4 0 You may also contact our Help Desk to obtain the most recent version if you do not have access to the BBS or WEB See Chapter 1 Section 3 0 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 Answer YES or NO to Do you want to print the USERGUIDE TXT now and press Enters Select the disk drive on which you want the DOS Utilities installed Press lt Enter gt Specify the destination subdirectory where the files are to be installed Press Enters B 1 7 Select the parts of the DOS Utilities you want to install by pressing SPACEBAR to toggle between YES and NO Press lt Enter gt 8 After the installation is completed tyoe CD NJPRO or CD and the subdirectory specified in Step 6 above and press Enter NOTE Note If you are already in the subdirectory where the files were installed this step is not necessary 9 NJPRO and press Enter 10 1 a
47. Retracting P N 2042464 9 28 Support Drive Shaft middle support P N 203556 2 9 29 Support Shaft P N 204760 eee eese esee esee eene ee 2 1 9 29 Wiper 4 P N 2047982 5 iri ro rp Rr RE RR ERR 9 29 NOVAJET SERIES Appendix EMERGENCY FIRMWARE DOWNLOAD PROCEDURE Flash EEPROM is blank or corrupt or if the firmware upgrade using the parallel cable does not work Keypad display will typically have the following indication XXXXXXXXXXXXXXXXXXXXX nore Note 1 This procedure should be used to download firmware if the This procedure should be performed with a 5422 Serial Cable only A parallel cable may not work This cable is available from ENCAD Inc The Part Number is 203977 See Chapter 9 of this manual If you prefer to make your own cable see Figure Appendix A 1 at the end of this appendix NOVAJET PROCEDURE DOS UTILITY FOR PC 1 The RS422 Serial Cable must be used for if the parallel firmware upgrade procedure fails see Note 4 of the Novajet Procedure Dos Utility for PC below Macintosh systems use a standard Image Writer cable Connect the RS422 Serial Cable to the computer and the braindead printer plotter which is 205727 ZIP as of the date of publication of this Note 3 You should use the most current version of the firmware V manual lt is available on ENCAD s BBS see Chapter 7 Section 4 0 You
48. WINDOWS DISK UTILITY ASSY MPCB ASSY CABLE SUPPORT SERVICE E SIZE ASSY CABLE SUPPORT SERVICE D SIZE BOX PLOTTER NJ PRO 50 MANUAL USER NOVAJET SERIES ASSY STABILIZER SERVICE D SIZE NJ PRO 50 ASSY SERVICE BOTTLE 1 Ink Reservoir X TUBING CHAIN ASSY NJ PRO 50 ASSY MPCB USED IN NJ4D 4 NJP 36 NJP 50 lt KK KK X If are ordering the Assy Cover P N 204711 1 P N 204711 31 or P N 204711 61 the Stop Retracting P N 204246 1 or P N 205694 and the Spring Compression P N 202010 are not included They must be ordered separately These parts make up the entire Display Keypad The Assy Keypad Top P N 203488 1 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 203457 for NJ 4 or NJP 36 or P N 205111 for NJP 50 or the Keypad Label included in P N 204994 are needed they must be ordered in addition to P N 203488 1 The MPCB has the Flash EEPROM already mounted but it is not programmed The 10 Stand Screws P N 203485 2 are not included in the Assy Hardware Kit Service P N 205440 NOVAJET SERIES Replacement Parts List 3 0 Alphabetical Listino USED IN DESCRIPTION PART 40 NJ4E NJP 36 NJP 50 ASSY ALIGNMENT MAINTENANCE KIT 205660 X X X X ASSY BRACKET DRIVE SHAFT left bracket w
49. amp 10 0 Carriage Assembly or components or Carriage Belt ALL CALIBRATIONS except Paper Skew Chapter 7 Sections 9 0 amp 10 0 Stabilizer Bracket ALL CALIBRATIONS except Paper Skew Chapter 7 Sections 9 0 amp 10 0 Lower Drive Shaft Assembly Stepper Motor Fan Assembly ALL CALIBRATIONS except Slide Shaft Profile Chapter 7 Section 6 0 Cartridge Head Height Chapter 7 Section 7 0 Y Arm Assembly Slide Shaft or Platen or if Cartridge Head Height Adjustment is performed ALL CALIBRATIONS Chapter 7 Sections 6 0 18 0 Upper Roller Supports All Calibrations listed in Section 11 2 Step 6 NOVAJET SERIES Disassembly Assembly 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 You must 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 1 If you remove the Plotter from the Stand for servicing we recommend that you place it on foam blocks on a stable work surface 2 NOVAJET 4 only Prior to removing the Plotter from the Stand the Cartridges should be removed from the Carriage Assembly 3 NOVAJET
50. the NOVAJET PRO 50 has two middle supports There are two screws in each support See Figure Chapter 6 27 NOTE Note Don t remove the two screws holding the Stepper Motor Assembly until Step 9 See Figure Chapter 6 27 6 68 NOVAJET SERIES Disassembly Assembly Figure Chapter 6 27 Removing the Lower Drive Shaft Screws NOVAJET SERIES 6 69 Disassembly Assembly 7 Remove the left Drive Shaft Support through the left end of the Platen and the middle Drive Shaft Support s through the Snap Plug opening s 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 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 6 28 Figure Chapter 6 28 Removing the Foam Block 6 70 NOVAJET SERIES Disassembly Assembly During Step 9 When you remove the two screws from the right Drive Shaft Support which hold the Stepper Motor Assembly see Figure Chapter 6 27 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 remove the 2 black flat head screws which hold the
51. 22 0 x 340 34 0 x 440 297 x 420mm 420 x 594mm 594 x 840 625 x 880 841 x 1189 337 x 460mm 460 x 634mm 610 x 860mm 634 x 881mm 860 x 1220mm 881 x 1229mm 1000 x 1414mm 1189 x 1682 250 x 353mm 353 x 500mm 500 x 707mm 707 x 1000 mm Normal Plot Area GRAPHICS U S OFFSET 9 8 x 12 8 9 8 x 15 8 158 x 20 8 178 x 238 18 8 x 26 8 20 8 x 24 8 20 8 x 32 8 21 8 x 338 22 8 x 27 8 23 8 x 36 8 24 8 x 358 25 8 37 8 28 8 x 40 8 30 8 42 8 32 8 42 8 33 8 x 43 8 34 8 x 438 38 8 x 48 8 46 8 x 63 8 48 8 x 63 8 U S ARCHITECTURAL 7 8 x 10 8 10 8 x 16 8 168 x 22 8 22 8 x 34 8 34 8 x 468 U S ENGINEERING 9 8 x 15 8 158 x 20 8 20 8 x 32 8 32 8 42 8 ISO A 267 x 390mm 390 x 564mm 564 x 810mm 595 x 850mm 811 x 1159 METRIC DIN 307 x 430mm 430 x 604mm 580 x 830mm 604 x 851mm 830 x 1190mm 851 x 1199 mm 970 x 1384 mm 1159 x 1652mm ISO B 220 x 323mm 323 x 470mm 470 x 677mm 677 x 970mm Expanded Plot Area 10 00 x 13 6 10 00 x 16 6 16 6 x 21 6 186 x 246 196 276 216 256 216 336 226 346 23 00 x 286 246 x 37 6 256 37 6 26 6 x 386 296 x 416 31 6 436 33 6 436 346 446 35 6 446 396 496 47 0 x 646 496 x 646 8 6 x 11 6 11 00 x 17 6 17 6 x 236 23 6 x 35 6 35 6 x 47 6
52. 222 2222222 201 9 21 Caster Non Locking Twin 202512 9 21 Assy Exhaust P N 204976 os 2 9 22 Foam Block Lower P N 204982 2 9 22 Foam Bottom Left P N 205452 9 22 Foam Bottom Right P N 205523 0 053 ER RR X RE 9 23 Foam Top Left P N 205453 2 00040404440000 9 23 Foam Top Right P N 205524 a 9 23 Frame Tensioner P N 203870 040040 8 9 24 P Keypad Bottom P N 203440 3 sese 9 24 ON OFF Switch Power Entry Module P N 204599 9 24 Paper Sensor w Flex P N 204559 9 25 Platen Machined NOVAJET PRO P N 204972 1 9 25 Power Supply 24V DC P N 204849 9 26 Roll Support P N 203868 2 2 9 26 Screws Stand 10 P N 203485 2 2 4221 9 26 Seal 4 P N 204731 c 9 27 Slide Shdl AB NOOR 9 27 Spring Compression Idler P N 203999 9 27 Spring Compression Top Cover P N 202010 9 28 Spring Extension Service Station Bottom P N 204763 9 28 Stop
53. 7 87 x 8 6 8 6 x 9 0 B 12 0 x 18 0 10 8 x 14 6 11 6 x 15 0 C 18 00 x 24 0 168 x 20 6 17 6 x 21 0 D 24 0 x 36 0 22 8 x 32 6 23 6 33 0 36 0 x 48 0 34 8 x 44 6 35 6 x 45 0 U S ENGINEERING B 11 00 x 17 0 9 8 x 13 6 11 00 x 14 0 C 17 0 x 22 0 15 8 x 18 6 16 6 x 19 0 D 22 0 x 34 0 20 8 x 316 21 6 x 31 0 E 34 0 x 440 32 8 x 40 6 33 6 x 41 0 ISO A A3 297 x 420mm 267 x 370mm 287 x 380mm A2 420 x 594mm 390 x 544mm 410 x 554mm 1 594 x 840mm 564 x 790mm 584 x 800mm 625 x 880mm 595 x 830 615 x 840mm AO 841 x 1189 811 x 1139 831 x 1149 mm METRIC DIN 337 460 307 x 410 327 420 2 460 634 430 x 584 450 x 594 610 x 860mm 580 x 810mm 600 x 820mm 1 634 881 604 831 624 841 860 1220 830 x 1170 850 1180 881 1229 851 x 1179 mm 871 x 1189 mm 1000 x 1414 mm 970 x 1364 mm 990 x 1374 mm 1189 x 1682 1159 x 1632mm 1179 x 1642mm ISO B B4 250 x 353mm 220 x 303mm 240 x 313mm B3 353 x 500mm 323 x 450mm 343 x 460mm B2 500 x 707mm 470 x 657 490 x 667 mm B1 707 x 1000mm 677 x 950mm 697 x 960 NOVAJET SERIES 1 11 General Information 6 0 General Product Notes 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 Carr
54. 9 3 Assy Cover Left P N 205020 9 10 Figure 9 4 Assy Cover Right P N 203476 4 9 10 Figure 9 5 Assy Encoder w Flex P N 204999 9 10 Fig re 9 67 Assy Fan P N 209443 o pe ho P co tt ee cies 9 11 Figure 9 7 Assy Hardware Kit NOVAJET PRO Service P N 205440 9 11 Figure 9 8 Assy Idler P N 208405 1 scri reete e DR 9 11 Figure 9 9 Assy Keypad Top P N 203488 1 9 12 Figure 9 10 Assy Legs and Basket P N 203484 3 9 12 Figure 9 11 Assy Lower Drive P N 2040417 04 9 13 Figure 9 12 Assy MPCB P N 205853 eene 9 13 Figure 9 13 Assy Pinch Roller 8 P N 204773 9 13 Figure 9 14 Assy Rollguide Left P N 204969 3 9 14 Figure 9 15 Assy Rollguide Right P N 203477 6 9 14 Figure 9 16 Assy Service Station P N 204629 9 15 Figure 9 17 Assy Servo Motor P N 203496 1 9 15 Figure 9 18 Assy Stabilizer Bracket Service P N 204699
55. Carriage Assembly See Section 7 1 of this chapter The Carriage PCB the Paper Sensor the Encoder and the Carriage Bushings can be replaced as individual components See Sections 7 9 through 7 13 as needed Power must be disconnected You must be grounded to a static station by an ESD wrist strap to prevent ESD damage whenever you are handling the Carriage Assembly Do not touch the Encoder Strip with any tools when removing the Carriage Belt from the Servo Motor Pulley Always handle the Trailing Cable with care Do not twist or turn the cable 1 Read Note 1 above and perform the necessary steps 2 Release the Electronics Cover on top of the Carriage Assembly by using a narrow flat tip screwdriver to push in and up on the two latches holding it onto the Carriage Assembly There is a latch inside the small rectangular opening about 1 from the top of the Carriage Assembly on each end of the Carriage Assembly See Figure Chapter 6 16 Do not remove the Electronics Cover yet 3 Slide the Carriage Assembly to the far left end of the Slide Shaft NOVAJET SERIES 6 31 Disassembly Assembly Figure Chapter 6 15 Trailing Cable Support Assembly 4 The Electronics Cover is easier to remove if the Trailing Cable Support Assembly is moved out of the way slightly See Figure Chapter 6 15 during this procedure a Loosen the far right screw which holds Trailing Cable Support Assembly on the Y Arm b Remove the ot
56. Delivery System PRIMIN IG ATTACHMENT PRIMING PLUNG ER Cl 3 8 AMP E ISE TUBING CLAMP REMOVING RIMING PUMP EN INK AND AIR BUBBLES BEING N DRAWN THROUGH LINE N AS PLUNGER OPENS N S s SLOWLY PLUNGER STEP B Figure Chapter 3 6 Priming the Delivery Line NOVAJET SERIES Ink Delivery System 2 3 Filling the NOVAJET PRO Cartridges The NOVAJET PRO is designed to use only specific ENCAD cartridges The NOVAJET PRO Carriage Assembly has non removable lock outs attached to it to preclude the use of any other cartridges Intentional modification of the lock out feature by the end user will void the warranty When you handle the Cartridge do not touch the Flex Contact area of the Cartridge See Figure Chapter 3 1 Leave the blue tape on the jet area on the bottom of the Cartridge until you are ready to install the cartridge on the Carriage Assembly see Figure Chapter 3 9 and hold the Cartridge upright once you have put ink in it This will prevent ink from coming out of the jet area or out of the opening in the top of the Cartridge Refer to Figure Chapter 3 7 during this procedure 1 Each NOVAINK ACCESSORY KIT contains a 20 ml container of ink Squ
57. E SIZE X 204966 ASSY CARRIAGE complete X 204969 3 ASSY ROLLGUIDE LEFT X 204972 1 PLATEN MACHINED E SIZE X X 204976 EXHAUST X 204982 FOAM BLOCK LOWER X X 204994 LABEL SET identifies keys X X X X LABEL RIGHT COVER AND KEYPAD 204996 ASSY CARRIAGE complete X X X 204999 ASSY ENCODER W FLEX X X 205023 TUBING CHAIN ASSY NJ PRO 36 X 205026 ASSY COVER LEFT includes Ink Reservoirs X X 205111 CABLE KEYPAD X 205116 SLIDE SHAFT D SIZE X 205121 PLATEN MACHINED D SIZE X 205122 ASSY LOWER DRIVE SHAFT W GEAR X 205128 ASSY STEPPER MOTOR SERVICE X X X X includes Gear 205179 ASSY CABLE TRAILING D SIZE X 205340 BELT 312 WIDE X 205350 ASSY STEPPER MOTOR BRACKET SVC X right bracket w bushing 205422 ASSY MAINTENANCE KIT X X 205439 ASSY STABILIZER BRACKET SERVICE X 205440 ASSY HARDWARE KIT SERVICE X 205451 BOX PLOTTER NJ PRO 36 X 205452 FOAM BOTTOM LEFT X X 205453 FOAM TOP LEFT X X 205458 DISK NJ PRO DOS UTILITY ENCAD X NOVAJET SERIES 9 3 Replacement Parts List PART 205523 205529 205534 205582 205660 205678 205694 205697 205757 205771 205772 205853 1 205875 1 205875 31 205876 205883 205897 206372 206376 206541 9 4 DESCRIPTION FOAM BOTTOM RIGHT BLOCK SUPPORT PAD BUSHING MANUAL SERVICE NOVAJET SERIES ASSY ALIGNMENT MAINTENANCE KIT BELT 312 WIDE E SIZE STOP RETRACTING ASSY CABLE TRAILING E SIZE CORD POWER BLACK 8 FT DISK
58. FILLED zt 2 500 ML BOTTLE OF INK SFILL TO POINT INDICATED Figure Chapter 3 4 Filling Ink Reservoirs NOVAJET SERIES 3 5 Ink Delivery System 3 6 Priming the Ink Delivery Lines Be sure to thoroughly rinse_and dry the Priming Pump before working with the next color to prevent colors from becoming mixed We suggest that Sections 2 2 through 2 4 be done for one color at a time to prevent colors from becoming mixed After Section 2 4 is completed for the first color start the process over from the beginning of Section 2 2 for the next color until the installation process is completed for each color Refer to Figure Chapter 3 5 and Figure Chapter 3 6 during this procedure 1 If you have not already done so load D size E size sheet of media It should hang over both the front and the back of the Platen so that no ink can be accidentally spilled onto the Platen Press ACCESS CARTRIDGES to move the Carriage Assembly out of the Service Station The Carriage Assembly has four blue Tubing Clamps on the top which are used to close and open the Ink Delivery Lines To close the Tubing Clamp press down on the left side of the Tubing Clamp until it snaps underneath the overhang To open the tubing Clamp press the overhang to the left side until the Tubing Clamp pops up See Figure Chapter 3 5 l SING TUBING CLAMP PENING TUBING CLAMP Figure
59. Figure 9 17 Figure 9 18 Figure 9 19 Figure 9 20 Figure 9 21 Figure 9 22 Figure 9 23 Figure 9 24 Figure 9 25 Figure 9 26 Figure 9 27 Figure 9 28 Figure 9 29 Figure 9 30 Figure 9 31 Figure 9 32 Figure 9 33 Figure 9 34 Figure 9 35 Figure 9 36 Figure 9 37 Figure 9 38 Figure 9 39 Figure 9 40 Figure 9 41 Figure 9 42 Figure 9 43 Figure 9 44 Title Part Page Assy Servo Motor 22 P N 203496 1 9 12 Assy Stabilizer Bracket Service P N 204699 9 13 Assy Stepper Motor Bracket Service right bracket P N 205350 9 13 Assy Stepper Motor Service includes Gear P N 205128 9 14 Assy Top Cover NOVAJET P N 204711 1 9 14 Assy Tubing Chain Support Service P N 2058668 9 15 Belt 312 Wide E SIZG oet orent eee P N 205678 9 16 Bushing Carriage 2 P N 203228 9 16 Gable K ypad P N 203457 9 16 Cable R8422 8 P N 203977 9 17 Cable Trailing with bend in cable P N 205697 9 17 Board s s cin orn REESE P N 204562 9 18 Caster Locking
60. 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 Never attempt to repair and reuse the Upper Roller Supports once you have removed them Always replace them with new Upper Roller Supports During Step 3 YOU MUST NOT DISTURB THE 3 SCREWS ON THE BACK OF THE Y BRACKET WHICH HOLD ON THE STABILIZER BRACKET Figure Chapter 6 24 identifies these screws If these are in any way disturbed the Cartridge Head Height will be changed which will affect the line quality NOVAJET SERIES 6 83 Disassembly Assembly 1 Remove the Top Cover Carriage Belt so that you have easier access to the Upper Roller Supports you should be aware that more Calibrations are required than if it is not loosened see Section 11 2 Step 6 nore Note 1 Step 2 below is optional If you choose to loosen the If the Carriage Belt is NOT loosened very close attention to Caution 1 above 2 Depress the back of the Frame Tensioner See Figure Chapter 6 10 NOVAJET PRO 50 only you may need to have an assistant compress the Frame Tensioner 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
61. NOVAJET SERIES Troubleshooting 5 0 LED Keys Ready Media Out Ink Low Mono Color Offline Reset Access Cartridges Prime Cut Feed Media Load NOVAJET SERIES Indicates that the plotter is on line Blinks when processing data or printing Indicates that the plotter is out of media This feature is not applicable to the NOVAJET PRO Available only on NOVAJET 4 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 perform other maintenance All plotter keypad and menu functions are available while plotter is offline 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 RESETZYES and then press SELECT Moves the Carriage out of the Service Station Fires the Cartridges to help clear the inkjets and prints test pattern Cuts roll media Interacts with display and arrow keys to move media forward or backward Loads and positions the media for printing Figure Chapter 5 1 LED Keys 5 19 Troubleshooting 6 0 LCD Keypad e The plotter goes into sleep mode after 7 minutes of inactivity Pressing any key puts it into ready mode e Press the MENU key to return to a previous menu level e Use the ARROW keys to scroll throug
62. NOVAJET SERIES 5 39 Troubleshooting 5 40 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 6 Section 10 2 Figure 6 26 if necessary The large 96 Teeth Gear may on the Lower Drive Assembly may be broken See Chapter 6 Section 10 0 for instructions for replacing the Lower Drive Assembly The Stepper Motor may be defective to the SERVICE DIAGNOSTICS Menu and perform the DIAGNOSTICS PAPER MOTOR test to run the motor from 0 to 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 6 Section 10 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 The MPCB Stepper Driver may be defective Replace the MPCB See Chapter 6 Section 4 0 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 EEPROM has failed Replace the MPCB See Chapter 6 Section 4 0 for the procedure 2 the socket on the MPCB is defective Replace the MPCB See Chapt
63. 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 Chapter 1 2 The media sizes and maximum plotting areas for Sheet media are listed in Table Chapter 1 3 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 NOVAJET 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 gt 5 Press SELECT to view the current maximum plotting areas NOVAJET SERIES 1 9 General Information Table Chapter 1 2 Media Sizes and Maximum Plotting Areas for Rollfeed Media gt m O O uj A2 A1 0 2 A1 0 11 00 x 140 11 00 x 17 0 17 0 x 22 0 19 0 x 250 20 0 x 280 22 0 x 26 0 22 0 x 340 23 0 x 35 0 24 0 x 29 0 25 0 x 38 0 26 0 x 380 27 0 x 390 30 0 x 420 32 0 x 440 34 0 x 440 35 0 x 45 0 36 0 x 45 0 40 0 x 50 0 48 00 x 65 0 50 0 x 65 0 9 0 x 12 0 12 0 x 180 18 0 x 24 0 24 0 x 360 36 0 x 48 0 11 00 x 17 0 17 0 x 22 0
64. Preparing the Plotter for Shipment to 3 30 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Correct Handling of Filled 2 2 4 22 3 2 NOVAINK ACCESSORY 3 4 Assembled Pouring Spout Tube 3 5 Pilling MK MEHR EEE 3 5 Closing and Opening Tubing 3 6 Priming the Delivery Line s i e SERO Renan 3 8 Initial Filling of NOVAJET PRO 2 3 10 Connecting Cartridge to Ink Delivery 3 11 Removing Blue Tape from Cartridge Jet Area 3 12 Priming Cartridge Prior to Installation in Carriage Assembly 3 13 Installing Cartridge in 3 14 Releasing Ink Reservoir Connector 3 19 Purging Ink Delivery Ls ea i e ORE EE Ra 3 21 NOVAJET SERIES 3 31 Ink Delivery System Figure 3 14 Figure 3 15 Figure 3 16 Figure 3 17 3 32 Removal of NOVAJET PRO Left Cover Assembly 3 23 NJP Left Cover Assembly with Ink Reservoirs in Packing Foam
65. Retainer Spring Post Torque to 6 IN LB Hook the Extension Spring onto the post on the Stepper Motor Bracket Complete the reinstallation of the Inner Platen Parts by following the procedures listed below in Section 10 4 NOVAJET SERIES Disassembly Assembly 10 4 Reinstalling the Inner Platen Parts 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 6 25 Figure Chapter 6 26 Figure Chapter 6 27 Figure Chapter 6 28 Figure Chapter 6 30 and Figure Chapter 6 32 during this procedure 1 NOVAJET SERIES Insert the Lower Drive Shaft Assembly and Stepper Motor Assembly part way into the right end of the Platen 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 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 ma
66. SERIES A 3 1 Insert disk into floppy drive and drag the UTILITY Folder onto systems hard disk You may want to duplicate the folder to copy do not create a new folder 2 To install ROM file Use a standard Image Writer cable and attach it to either the printer or modem port alternate only Attach the other end to the RS 422 Novajet port Make sure you configure the plotter through the front panel Use the following settings for the RS 422 port Speed 9600 8 Bit Parity Off Normal Handshake Hardware configure the download utility a Open the UTILITY Folder and double click on the download application b In the dialog box select the ROM File and click OK Select the printer or modem port and click d Turn the plotter ON and hold down the PRIME button e Click OK at your MAC and the FLASH update will begin printer port You may also have to deactivate the application NOTE If you experience communication problems use the computer while using the plotter a If your customer has a PowerMac 8500 or 9500 insure that Apple s 7 5 2 printing fix is installed on the system You may experience problems communicating on the RS 422 line without it You can obtain the fix from Apple Computer and American Online 15 When the process is completed reset the plotter s User Settings to the desired selections and start plotting again 4 NOVAJET SERIES
67. TIME ON THE SAME UPPER ROLLER SUPPORT It is extremely important that you maintain downward pressure towards the floor on the head of each screw at the same time as you loosen or tighten the screw 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 See Figure Chapter 7 5 1 The torque requirements for the Upper Roller Support mounting Screws is 3 in Lbs 0 5 2 Figure Chapter 7 4 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 R LLER o P4 v PINCH ROLLER ASSEMBLY N CM 7 LEFT MOUNTING SCREW RIGHT MOUNTING SCREW RIENTATION STANDING BEHIND THE PLOTTER FACING THE BACK DF THE PLOTTER Figure Chapter 7 4 Upper Roller Support and Mounting Screws NOVAJET SERIES 7 33 Calibration 3 Become familiar with the actions and results shown in Table Chapter 7 1 Note that these actions are performed from behind the plotter Table Chapter 7 1 Mounting Screw Actions and Results 7 Not maintaining downward pressure towards 7 Th
68. W Typical 63 W Max Certifications Safety CSA CSA NRTL equivalent to UL1950 TUV GS FCC Class B VDE Class B CE Mark CSPR Class B Operating Environment 41 to 104 F 5 to 40 C 20 to 80 RH Non condensing Storage Environment 40 to 140 F 40 to 60 C 10 to 80 RH Non condensing EMI NOVAJET SERIES General Information Physical Specifications NOVAJET PRO 36 Dimensions Height 48 121 cm Width 60 5 154 cm Depth 28 5 72 39 cm Weight Assembled 56 Ibs 25 4 kg Shipping Plot head Shipping Stand 76 Ibs 34 5 kg 41 Ibs 18 6 kg NOVAJET 4 E Size Dimensions Height 48 121 cm Width 55 140 cm Depth 28 72 cm Weight Assembled 58 16 26 5 kg Shipping Plot head 58 16 26 5 kg Shipping Stand 43 Ibs 19 5 kg Feeder Takeup Mechanism Weight Shipping lbs xxx kg NOVAJET SERIES NOVAJET PRO 50 Dimensions Height 48 121 cm Width 74 5 189 2 cm Depth 28 5 72 39 cm Weight Assembled 86 Ibs Shipping Plot head 85 Ibs Shipping Stand 41 Ibs Shipping Media Handler 26 lbs 39 kg 38 6 kg 18 6 kg 11 8 kg 4 D Size Dimensions Height 42 105 cm Width 44 112 cm Depth 28 72 cm Weight Assembled 53 16 24 kg Shipping Plot head 50 Ibs 22 7 kg Shipping Stand 39 Ibs 17 7 kg General Information 9 00 Lin
69. Y MEDIA PERIMETER Ly _ Figure Chapter 1 5 Skew Given a specified rectangle Lw wide and L high the diagonal error L1 Lo defines the skew The maximum acceptable skew is EQUAL 0 2 of L4 0 2 of Lo or 0 4 of L4 L2 EXAMPLE f Lw 60cm L 80cm Then 1 should Lg 100cm Actual permissible skew L4 Lo 4 x 100cm 4cm or 0 157 inches 1 20 NOVAJET SERIES General Information NOTE 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 NOVAJET SERIES 1 21 General Information 11 0 Acronyms and Abbreviations ACK A D ANSI ARCH ASCII AUTO BTU CAD CHG cm cm s CPU CTRL CTS d orA dB DC DPI DRAM DSR DTE DTR ENQ FCC g gm GND HP GL HP GL 2 1 22 Acknowledge Analog to Digital American National Standards Institute Architectural Address Strobe American Standard Code for Information Interchange Automatic British Thermal Unit Celsius Computer Aided Drafting Change Centimeter Centimeter per second Central Processing Unit Control Clear to Send Differential Decibel Direct Current Dots Per Inch Dynamic Random Access Memory Data Set Ready Data Terminal Equipment Data Termina
70. a clock signal is not required Any Raster plot anomaly caused by jet s misfiring improper paper media feeding or ink being laid down too fast a repeating inconsistency in plot appearance Beginners All Purpose Symbolic Instruction Code Acommon programming 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 O 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 1 23 General Information BUS CAD CALIBRATION CARRIAGE CARRIAGE AXIS CARTRIDGE CENTRONICS CONFIGURATION CPU DATA DEADBAND DEFAULT 1 24 A group of computer circuits used for a common purpose Computer Aided Drafting computer system or software designed to create drawings The
71. and the plotter for example mismatched interfacing conditions such as baud rate and parity General Information LAN LINEAR ENCODER MEDIA MENU MODE COMMAND MODIFY MONOCHROME NESTING ORIENTATION 1 1 26 Local area network linking computers On ENCAD plotters this is a plastic strip containing lines which are read by the optical sensor on the Carriage Assembly These lines are converted into data for determining the Carriage Assembly position 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 This command sets the protocol parameters used to initialize the Asynchronous Communications Adapter Serial 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 direction of the plotted image on the media that is portrait or landscape For all HP GL emulations P1 and P2 defaults are located 0 6 inches inside the printing area the Normal setting With HP GL 2 emulations the and P2 defaults are at the corners of the printing area the Maximum setting your CAD software allows specification of the location of P1 and P2 you can choose either Normal or Maximum locations t
72. and zero gauge NOVAJET SERIES 7 21 Calibration 4 Snap lock the cartridge micrometer gauge into the appropriate location NJ blue black cartridge place in Cyan cartridge location 5 Move the carriage assembly to the left to begin measurements Do not allow the micrometer gauge tip to drag across the platen Note the difference on the RED numbers With your hand gently raise lower the carriage assembly until height is obtained as a test Measure First Gently push up or down to see which way you need to adjust Observe the RED numbers 6 Remove the top cover and move around to the rear of printer plotter to observe gauge indications 7 22 NOVAJET SERIES Calibration Rear Side View Adjust each bolt with allen head wrench Apply upward or downward pressure while monitoring gauge for correct value Tighten bolt down when correct 7 Adjust only if required Use the torque screwdriver pre set at 12 in lbs with 3 32 Allen bit to loosen all three Allen head screws on the Y Arm Ensure the measuring tip extension makes contact with the platen surface at all times when adjusting for 0 065 0 003 at all three locations Right position in front of the Platen s Front Media Alignment Mark see Chapter 1 Figure 1 1 Center position directly in line with the center of the turnbuckle screw see Figure 7 2 Left position in front of the inner screw which is to the right of the left Support Bracke
73. assembly design allows for easy replacement of PCB Paper Sensor Encoder or Bushings without the necessity of replacing the entire assembly Electronic Paper Sensor Opto NJP 36 NJP 50 only Carriage Assembly carries tubing for extended ink supply NJP 36 NJP 50 only Carries Trailing Cable Ink Delivery Lines and Chain NJ 4 only Carries Trailing Cable Encoder Strip mounted on Stabilizer Bracket New design eliminates manual backlash adjustment 1 7 General Information FEATURE NJP 36 NJP 50 NJ 4 10 Upper Roller Adjustment nuts accessed Adjustment screws located Supports from front of plotter on back of Y Arm Assembly 11 Lower Drive Shaft is longer Two Shaft designed to allow room Assembly internal foam blocks for internal Power Supply One internal foam block NJP 50 only Two middle Drive Shaft Support Brackets 12 Service Station One electronically activated No electronics One Wiper Assembly Wiper for each Cartridge Wipers and Seals mounted in an easily removeable Assembly 13 Power Media Not available NJP 50 only Feed and Standard Take Up System NJP 36 amp NJ 4 E Size only Optional 14 RIP Box Not available Optional 1 8 NOVAJET SERIES General Information 5 0 Media Sizes and Plotting Areas The NOVAJET plotters are designed to recognize specific standard media sizes by checking the narrow dimension of the media as it is loaded The
74. 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 Reconnect the Red and Blue Servo Motor wire to the J6 connector the Stepper Motor wire to the JP5 connector and the Red and Black Fan wire to the J5 connector See Figure Chapter 6 5 Reinstall the Right Cover Assembly Make sure that of the harnesses or cables are pinched between the cover assembly and the Right Side Plate See Section 4 6 Reinstall the Plotter on the Stand See Section 3 2 Reinstall the Left Cover Assembly See Section 7 4 Step 2 NOVAJET 4 only Reinstall the Cartridges according to the procedures in Chapter 3 Section 4 0 NOVAJET PRO only Reinstall the Cartridges and reestablish the siphon in the Ink Delivery System according to the procedures in Chapter 3 Section 2 0 6 81 Disassembly Assembly 17 Reinstall the Top Cover The entire plotter is now reassembled 6 82 NOVAJET SERIES Disassembly Assembly 11 0 Upper Roller Supports 11 1 Removing the Upper Roller Supports NOTE This procedure is to be used only if the Upper Roller Supports become worn or damaged 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 During this procedure be very careful not to damage the
75. bumps which are close together must be between the left and right posts on the Belt Clamp as shown in Figure Chapter 6 18 1 The bumps on the belt where the ends of the belt are joined together to make the belt continuous must be positioned between the left and right posts of the Belt Clamp See Figure Chapter 6 18 2 Slide the new Carriage Belt between the right post and the middle post and guide it down into the Belt Clamp Then slide the Carriage Belt between the left post and the middle post and finish placing the Carriage Belt into the Belt Clamp 3 Check the position of the Carriage Belt to make sure it matches Figure Chapter 6 18 4 Refer to Sections 7 3 and 7 4 in this chapter to reinstall the Carriage Assembly NOVAJET SERIES 6 45 Disassembly Assembly 7 9 Removing the Carriage PCB 1 Follow all procedures in Sections 7 1 and 7 2 in this chapter to remove the Carriage Assembly from the Slide Shaft 2 Remove the Strain Relief by pushing down slightly on the right side of it and then pull straight up to remove it from the hook See Figure Chapter 6 16 3 Unlock the connectors and remove all flex cables on the Carriage PCB this order J1 J7 J2 J3 44 and J6 See Figure Chapter 6 19 4 Unlock the latch on the right end of the Carriage PCB and lift up the right end of the Carriage PCB See Figure Chapter 6 19 5 Slide the Carriage PCB to the right to remove the tab on the left end of the C
76. care to make sure that the Carriage does not scratch the Encoder Strip during this procedure You will need the following e The Height Gauge Kit Assembly P N 205660 e Torque screwdriver pre set at 12 in Ibs with 3 32 Allen bit ASSY KIT HEIGHT GAUGE 205660 CADJET 2 NOVAJET SERIES 7 20 NOVAJET SERIES Calibration 7 1 Initial Adjustment Procedure Novajet 4 Pro Pro 50 cartridge height should be 0 065 0 003 and the shaft itself should remain relatively perpendicular to the platen surface The shaft height to cartridge height ratio is the important factor that you should be aware of The design specification is very accurately measured during the manufacturing process within 0 001 You will need to ensure that the cartridge height is accurate so that quality printing can be achieved Ensure the Novajet 4 Pro Pro 50 cartridge is used for adjustment Novajet 4 50 use the blue black cartridge place in Cyan cartridge location Procedure 1 Assemble cartridge as shown below Attach all pieces to maximum range no slack Ensure set screw is tight Note The tip of the micrometer gauge must be removed to attach the extension or measuring tip MICROMETER GAUGE MEASURING TIP WITH SET SCREW NOVAJET CARTRIDGE 2 Rotate head of micometer gauge 180 degrees so gauge only be read when viewing contact side of cartridge 3 Place Cartridge upright on a flat surface
77. 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 NOVAJET SERIES 5 23 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 No I O error has occurred ERR 10 Output instruction received while another output instruction is being executed The first is executed while the next instructions are ignored ERR 11 Invalid byte received after the first three characters in a device control instruction ERR 12 Invalid byte received while parsing a device control instruction The parameter containing the invalid byte and all following parameters are defaulted ERR 13 Parameter out of range ERR 14 Too many parameters received Additional parameters after the correct number are ignored ERR 15 A framing error parity error or overrun error has occurred ERR 16 Input buffer overflow This will result in the loss of data and probably an HP GL emulation error ERR 17 Baud rate mismatch ERR 18 error indeterminate ERR 20 RS 422 RS 232 serial xtda xrda failure Occurs only with a loop back connector in test ERR 21 RS 422 RS 232 or CTS test failure Occurs only with a loop back connector in test 5 24 NOVAJET S
78. detects edges halfway between where the other detects edges This is known as quadrature signals It gives an effective resolution of 600 lines per inch The direction that the Carriage Assembly is moving is known based upon the state of one detector s output and the direction of the transition of the other detector s output A hardware counter in the gate array increments as the Carriage Assembly moves left and decrements as the Carriage Assembly moves right The hardware counter is only eight bits wide so it cannot store a value large enough to represent an absolute Carriage Assembly position Instead it is read during the servo interrupt and its value compared with that from the previous interrupt This difference is used to update the absolute position value in the software NOVAJET SERIES 2 15 Theory of Operation 3 13 Parallel and Serial Ports 2 16 SERIAL MICRO GATE PARALLEL CONNECTOR TRANSCEIVER processor array CONNECTOR 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 to DRAM The serial port is designed primarily to interface to a Macintosh printer port It has an eight pin Mini DIN connector The data TXD RXD signals meet RS422 electrical specificatio
79. during the initial siphoning of the Ink Delivery Line NOVAJET SERIES 1 Nozzles may have become clogged possibly from a substandard Service Station wipe See Chapter 4 Sections 4 0 and 6 1 2 for cleaning instructions for the Service Station and the Cartridge NOTE the Service Station should be cleaned weekly If Step 1 does not help spray from plotting may have contaminated the Flex Contact Perform the Cartridge Swapping Procedure in Table Chapter 5 7 if cleaning the Flex Contact does not help Replace the Carriage Assembly See Chapter 6 Section 7 0 Replace the MPCB See Chapter 6 Section 4 0 Call ENCAD s Technical Support Department Spray from plotting may have contaminated the Flex Contact or a quadrant of jets has failed Cleaning the Flex Contact will not solve the problem To be certain that the problem is caused by the Cartridge perform the Cartridge Swapping Procedure in Table Chapter 5 7 Replace the Carriage Assembly See Chapter 6 Section 7 0 Replace the MPCB See Chapter 6 Section 4 0 Call ENCAD s Technical Support Department When a used Cartridge is being reconnected the jet plate will leak a few drops until a negative pressure is established by using the Suction Bulb to draw ink through the jet plate Load a sheet of paper into the plotter before reconnecting the Cartridge to avoid ink spilling onto the Platen The jet plate on the Cartridge is flooded because the Firing Rate has been
80. during printing NOVAJET SERIES Power Media Feed Take Up System 3 0 Parts List This chapter lists the part names and part numbers for field replaceable parts and assemblies of the Power Media Feed and Take Up System 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 PART DESCRIPTION 204849 Power Supply 0 EY ID RETR Switch ON OFF 205058 m teat eee doma Coal atta Gear Motor 75 P D 206059 paa d Gear Drive 2 5 24815181218 TEE Guide Paper Idler 2191 518746 ette ia oa va tte Guide Paper Drive doa DERE ed o d v e v E Core Adaptor 3 206082 THREE REESE RE metas Sensor Photoelectric PUNO buie ai P nuncium vn Sensor Photoelectric Eu E Logic Board ADAE Take up Rail 36 Take up Rail 50 Zl puo re Take up and Feed Drive Unit 206124 PEDE Motor 30 96 2 Ratio 206134 tems Sens Switch DPDT
81. e if the right edge of the paper drifts to the left side of the Media Alignment Mark the Upper Roller Supports will need to be adjusted to the left 10 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 7 7 ae NN NN A Vi n in Figure Chapter 7 7 Visual Verification of Gap between Roller and Y Arm J NOVAJET SERIES 7 37 Calibration 10 4 2 Observation of Paper Skew at Rear Media Alignment Mark 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 right hand side is aligned with the Front Media Alignment Mark on the front of the Platen paper and the left edge of the Front Media Alignment Mark on the Platen nore Note Make sure that there is no gap between the right edge of the 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 7 38 NOVAJET SERIES Calibration
82. from the jet area of the Cartridge 7 A REMOVE BLUE 1 Y WHEN YOU ARE READY INSTAL gt al CARRIAGE ASSEMBLY Figure Chapter 3 9 Removing Blue Tape from NJP Cartridge Jet Area 3 12 NOVAJET SERIES Ink Delivery System To prime the Cartridge to remove any air bubbles inside the Cartridge and start the flow of ink squeeze the Suction Bulb Figure Chapter 3 10 Step A Item 1 and place the Suction Bulb over the jet area of the Cartridge Figure Chapter 3 10 Step A Item 2 Make sure the Suction Bulb is making good contact with the jet area Figure Chapter 10 Step B 3 and release the pressure on the Suction Bulb so that it draws ink through the jet area of the Cartridge Remove the Suction Bulb from the jet area If no ink is seen at the jet area repeat Steps 6 and 7 again Blot the jet area by pressing lightly against the jets Use a lint free non paper cloth Do not use tissues and do not wipe across the jet area STEP A STEB D SQUEE SUCTIUN BULB BEFUR PLACING DIVER JET AREA 2 JET AREA MAINTAIN ID CUNTACT AS RELEASE PRESSURE N SUCTION BULB
83. front of your NOVAJET PRO User s Guide for further information 1 If you have not already done so load a D size or E size sheet of media It should hang over both the front and the back of the Platen 2 Press ACCESS CARTRIDGES to move the Carriage Assembly out of the Service Station 3 Close the Tubing Clamp on the line leading to the Cartridge which you are removing or all four Tubing Clamps if you plan to unload the entire Extended Ink Supply Refer to Figure Chapter 3 5 4 Unscrew the Tube Fitting refer to Figure Chapter 3 8 Item 2 and remove the Cartridge from the Carriage Assembly Wipe off the ink on the outside of the needle NOVAJET SERIES NOVAJET SERIES Ink Delivery System Lay the Cartridge on its front side so that the Flex Contacts are facing up see Figure Chapter 3 1 This will prevent the ink from leaking out of either the opening in the top or out of the jet area on the bottom If you are installing a new Cartridge follow the instructions in Sections 2 3 and 2 4 If you are returning the Cartridge to ENCAD please drain or extract as much of the ink out of the Cartridge as possible enclose it in a plastic bag and seal the bag If you are preparing to ship the plotter remove all four Cartridges Make sure the Tubing Clamps on the Ink Delivery Lines are closed so that no ink comes out as you begin the instructions in Section 3 2 3 17 Ink Delivery System 3 2 Purging the Ink Delivery
84. 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 NOVAJET SERIES 5 29 Troubleshooting Figure Chapter 5 3 Cable and Schematic for Parallel and Serial Loop Back Tests 5 30 NOVAJET SERIES Troubleshooting Figure Chapter 5 4 Correct Usage of Cable for Parallel and Serial Loop Back Tests NOVAJET SERIES 5 31 Troubleshooting 11 4 No Movement in the Carriage Axis 5 32 1 2 Is power applied to the plotter Is the front panel display ON If NO If YES a Check the Keypad cable s connection J1 to the Main Printed Circuit Board Be certain that it is fully seated See Chapter 6 Section 6 2 Check for voltage coming out of the Power Cable see Appendix C Schematic for MPCB for voltages 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 Check for voltages at the Main Printed Circuit Board Turn power off and disconnect the power cord Remove the Left Cover Assembly and Left Side Plate and check the fuse on the Power Supply See Chapter 6 Section 8 0 Use only a 250 Volt 2 Amp Fast Blow fuse 5mm x 20mm Be careful not to mistakenly use a 32 Volt fuse 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
85. ink bottle to save any remaining ink for future refilling Wipe any drops that may have leaked from the refill hole Allow the Cartridge to stand for a moment until ink droplets stop forming on the jet area If the Cartridge is overfilled ink droplets will continue to form and you will need to remove excess ink from the Cartridge by drawing it back into the ink bottle through the refill hole in the Cartridge Reinstall the Cartridge in the Carriage Assembly by putting the bottom of the Cartridge into the correct position in the Carriage Assembly Then press the top of the Cartridge toward the Carriage Assembly to snap it into place After all four Cartridges are installed press the PRIME key to run the Prime plot Check the Prime plot to see if the Cartridges are firing properly The bands should be smooth without dark streaks or white lines The diagonal lines should not look fuzzy or contain gaps You may need to run the Prime plot more than once If a Cartridge is not firing properly see Chapter 5 Section 11 7 for troubleshooting information Once all the Cartridges are firing properly perform the Color Calibration in Chapter 7 Section 15 0 of this Service Manual 4 2 Preparing the Plotter for Shipment to ENCAD 3 30 1 2 Remove all four Cartridges from the Carriage Assembly Store them in plastic bags and seal the bags tightly Follow the instructions in Chapter 6 Section 3 0 except for those labeled
86. issue 11 10 Plotter Hesitates During Plotting Refer to the procedures in Section 11 9 in this chapter 11 11 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 NOVAJET SERIES 5 53 Troubleshooting 11 12 Plots are Cut Off 5 54 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 2 and 1 3 of this Service Manual for the Normal and Expanded plot areas for the different media standards 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 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 2 and 1 3 of this Service Manu
87. it is exposed to sunlight during shipping Also write the RA number in large numbers on the outside of the box and on the shipping documents If you don t receive the Mailing Label or if you have any questions about these procedures please call our Help Desk See Chapter 1 Section 3 0 3 2 Placing the Plotter on the Stand See the plotter assembly procedures included in the box that the replacement plotter came in or that came with the original unit 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 NOVAJET SERIES 6 9 Disassembly Assembly ht Cover Assembly MPCB and SIMM 4 1 Removing the Right Cover Assembly Removing the Right Cover Assembly provides access to the SIMM MPCB and all MPCB connectors Stepper Motor Servo Motor Fan Keypad and Trailing Cable NOTE Note If the LED Keypad on the Right Cover Assembly needs to be replaced the entire Right Cover Assembly must be replaced a 1 Figure Chapter 6 4 Inside View of Right Cover Assembly 6 10 NOVAJET SERIES Disassembly Assembly To remove the Right Cover Assembly 1 NOVAJET SERIES Remove the Top Cover Keep the left end of the Top Cover tilted up so that the Retracting Stop and Compression Spring don t fall out You may find it helpful to wrap a rubberband around the connector clips on the parallel port to hold them out of th
88. may be faulty Replace the Servo Motor first See Chapter 6 Section 5 0 for instructions If ERROR still appears replace the MPCB See Chapter 6 Section 4 0 for instructions NOVAJET SERIES Troubleshooting 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 6 Figure 6 17 b sure the belt is properly installed in the Belt Clamp Also check to see if the Belt Clamp is cracked Refer to Chapter 6 Section 7 7 5 Servo Motor cabling may be intermittent Check the connections at J6 on the MPCB see Chapter 6 Figure 6 6 If necessary make sure the other end of the cable is seated correctly in the connector on the Servo Motor See Chapter 6 Section 5 0 for procedures for obtaining access to the Servo Motor 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 6 Section 5 0 7 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 You will need to remove the Carriage Assembly from the Slide Shaft to obtain access to the Bush
89. packing foam that came with the plotter so that the ink does not leak out of the air vents in the top of the Ink Reservoirs See Figure Chapter 3 15 NOVAJET SERIES 3 25 Ink Delivery System 3 26 Figure Chapter 3 16 Removing Black Foam Support 5 10 11 12 Remove the black Foam Support from the inside of the Left Cover Assembly See Figure Chapter 3 16 Remove each Ink Reservoir and attach a label indicating the ink color it contains If you save the ink it must be stored in a clean container which can be sealed and which will allow you to easily refill the Reservoir Otherwise you should dispose of the ink Thoroughly rinse each Ink Reservoir with distilled water or R O water Reverse Osmosis Each Reservoir should dry completely Put the Ink Reservoirs back in the Left Cover Assembly in the reverse order in which they were removed Reinsert the black Foam Support Have someone help you reinstall the Left Cover Assembly on the plotter Do not overtighten the three Phillips screws Reconnect each Ink Delivery Line to the appropriate Ink Reservoir and open all the Tubing Clamps Install the Top Cover You will need to perform the entire procedure for loading the Extended Ink Supply given in Section 2 0 when you are ready to begin using the plotter again NOVAJET SERIES Ink Delivery System 4 0 NOVAJET 4 Refillable Cartridges 4 1 Installing and Refilling NOVAJET 4 Cartridges Use of
90. procedures for adjusting the ink cartridge alignment line length accuracy and deadband 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 the Horizontal Axis The plastic housing containing the ink and the ink nozzles Four 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 microprocessor 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 NOVAJET SERIES DIAGNOSTICS DISPLACEMENT DPI DUTY CYCLE EMULATE FLASH EEPROM GRAVITY
91. read CALIBRATION COLOR 4 Press SELECT The display will read CALIBRATION HORIZ YELLOW 0 NOVAJET SERIES Calibration 5 The plotter will begin printing three sets of color line patterns in the following order see the NOVAJET PRO User s Guide Appendix A for samples of the patterns for 5 b and 5 c below 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 Appendix A sample of the pattern for Current Heads The wr An error was made in the NOVAJET User s Guide pattern drawn looks like this b COLOR HORIZONTAL HEAD TO HEAD CALIBRATION The second pattern is used to align the four Cartridge heads horizontally The following will be printed 1 row of numbers will print first These numbers represent alignment values 2 Yellow and Magenta Cartridges will each print 3 short lines above each number 3 Magenta and Cyan Cartridges will then each print 3 short lines above each number 4 The Cyan and Black Cartridges will then each print 3 short lines above each number NOVAJET SERIES 7 59 Calibration 7 60 COLOR VERTICAL HEAD TO HEAD CALIBRATION The third pattern is used to align the four Cartridge heads vertically The numbers printed in the previous pattern Color Horizontal Head to He
92. set too high Reset the Firing Rate 5 000 Hz is the optimum setting Make sure the Tubing Clamp on the Carriage Assembly is open Make sure the Ink Delivery Line s CPC Coupling is snapped into the Ink Reservoir correctly The Ink Delivery Line may be blocked by contaminants Flush the line with distilled water or R O water Reverse Osmosis using the procedure given in Chapter 3 Section 3 2 You will need someone to help you with this procedure If Steps 1 and 2 do not solve the problem and you are unable to purge the line with the procedure in Step 3 replace the Tubing Chain Assembly See Chapter 6 Sections 7 14 and 7 15 for the replacement procedure 5 45 Troubleshooting CONDITIONS ACTIONS 8 The initial siphon cannot be 1 Make sure there is ink in the Ink Reservoir established because air 2 If there is ink in the Ink Reservoir and the siphon cannot bubbles are drawn through be established there probably is a leak in the Ink Delivery Line the Ink Delivery Line or in the Tube Fitting which connects to the Cartridge or in the CPC Coupling which connects to the back of the Ink Reservoir Replace the Tubing Chain Assembly See Chapter 6 Sections 7 14 and 7 15 for the replacement procedure The initial siphon is The Tube Fitting may not be connected to the Cartridge established but is tightly enough and air may be entering the Ink Delivery immediately lost after the Line Reestablish the siphon Chapter 3 Sections
93. siphon See Chapter 3 Section 2 2 Then use the Suction Bulb to remove any excess air from the Cartridge See Chapter 3 Section 2 4 Check the level of ink in the Ink Reservoir We recommend that the Reservoir be filled only up to the second line from the top of the Reservoir see Figure xx Too much ink in the Ink Reservoir will cause a loss of negative pressure and ink will be discharged Use the Priming Pump to draw any excess ink out of the Reservoir and reestablish the siphon See Chapter 3 Section 2 2 5 46 NOVAJET SERIES Troubleshooting Table Chapter 5 6 NOVAJET 4 Refillable Cartridges Troubleshooting Table 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 A NOVAJET 4 CARTRIDGE CONDITIONS The Cartridge does not fire after initial installation or stops firing after it has been in use 2 One nozzle stops firing 3 Many nozzles stop firing NOVAJET SERIES ACTIONS Make sure that the blue tape has been removed from the Cartridge s jet plate Nozzle may have become clogged See Chapter 4 Section 6 1 2 for jet cleaning procedures Make sure that the Flex Contacts on the Cartridge and on the Carriage Assembly are clean and dry See Chapter 4 Section 6 1 1 for cleaning instructions Perform the Cartridge Swapping Procedure in Table Chapter 5 8 Replace the Carriage A
94. spills into the other vacuum holes should also be avoided to prevent damage to internal parts If any liquid spills onto the Platen immediately blot it up with a dry cloth Do not wipe across the vacuum holes wipe away from them Do not use abrasive cleansers of any sort on any area of the CAUTION 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 4 2 NOVAJET SERIES Maintenance 3 0 Slide Shaft Maintenance 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 Assembly which will affect the plot quality The plotter may also experience Carriage Axis Failure You may in particular notice a buildup near the ends of the Slide Shaft This is caused by high usage of the plotter This is normal wear and should not be a cause for concern We recommend that you clean the Slide Shaft after every 100 hours of use However please note that some environmental conditions may make it necessary to clean the Slide Shaft more frequently To clean the Slide Shaft 1 Park the Carriage As
95. 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 NOVAJET SERIES 1 3 General Information 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 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 Carriag
96. the Service Menu the display will also reflect the particular model of plotter ROM REVISION NovaJet PRO 1 00 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 Section 3 0 of this manual The Service Menu has three levels or submenus Detailed descriptions of these three levels are given in Section 4 0 below NOVAJET SERIES 5 9 Troubleshooting 4 0 Service Menu Description 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 e SERVICE INFORMATION e SERVICE DIAGNOSTICS and e SERVICE CALIBRATION 5 10 NOVAJET SERIES Troubleshooting 4 1 Service Information This level provides information about the User INFORMATION Settings There are two sub levels e INFORMATION DISPLAY SETTINGS and e INFORMATION PRINT SETTINGS 4 1 1 Information Display Settings INFORMATION This option displays only the current users User DISPLAY SETTINGS Settings 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 DATE X
97. the Cartridges are firing properly The bands should be smooth without dark streaks or white lines The diagonal lines should not look fuzzy or contain gaps You may need to run the Prime plot more than once If a Cartridge is not firing properly remove it from the Carriage Assembly and repeat Steps 6 through 12 of this section again If necessary see Chapter 5 Section 11 7 for more detailed troubleshooting information Once all the Cartridges are firing properly perform the Color Calibration in Chapter 7 Section 15 0 of this Service Manual 3 15 Ink Delivery System 3 0 3 1 CAUTION 3 16 Unloading the NOVAJET PRO Extended Ink Suppl Removing the NOVAJET Ink Cartridges Read and observe all applicable Warnings and Cautions given at the beginning of this chapter If you are preparing to unload the entire Extended Ink Supply read through all of Section 3 0 before beginning to unload the system Note 1 This section is to be followed any time an individual Cartridge needs to be replaced If you are preparing to unload the entire Extended Ink Supply you will need to remove all four Cartridges If you are exchanging a Cartridge the Trailing Cable Support Bracket which contains the Ink Delivery Lines and the Chain or the plotter you must contact ENCAD s Help Desk see Chapter 1 Section 3 0 prior to shipping anything Please consult the Warranty or Damage Claims section in the
98. the Servo Motor wires on the Platen s opening Make certain that the connector on the Servo Motor faces the FRONT of the Platen 1 Insert the Servo Motor part way into 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 with the connector facing the FRONT side of the Platen The pulley must go up through the opening in the Y Arm see Figure Chapter 6 11 before the connector is guided through the opening in the bottom of the Platen The bottom of the motor will be tilted towards the back of the Platen as you guide the connector through the opening 4 When the Servo Motor is inside the Platen push up on it and align the screw holes with the screw hole openings 5 Thread the front screw into the Servo Motor but do not tighten it 6 Gently lift up and hold the Trailing Cable Support Assembly s right end the Carriage Assembly should still be at the far left end of the Slide Shaft Insert the back screw into the Servo Motor and tighten it Make sure the screw does not go into the motor at an angle and be careful not to strip the head of the screw Make sure the front screw and the back screw are both tight 7 Putthe plug back into the bottom right end of the Platen 8 Reinstall the Service Station Make sure that the latch on the right end of the Service Station is locked into place You ma
99. 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 Remove the Left Cover Assembly and the Left Side Plate and make sure the fuse on the Power Supply is good See Chapter 6 Section 8 0 Use only a 250 Volt 2 Amp Fast Blow fuse 5mm x 20mm Be careful not to mistakenly use a 32 Volt fuse 5 26 NOVAJET SERIES 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 extra SIMM has been installed a The SIMM contacts may need to be cleaned Clean the SIMM contacts b The SIMM may be defective Replace the extra SIMM if cleaning the contacts does not improve the performance See Chapter 6 Section 4 0 for the procedures for replacing the SIMM C performance is not improved after replacing the extra SIMM the SIMM socket may be defective In this case you must replace the MPCB See Chapter 6 Section 4 0 2 There may be a defective Flash EEPROM on the Main Printed NOVAJET SERIES Circuit Board Because the Flash EEPROM is soldered to the MPCB it is necessary to replace the MPCB Refer to Chapter 6 Section 4 0 of this manual for the removal and replacement procedures for the MPCB 5 27 Troubleshooting 11 3 Plotter Will Not Plot 5 28 1 Make sure the ink cartridges are properly installed T
100. the parallel port and choose the COM 1 or COM 2 port whichever is being used using the arrow key to arrow through selection and space bar to make selection Press ENTER 8 From the four choices type 3 serial download and press ENTER 9 Verify revision NJPRO101 ROM for the NJ Pro 36 model Press ENTER 10 A Warning page will flash up Technicians only statement Press ENTER 11 At printer plotter hold the PRIME key power on printer plotter A 2 NOVAJET SERIES 12 After fan energizes wait 5 seconds release the PRIME key 13 Press ENTER at PC Download should begin LCD should gt be busy for about 2 minutes writing zeros and ones to the MPCB EEPROM DO NOT HALT THIS PROCESS UNTIL IT IS COMPLETED 14 When download is complete a REBOOT message should appear PLEASE REBOOT PLOTTER 15 Turn printer plotter OFF and then ON Ensure printer startup is normal with the correct firmware revision displayed NOVAJET ALTERNATE PROCEDURE DOS UTILITY FOR PC 1 2 Follow steps 1 9 above Hold down the PRIME key Power on the printer potter fan energizes wait at least 5 seconds While holding the PRIME key turn power switch OFF and back ON immediately Fan energizes wait at least 5 seconds again Release the PRIME key At PC press the ENTER key to start the download Follow steps 13 and 14 above NOVAJET PROCEDURE MAC UTILITY NOVAJET
101. will verify that the parallel or serial communications circuits of the plotter are functioning correctly This test requires the use of the cable which is shipped with each plotter If you do not have this cable it is Part Number 205462 see Figure Chapter 5 3 and it may be ordered through ENCAD s Help Desk see Chapter 1 Section 3 0 You can also make one by following the schematic in Figure Chapter 5 3 If you are using the cable provided with the Plotter P N 205462 NEVER plug both ends of it into the ports on the Plotter at the same time THIS WILL CAUSE SERIOUS DAMAGE TO THE PLOTTER See Figure Chapter 5 4 for the correct usage of this cable 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 plotter s 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 not communicating correctly and the Main PCB must be replaced 5 displays RESULT OK then the communications circuits of the plotter are
102. 0 line will be drawn Press FEED MEDIA and DOWN ARROW to unload the paper Verify that the line length is correct Proceed to Section 13 2 and calibrate the X Axis 7 49 Calibration 13 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 14 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 14 0 and do the Deadband Calibration 7 50 NOVAJET SERIES Calibration 14 0 Deadband Calibration De
103. 0 2 Mounting Screw Information 7 31 10 3 Other Functional 7 34 10 4 Adjustment of Upper Roller 7 35 10 4 1 VISUAL VetitiGallOlk 7 35 10 4 2 Observation of Paper Skew at Rear Media Alignment ui c 7 36 10 4 8 Observation of Paper Skew at Front Media Alignment Mall arae S ok tame erue EF 7 38 10 4 4 X Adjustment of the Mounting Screws 7 39 10 5 Minimum Pull Force Verification 7 40 NOVAJET SERIES Table of Contents CHAPTER 7 CALIBRATION continued 11 0 Setting the Print 7 41 Prime PICEA tse i ae eee BA bs ae Be 7 43 X MSS rime 7 45 13 1 Calibrating the Y Axis Carriage Axis or Horizontal Axis Calibration e I 7 46 13 2 Calibrating the X Axis Paper Axis or Vertical Axis Calibration 7 48 14 0 S Beadband AUN A Oise Ss eh bbb a ob ba db ha db etes 7 49 14 1 Slow Deadband 7 50 14 2 Fast Deadband Height 7 52 14 21 Adjusting Fast Deadband Vertical Lines All and Vertical Lines One 7 53 15 0 Color Calibration Horizontal and
104. 0 3 X X X X KEYPAD TOP 203487 6 X LABEL SET identifies keys LABEL RIGHT COVER AND KEYPAD 204994 X X X X LOCTITE BLACK MAX 200172 X X X X 9 6 NOVAJET SERIES USED DESCRIPTION MANUAL SERVICE NOVAJET SERIES MANUAL USER NOVAJET SERIES ON OFF SWITCH POWER ENTRY MODULE PAD BUSHING PAPER SENSOR W FLEX PLATEN MACHINED PLATEN MACHINED D SIZE PLATEN MACHINED E SIZE POWER SUPPLY 24V DC POWER SUPPLY 24V DC ROLL SUPPORT SCREWS STAND 10 SEAL 4 SIDEPLATE LEFT SIDEPLATE RIGHT SLIDE SHAFT SLIDE SHAFT D SIZE SPRING COMPRESSION IDLER SPRING COMPRESSION TOP COVER SPRING EXT SERVICE STATION BOTTOM STOP RETRACTING STOP RETRACTING SUPPORT SHAFT SUPPORT DRIVE SHAFT middle support SUPPORT SHAFT TUBING CHAIN ASSY NJ PRO 36 TUBING CHAIN ASSY NJ PRO 50 WIPER 4 NOVAJET SERIES PART 205582 205883 204599 205534 204559 204906 205121 204972 1 204849 204849 1 203868 2 203485 2 204731 204740 204898 204774 205116 203999 202010 204763 204246 1 205694 203565 2 203556 2 204760 205023 206541 204732 Replacement Parts List 40 NJ4E NJP 36 NJP 50 Replacement Parts List If ordering the Assy Cover P N 204711 1 P N 204711 31 or P N 204711 61 the Stop Retracting P N 204246 1 or P N 205694 and the Spring Compressi
105. 0 NOVAJET SERIES Replacement Parts List Figure Chapter 9 6 Assy Fan P N 203443 NOTE Note 1 See Chapter 5 Figure 5 1 for the contents of the Hardware 4 Kit 2 The Hardware Kit does not include the stand screws See Figure Chapter 9 44 P N 203485 2 Figure Chapter 9 7 Assy Hardware Kit NOVAJET PRO Service P N 205440 Figure Chapter 9 8 Assy Idler P N 203405 1 NOVAJET SERIES 9 11 Replacement Parts List 9 12 BOTTOM VIEW OF DISPLAY SERVICE ASSY Figure Chapter 9 9 Assy Keypad P N 203488 1 LEGS ASSEMBLY BASKET ASSEMBLY Figure Chapter 9 10 Assy Legs and Basket P N 203484 3 NOVAJET SERIES Replacement Parts List NEM Dm Hie Hi Hesh HeH gt uss leu 15 18
106. 1 7 above and change the numbers to a more acceptable value which will meet the minimum acceptance criteria for Line Quality 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 ENCAD s Technical Support and Service department See Chapter 1 Section 3 0 Press MENU 3 times The display will read NOVAJET SERIES Calibration MAIN MENU UTILITIES 11 Proceed to Section 15 0 NOVAJET SERIES 7 57 Calibration 15 0 Color Calibration Horizontal and Vertical 7 58 Note The Color Calibration should be performed each time the Cartridges are removed or changed This section describes how to check that the cartridges are properly aligned for color plotting amp should be followed each time the ink cartridges are installed 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
107. 18 3 3 Removing the Left Cover 3 22 3 3 1 Preparing the Plotter for Shipment to ENCAD 3 22 3 3 2 Preparing the Plotter for Storage or Transporting 3 25 NOVAJET SERIES Table of Contents CHAPTER4 MAINTENANCE 1 0 2 0 3 0 4 0 5 0 6 0 7 0 Maintenance of Unit Slide Shaft Service Station Encoder Strip Cartridges Ink Delivery System and Rollers DE 4 1 ExIamal stehe e oni 4 2 Slide Shaft Maintenance t ero e qund o aparte qo asd 4 3 Service Station 00224 0 00 00 4 5 Encoder Strip vaca atic 4 7 Ink Delivery System Maintenance 2 4 8 6 1 Cleaning the 4 8 6 1 1 Flex Contact AO onore nipote 4 8 6 1 2 tad A in eM 4 8 6 2 Extended Periods of 4 11 6 3 Ink Reservoirs and Delivery 4 12 Upper and EoWelHOlIBES d tenere iret ine dixe teras 4 13 NOVAJET SERIES Table of Contents CHAPTER5 TROUBLESHOOTING 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 xii Chart of p
108. 2 2 Cartridge is connected and and 2 4 and make sure the Tube Fitting is connected the Tubing Clamp is opened tightly enough but do not overtighten you will see an air bubble Did you use the 20 ml Squeeze Bottle and put the initial move up into the Ink Delivery 20 of ink into the Cartridge before attaching it to the Line Ink Delivery Line If not close the Tubing Clamp remove and disconnect the Cartridge and follow the instructions in Chapter 3 Sections 2 2 2 3 and 2 4 If the Cartridge is held upside down after it has been primed with the Suction Bulb air can go up into the tubing It is also possible that not enough ink was drawn during the priming of the Ink Delivery Line Close the Tubing Clamp remove and disconnect the Cartridge and follow the instructions in Chapter 3 Sections 2 2 and 2 4 for priming the Ink Delivery Line and installing and priming the Cartridge If Steps 1 2 and 3 do not work there may be a leak in the weld joint which joins the body of the Cartridge and the Cartridge s lid Replace the Cartridge If replacing the Cartridge does not correct the situation there may be a leak in the Tube Fitting which connects to the Cartridge Replace the Tubing Chain Assembly See Chapter 6 Sections 7 14 and 7 15 for the replacement procedure 10 Cartridge discharges a large 1 There is too much air in either the Ink Delivery Line or in amount of ink the Cartridge Use the Priming Pump to reestablish the
109. 5 MEMO consi aL 2 9 Su Ekldstt EEPROM 2 10 38 DRAM 2 11 3 9 Seral EEPROM 2 11 ea step EOP EPO 2 12 9H O15 1 MOto Nm evn ere 2 13 3 12 SEVO REPE 2 15 3 13 Parattel and Seral Ports e e t n eaa e aded 2 16 3 14 Keypad Display m 2 17 3 15 Carriage Assembly 2 2 18 3 16 LEDS Beeper atid Patr uuo eo roe eoe eon e eod ee eor ns 2 19 3 17 Dot Firing Sequence osse eiit efiam fatta pi me c c eo n 2 19 3 18 Schematic x bea aa 2 19 2 20 NOVAJET SERIES Theory of Operation FIGURES Figure 2 1 Major Functional Areas of the 2 2 2 2 2 5 Figure 2 2 Gate AMY 2 12 Figure 2 3 Stepper Motor 2 14 Figure 2 4 Servo Motor s d ede edd 2 15 Figure 2 5 Parallel and Serial Potts oet be bere 2 16 Figure 2 6 Keypad ae o eai eaa i 2 17 Figure 2 7 Carriage Assembly Circuits 2 18 NOVAJET SERIES 2 21 Chapter 3 INK DELIVERY SYSTEM 1 0 Introduction Section 1 0 of this chapter contains information which applies to
110. 6 9 0 7 28 10 0 Paper Skew 7 31 10 1 Paper Skew Adjustment 7 32 10 2 Mounting Screw Information 7 33 10 3 Other Functional Requirements 80 7 36 10 4 Adjustment of Upper Roller 7 37 10 4 1 Visual Velit aloes tet botte 7 37 10 4 2 Observation of Paper Skew at Rear Media Alignment Mark 7 38 10 4 3 Observation of Paper Skew at Front Media Alignment Mark 7 40 10 4 4 Adjustment of the Mounting 5 7 41 10 5 Minimum Pull Force 7 42 11 0 Setting ING Print MOUG ete ae at ente Rr ede 7 43 o uie dee 7 45 TO AY 7 47 13 1 Calibrating the Y Axis Carriage Axis or Horizontal Axis Calibration 7 48 13 2 Calibrating the X Axis Paper Axis or Vertical Axis Calibration 7 50 NOVAJET SERIES 7 69 Calibration 14 0 Deadband 7 51 14 1 Slow Deadband lt RR Uo nx uA HR Uo n Rc ANS
111. 7 52 14 2 Fast Deadband Height 7 54 14 2 1 Adjusting Fast Deadband Vertical Lines and Vertical Lines One 7 55 15 0 Color Calibration Horizontal and 7 58 15 1 Adjusting the Horizontal Head to Head Calibration 7 61 15 2 Adjusting the Vertical Head to Head Calibration 7 62 16 0 Color Deadband Calibration iii ia tn rra aaa 7 63 16 1 Color Deadband 7 64 17 0 Line Quality Plot Computer Tesla rr reo e Rr EHE 7 65 18 0 Production Gold Standard Computer 7 67 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Upper Roller Supports Numbering 7 14 Center and Left Positions for Slide Shaft Profile Adjustment 7 18 Paper Sensor Voltage 7 28 Upper Roller Support and Mounting 7 33 Correct Positioning of the Spring in the Upper Roller Support 7 35 Figure 7 6 Test for Minimum Acceptable 7 36 Figure 7 7 Visual Verification of Gap between Roller and Y Arm 7 37 Figure 7 8 Pa
112. AGENTA DB X 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 X CURRENT VALUE FOR CYAN DB X CYAN DB 5 Press SELECT and the UP ARROW or DOWN ARROW to change the value Press SELECT to save the new value 6 Press MENU The display will read 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 adjustment again with another value until you have selected the Color Deadband values which achieve the best results Proceed to Section 17 0 7 64 NOVAJET SERIES Calibration 17 0 Line Quality Plot Computer Test The purpose of this test is to examine the quality of the lines and circles produced Bi Directional when the NJPTEST PLT is plotted To obtain this file see Section 4 0 of this chapter if you do not already have this file Whenever the Line Quality Plot Test is performed the plotters Print Mode must be set to DRAFT The NJPTEST PLT file will automatically set the plotter to DRAFT mode for you 1 Unless one is already in place install a Cutter in the Carriage Assembly 2 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 3 T
113. APER PAPER m an 0 00 RIGHT PAPER S ACCEPTANCE RANGE ONE LINE ONE LINE WIDTH THE WIDTH OF THE MEDIA ALIGNMENT Figure Chapter 7 9 Paper Skew Acceptance Range for Front Media Alignment 7 40 Mark If the criteria in Sections 10 4 2 and 10 4 3 is not met adjust the rollers according to Section 10 4 4 until the criteria is met If the criteria is met for Rollers 8 7 and 6 adjust Rollers 5 and 4 beginning with Section 10 4 1 After Rollers 5 and 4 are adjusted adjust Rollers 3 2 and 1 beginning with Section 10 4 1 Once all rollers are adjusted proceed to Section 10 5 NOVAJET SERIES Calibration 10 4 4 Adjustment of the Mounting Screws Figure Chapter 7 10 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 Note Pay attention to the orientation in Figure Chapter 7 10 IF ROL
114. Assembly In case the labels are missing the proper left to right sequence when facing the front of the plotter is Yellow Magenta Cyan and Black Replace the lid on the 500 ml ink bottle with the Pouring Spout Lid and insert the Pouring Spout Tube into the Pouring Spout Lid Be sure the cutout on the pouring tube is fully contained under the grommet in the lid Figure Chapter 3 2 and Figure Chapter 3 3 The Ink Reservoir holds about 470 ml of ink therefore you will have ink left in the 500 ml ink bottle after filling the Ink Reservoir Pour the ink Figure Chapter 3 4 Item 2 into the Ink Reservoir and stop when the ink reaches the top of the front of the Reservoir Figure Chapter 3 4 Item 3 Do not overfill the Ink Reservoir Place the rubber cap back on the Pouring Spout Tube Place the rubber cap back on the Ink Reservoir Repeat these steps until all the Ink Reservoirs are full Be sure to have only one Ink Reservoir uncapped at a time Proceed to Section 2 2 POURING SPOUT TUBE 20 ML SQUEEZE BOTTLE POURING SPOUT LID 4 1 CARTRIDGE Figure Chapter 3 2 ACCESSORY NOVAJET SERIES Ink Delivery System Figure Chapter 3 3 Assembled Pouring Spout Tube and Lid D RESERVOIR TO BE
115. Chapter 3 5 Closing and Opening Tubing Clamps NOVAJET SERIES NOVAJET SERIES Ink Delivery System Prime each Ink Delivery Line to establish an ink siphon before attaching the Cartridges A Priming Pump with a black rubber Priming Attachment is provided for this purpose Unscrew the clear plastic tip from the Priming Pump and replace it with the Priming Attachment Fully close the plunger on the Priming Pump See Figure Chapter 3 6 Step A Insert the needle Figure Chapter 3 6 Step A for the color you want to prime about 3 8 into the small hole in the end of the Priming Attachment Open the Tubing Clamp on the line Figure Chapter 3 6 Step A Slowly open the Priming Pump so that it draws ink through the Ink Delivery Line Figure Chapter 3 6 Step B Watch the line for the flow of ink and for any air bubbles You will need to draw out approximately 8 cc of ink Once you are satisfied that all air bubbles have been removed from the Ink Delivery Line push down on the left side of the Tubing Clamp Figure Chapter 3 6 Step to close the Ink Delivery Line Remove the Ink Delivery Line from the Priming Pump Be careful not to spill ink when you remove the Priming Pump Dispose of the ink in the Priming Pump to prevent contamination of the ink do not put it back into the 500 ml bottle Thoroughly rinse the Priming Pump with distilled water or R O water Reverse Osmosis Proceed to Section 2 3 3 7 Ink
116. Cover and the Right Cover Assembly 3 Remove the Service Station Assembly see Chapter 4 Figure 4 1 4 Compress the back of the Frame Tensioner with your left index finger See Figure Chapter 6 10 5 Use the end of a screwdriver to gently remove the Carriage Belt from the Servo Motor pulley See Figure Chapter 6 11 Figure Chapter 6 10 Compression of Frame Tensioner 6 22 NOVAJET SERIES 5 5 Disassembly Assembly Figure Chapter 6 11 Servo Motor Move the Carriage Belt to the left so it is out of the way of the Servo Motor pulley Move the Carriage Assembly to the far left end of the Slide Shaft Use the tips of two flat blade screwdrivers to pry the Snap Plug out of the bottom right end of the Platen so the Servo Motor can be removed through the bottom of the Platen To obtain access to the back screw on the Servo Motor you will need to lift up the right end of the Trailing Cable Support Assembly Refer to Figure Chapter 6 12 during this part of the procedure a Loosen the Phillips screw on the far left end of the Trailing Cable Support Assembly b Remove the other Phillips screws which hold the Trailing Cable Support Assembly in place NJ 4 D Size remove 2 screws NJ 4 E Size remove 3 screws NJP 36 remove 3 screws NJP 50 remove 4 screws 6 23 Disassembly Assembly Figure Chapter 6 12 Trailing Cable Support Assembly c Gently pull up on the part of the Trailing Cab
117. DICES Procedure for downloading firmware to a NOVAJET PRO Color Inkjet Plotter which has a blank or corrupt Flash EEPROM Emergency Firmware Download A 1 APPENDIX PRINTER FIRMWARE UPGRADE PROCEDURE Procedure for upgrading a NOVAJET PRO Color Inkjet Plotter to the newest version of firmware Flash EEPROM is not blank or corrupt Printer Firmware Upgrade 04 B 1 APPENDIX SCHEMATICS Schematics for the NOVAJET PRO Color Inkjet Plotters Boards Main PCB Assembly Rev A o oo ae oleae bas 9 pages Main PCB Assembly ROVA ox n RE RR REA RIDE 9 pages Keypad PCB Assembly Rev A uice etes be Ee eee 1 page Carriage PCB Assembly Rev 2044 1 page Cartridge Driver Flex Circuit Rev RE eR ret 1 page Paper Sensor Flex Circuit Rev 1 page Paper Sensor Flex Circuit Rev 1 page Xx NOVAJET SERIES Table of Contents FIGURES CHAPTER 1 GENERAL INFORMATION Number Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Title Page Front View of 4 1 12 Back View of NOVAJET PHO e RR RR 1 13 Line Length rio TC 1 15 Siu 1 16 2 THEORY OF OPERATION Number Figure 2 1 Figure 2 2 Figure 2 3 F
118. EEPROM stores calibration and configuration information It retains data while the unit is off NOVAJET SERIES 2 11 Theory of Operation 3 10 Gate Array PARA STATIC RAM LLEL GATE ARRAY SERVO MOTOR CARRIAGE PCB ENCODER STRIP Figure Chapter 2 2 Gate Array The gate array contains the hardware logic for dot firing monitoring changes in the Carriage Assembly 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 NOVAJET SERIES 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 width of the plotter The media in the plotter can advance forward and backward depending upon the commands which the Stepper Motor receives from th
119. ENCAD Inc m A Kodak Company NJ PRO 36 NJ PRO 50 NJ 4 Service Manual Copyright 1995 and 1996 ENCADe rights reserved ENCAD NOVAJET registered trademarks of ENCAD Inc 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 NOVAJET SERIES FCC Statement U S A The United States Federal Communications Commission has specified that the following notice be brought to the attention of the users of the NOVAJET plotters FEDERAL COMMUNICATIONS COMMISSION RADIO AND TELEVISION INTERFERENCE FOR CLASS B DEVICE This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordan
120. ERIES Troubleshooting 10 0 RAM Error At Initialization a message of RAM HIGH or RAM LOW may appear for one of the following reasons 1 NOVAJET SERIES The most common cause of this message is the incorrect installation of any extra RAM SIMM Refer to the removal and replacement procedures in Chapter 6 Section 4 0 and check the SIMM installation if any extra RAM was installed on the plotter The SIMM may be defective or not compatible with the plotter circuits The SIMM type speed needs to be 70 nanoseconds or faster See the NOVAJET Series User s Guide Appendix B for information concerning the acceptable SIMM sizes and the replacement procedure in Chapter 6 Section 4 0 of this service manual The SIMM socket on the MPCB may be defective In this case replace the MPCB according to the procedure in Chapter 6 Section 4 0 5 25 Troubleshooting 11 0 Operation Problems The information in this section will help to solve a variety of operational problems which may occur with the NOVAJET PRO or NOVAJET 4 plotters Follow the procedures carefully Establish a logical procedure for troubleshooting by referencing the Troubleshooting Chart in Section 2 2 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 Check for voltage coming out of the Power Cable see Appendix C Schematic for MPCB for voltages If there is voltage
121. ES 9 5 Replacement Parts List USED IN DESCRIPTION PART NJ4D NJ4E 36 NJP 50 ASSY STABILIZER BRACKET SERVICE 205439 X ASSY STABILIZER BRACKET SERVICE E SIZE 204699 X ASSY STABILIZER SERVICE D SIZE 205897 X ASSY STEPPER MOTOR BRACKET SVC right bracket w bushing 205350 X X ASSY STEPPER MOTOR SERVICE includes Gear 205128 X X X X ASSY TOP COVER D SIZE 204711 31 X ASSY TOP COVER E SIZE 204711 1 X X ASSY TOP COVER NJP 50 204711 61 X BELT 312 WIDE D SIZE 203037 X BELT 312 WIDE 205340 X BELT 312 WIDE E SIZE 205678 X X BLOCK SUPPORT 205529 X BOX PLOTTER D SIZE 203772 2 X BOX PLOTTER E SIZE 203479 2 X BOX PLOTTER NJ PRO 36 205451 X BOX PLOTTER NJ PRO 50 205876 X BUSHING CARRIAGE 2 203228 X X X X CABLE KEYPAD 203457 X X X CABLE KEYPAD 205111 X CABLE RS422 for firmware transfer only 203977 X X X X CARRIAGE BOARD 204562 X X X X CASTER LOCKING TWIN 202513 X X X X CASTER NON LOCKING TWIN 202512 X CORD POWER BLACK 8 FT 205757 X DISK NJ PRO DOS UTILITY ENCAD 205458 X DISK UTILITY 205772 X X DISK WINDOWS 205771 X X DISK WINDOWS DRIVER ENCAD 203957 3 X EXHAUST 204976 X FOAM BLOCK LOWER 204982 X X FOAM BOTTOM LEFT 203480 1 X X FOAM BOTTOM LEFT 205452 X X FOAM BOTTOM RIGHT 203481 1 X X FOAM BOTTOM RIGHT 205523 X X FOAM TOP LEFT 203788 1 X X FOAM TOP LEFT 205453 X X FOAM TOP RIGHT 203789 1 X X X X FRAME TENSIONER 203870 1 X X X X KEYPAD BOTTOM 20344
122. FETY PRECAUTIONS BEGIN WITH CONDITIONS ASSUMPTIONS 1 RS422 232 ERROR STATUS 2 ONLINE SYSTEM CONNECTION CONDITIONS COLUMN NUMBERS VO ERROR 0 ERROR HAS OCCURRED 1 2 3 4 5 6 7 8 9 10 11 12 13 VO ERROR 11 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 TOO MANY PARAMETERS RECEIVED ADDITIONAL PARAMETERS AFTER THE CORRECT NUMBER ARE IGNORED ARITY AND DATA BITS WRONG HANDSHAKE CHECK THE LOSS OF DATA AND PROBABLY AN HP GL EMULATION ERROR RS422 232 SERIAL XTDA XRDA FAILURE OCCURS ONLY WITH A LOOP BACK CONNECTOR IN TEST 5 8 NOVAJET SERIES 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 ROM revision level is found by scrolling to the following display which is located in the SERVICE INFORMATION level of
123. Fan Assembly 8 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 The Exhaust must be oriented correctly in order to achieve the proper vacuum inside the Platen See Figure Chapter 6 25 9 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 10 Reinsert the Snap Plug s in the bottom of the Platen and turn the Platen onto its bottom side 11 Go to Section 10 5 6 78 NOVAJET SERIES Disassembly Assembly 10 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 4 the Power Cable has a Grounding Braid make sure it is still connected to the inside of the Platen at the same location as the ON OFF Switch Ground See Figure Chapter 6 31 Reinstall the Power Supply See Section 8 2 Steps 1 5 Figure Chapter 6 31 Ground for Left End of Power Cable and ON OFF Switch 5 If applicable reinstall the Left and Right Rollguides 6 Reinstall the Left Side Plate See Section 7 4 Step 1 7 If the Power Cable has a Grounding Braid attach it to the inside of the Right Side Plate ne
124. IAGNOSTICS Menu and run DIAGNOSTICS PAPER SENSOR You will need to replace the Paper Sensor if it is not working properly Refer to the Disassembly Assembly procedures in Chapter 6 Section 7 9 The Cartridge Head Height may be set incorrectly Check the Cartridge Head Height alignment Refer to Chapter 7 Sections 7 0 of this manual for the Cartridge Head Height Adjustment The Paper Sensor voltage may be set incorrectly See Chapter 7 Section 8 0 for the Paper Sensor Adjustment The Trailing Cable may be defective See Chapter 6 Sections 7 5 and 7 6 for the removal and installation procedures NOVAJET SERIES 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 f 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
125. ION SSCS P VERIFY TENSIONER SPRING POSTON 111141 REPLACE FAN ASSEMBLY 1 1 1 1 GO TO DECISION LOGIC TABLE 2 DLT 2 5 4 NOVAJET SERIES Troubleshooting Table Chapter 5 2 Decision Logic Table Two DLT 2 REFERENCES CALIBRATION PROCEDURES USER S GUIDE amp SERVICE MANUAL BEGIN WITH DECISION LOGIC TABLE ONE DLT 1 EXIT TO DECISION LOGIC TABLE THREE DLT 3 ASSUMPTIONS 1 NOVAJET PRO or NOVAJET 4 SERIES PLOTTER 2 POWER ON SEQUENCE OK COLUMN NUMBERS CONDITIONS 2 5 PLOTTER INTERMIT ACTIONS CLEAN AND RESEAT ANY EXTRA SIMM TEST AND REPLACE ANY EXTRA SIMM POWER OFF AND CALL ENCAD TECHNICAL SUPPORT see Chapter 1 Section 3 0 NOVAJET SERIES 5 5 Troubleshooting Table Chapter 5 3 Decision Logic Table Three DLT 3 REFERENCES CALIBRATION PROCEDURES USER S GUIDE amp SERVICE MANUAL ASSUMPTIONS 1 NOVAJET PRO or NOVAJET 4 SERIES PLOTTER 2 ON SEQUENCE COLUMN NUMBERS CONDITIONS 1 2 3 4 5 6 7 8 9110 11 INPUT POWER CONDITIONING USE ROLL FEED SOFTWARE DRIVER 5 RETEST WITH ENCAD SUPPORTED QUALITY MEDIA VERIFY PRIME amp REPLACE CARTRIDGE AS REQUIRED CARRIAGE HEIGHT ADJUSTMENT CALL ENCAD TECHNICAL SUPPORT see Chapter 1 5 6 NOVAJET SERIES Troubleshooting Section 3 0 NOVAJET SERIES 5 7 Troubleshooting Table Chapter 5 4 Decision Logic Table Four DLT 4 WARNING OBSERVE ALL STANDARD STATIC AND SA
126. IRE NEEDLE NOSE WRENCH ANGLE WRENCH CUTTERS PLIERS WEEZERS X ACTO KNIFE ESD WRIST STRAP REAMER SCRIBER Figure Chapter 6 1 Recommended Tools NOVAJET SERIES 6 5 Disassembly Assembly If you need to ship a plotter to ENCAD for replacement or 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 extra SIMM that has been installed Label all hardware and parts for ease of reassembly It is not necessary to ship the following When returning a plotter to ENCAD for servicing remove e Left Cover Assembly with Ink Reservoirs NOVAJET PRO only or Cartridges Stand Basket or Feeder Takeup Mechanism hardware 3 1 Removing the Plotter from the Stand 1 Disconnect the power cord and interface cables 2 Lock both of the stand s locking casters 3 Remove any extra SIMM that has been installed See Section 4 5 1 Extra Memory SIMM Removal in this chapter 4 NOVAJET PRO Unload the Ink Delivery System and remove the Left Cover Assembly according to the directions given Chapter 3 Section 3 0 NOVAJET 4 Remove Cartridges from the Carriage Assembly If they will not be used in a replacement plotter right away store them according to the directions in Chapter 4 Section 6 2 Move the Carriage Assembly out of the Service Station Re
127. LER MOVES IF R ER MOVES THE RIGHT LEFT AND TOUCHES AND UCHES ea N GAP IRIENTATIUN STANDING BEHIND THE PLOTTER B PA FACING THE BACK OF THE PLOTTER TIGHTEN THE HEN TIGHTEN THE LEFT MOUNTING SCREW RIGHT MOUNTING SCREW 172 TURN AT A TIME 1 8 TURN AT A TIME Figure Chapter 7 10 Motion of Rollers and Adjustment of Mounting Screws NOTE After the mounting screw has been tightened to the maximum torque of 3 in Lbs 0 5 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 10 4 1 After Rollers 5 and 4 are adjusted adjust Rollers 3 2 and 1 beginning with Section 10 4 1 Once all rollers are adjusted proceed to Section 10 5 NOVAJET SERIES 7 41 Calibration 10 5 Minimum Pull Force Verification This test determines whether the pinch force between the Upper Rollers and Lower Rollers is correct You will need e Fixture Feeler Gauge 0 0015 thick 1 Holding the 0 0015 thick Feeler Gauge Fixture at the marker line insert its front edge between the Upper Roller and the Lower Roller Do not insert the Feeler Gauge from the sides of the rollers 2 If the gauge does not penetrate between the rollers but instead buckles the pinch force is correct for that Upper Rolle
128. Lines NOTE Note 1 This procedure should be performed the following situations only a when you are preparing the plotter for shipment or storage if you are replacing the Trailing Cable Support Bracket which contains the Ink Delivery Lines and the Chain or c you are doing other repair work on the plotter which requires the removal of the Left Cover Assembly Draining the lines will avoid the possibility of ink spills if a Tubing Clamp is inadvertently opened during the repairs 2 You will need someone to assist you with this procedure 1 You should already have removed all four Cartridges before beginning this section If you have not see Section 3 1 2 Remove the Top Cover by sliding the Retracting Stop on the left end of the Top Cover to the right until it comes out of the Left Cover Assembly The Retracting Stop and spring will come out of the Top Cover if the left end is tipped down so be careful not to lose them 3 Make sure the Tubing Clamps on the Ink Delivery Lines are closed so that no ink comes out Refer to Figure Chapter 3 5 4 Disconnect the Ink Delivery Lines from the back of the Ink Reservoirs one at a time There is a shiny metal plate facing downward on the connector Reach through the opening in the back of the Left Cover Assembly and press up on the metal plate to release the connector from the Ink Reservoir See Figure Chapter 3 12 Wipe off any drops of ink that are in the end of
129. MWARE ver 1 51 for CADJET area where ean download a file 4 lImportant README TXT for FIRMWARE 1 5 Press ENTER until 5 NEW ADI DRIVERS 1 7 RELEASED you get to the screen at the left When 6 INTERNET EMAIL ADDRESS FOR SYSOP there press N and the ENTER key Bulletins updated ALL NOVAJET SERIES 7 7 Calibration Enter bulletin 1 6 R elist menu NJew D ownload Qluit Steve your quote for today is 7 8 5 5 Calibration Press ENTER until the ENCAD Main Menu shown below is displayed Join Conference p We Hho s Online Your Settings Doors System Stats Questionnaires Initial Helcome Command Help Page Online User Conference CAD Questions Time Left 997 Time On Herna Command gt gt You want to download a file so press and then press ENTER The File Access Menu will be displayed Quit Main S Join A Conf Hezzage Menu Help Leusl M Hew Files Since Personal Stats Command Help D Download Files Info On File Upload Files Wiew A Zip File Search Files i Edit Hark List O Read Text File 1 Sysop Menu Transfer Info Conference CAD Questions Time Left 996 Time On 2 File Menu Command gt gt Now you are almost at the point of being able to download files You should see the File Menu on your screen similar to the one shown above To display a listing of avail
130. Maintenance Wipers may affect the print quality For optimum print quality nore Note 1 Ink and dust accumulation on the Service Station s Seals and the Seals and Wipers should be cleaned once a week We also recommend that you replace the Wipers periodically all four at the same time High volume users plotter is in use 5 or more hours per day should change the Wipers every 3 to 4 months Low volume users plotter is in use less than 5 hours per day should change them every 6 months To change the Wipers 1 2 Remove the Wipers by pulling straight up on them When you install the new Wipers push them as far down on the post as possible so they touch the surface of the sled This is necessary for proper wiping of the Cartridges To clean the Service Station 1 Turn off the plotter and raise the Top Cover Move the Carriage Assembly away from the Service Station area Remove the Service Station by moving the latch on the right end of the Service Station to the left until it releases See Figure Chapter 4 1 Rinse the entire Service Station under warm water You may need to use a cotton swab to remove any buildup from the Seals or Wipers Use a dry lint free cloth to dry the outside of the Service Station Remove all moisture from the seals and the wiper with a dry cotton swab Reinstall the Service Station Insert the left side of it into the Platen first and push down on the right side of it u
131. NOVAJET PRO the Ink Delivery Lines will not need to be drained You must remove the Plotter from the Stand to access all of the screws on the bottom of the Platen which hold the Power Supply in place You will need to put it on foam blocks 1 NOVAJET 4 only Remove the Top Cover Left Cover Assembly and Left Side Plate See Section 7 1 of this chapter NOVAJET PRO only a Close the Tubing Clamps on all the Ink Delivery Lines b Disconnect the Ink Delivery Lines from the Ink Reservoirs See Chapter 3 Section 3 2 Step 4 if necessary c Remove the Top Cover Left Cover Assembly with the Ink Reservoirs and the Left Side Plate See Chapter 3 Section 3 3 1 Steps 2 4 and Section 7 1 of this chapter 2 Remove the Plotter from the Stand See Section 3 1 Steps 1 2 16 and 17 if necessary Place the Plotter on foam blocks on a stable work surface 3 Using a 2 Phillips screwdriver remove the 4 screws near the bottom left end of the Platen which hold the Power Supply in place NOVAJET SERIES 6 57 Disassembly Assembly 4 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 5 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 6 If the ON OFF Switch needs to be replaced push the top of the sw
132. NOVAJET SERIES Disassembly Assembly 7 7 Removing the Carriage Belt from Carriage Assembly 6 43 7 8 Installing the Carriage Belt on Carriage Assembly 6 45 7 9 Removing the Carriage PB iti roe 6 46 7 10 Installing the Carriage 6 47 7 11 Removing the Paper Sensor or the Encoder 6 48 7 12 Installing the Paper Sensor or the Encoder 6 50 7 13 Replacing the Carriage esu Rr EUR 6 52 7 14 Removing the Tubing Chain Assembly 2 6 54 7 15 Installing the Tubing Chain 6 56 8 0 Power Supply and ON OFF Switch 2 4 4 6 57 8 1 Removing the Power Supply and ON OFF 6 57 8 2 Installing the Power Supply and ON OFF 6 59 9 0 Stabilizer Bracket and Encoder 6 60 9 1 Removing the Stabilizer 6 61 9 2 Reinstalling the Stabilizer 6 62 10 0 Lower Drive Assembly Fan Assembly and Stepper Motor Assembly Inner Plate Parts iii baro Au ee Soh etre tee va uU leet 6 64 10 1 Disassembl
133. PRO Tubing Chain Assembl 7 1 Removing the Left Cover Assembly and Left Side Plate 1 NOVAJET PRO only Follow the procedures in Chapter 3 Section 3 0 for unloading the Ink Delivery System and removing the Left Cover Assembly You need to remove the Cartridges and drain the Ink Delivery Lines but you do not need to empty the Ink Reservoirs NOVAJET 4 only Remove the Cartridges and blot the jet area of each Cartridge with a lint free cloth that has been moistened with distilled or R O Reverse Osmosis water to remove any ink If it is available place the blue tape over the jet area do not substitute any other type of tape it may damage the jets Place the Cartridges in sealed plastic bags until you are ready to reinstall them 2 After the Left Cover Assembly has been removed use a 2 8 Phillips screwdriver to remove the 4 screws on the outside of the Left Side Plate Do not remove the bottom middle screw It does not hold the Left Side Plate on the Platen 6 30 NOVAJET SERIES Disassembly Assembly 7 2 Removing the Carriage Assembly NOTE Note 1 NOVAJET PRO only Remove the Top Cover remove the Cartridges drain the Ink Delivery Lines remove the Left Cover Assembly and remove the Left Side Plate before removing the Carriage Assembly See Section 7 1 of this chapter NOVAJET 4 only Remove the Top Cover remove the Cartridges remove the Left Cover Assembly and remove the Left Side Plate before removing the
134. PRO only Prior to removing the Plotter from the Stand the Left Cover Assembly with the Ink Reservoirs must be removed so that ink does not spill into the Plotter or onto other surfaces See Chapter 3 Section 3 0 NOVAJET SERIES 6 3 Disassembly Assembly 2 0 Tools and Eguipment Required Figure Chapter 6 1 illustrates the following tools which are recommended to disassemble and reassemble the plotters Torque Screwdriver 1 B6 Special Phillips Bit 1 Phillips Screwdriver 2 Phillips Screwdriver 2 Stub Phillips Screwdriver 1 8 x 6 Slotted Screwdriver 1 4 x 6 Slotted Screwdriver 11 32 Magnetized Nut Driver 5 16 Hex Nut Driver 7 64 Hex Nut Driver 1 4 Open End Wrench 1 4 Open Box End Angle Wrench Wire Cutters Needle Nose Pliers Angled Flat Reamer Straight Fork Tip Machinist Scriber Tweezers X ACTO Knife ESD Wrist Strap Machinist Scriber should have one straight point and one 90 bent point The following materials also are required Isopropyl Alcohol Q Tips Lint Free Cloth Double Sided Tape 1 16 thick 3 4 wide Loctite Blackmax Loctite 222 A Hardware Kit is available for each plotter See Chapter 9 of this manual for the part number 6 4 NOVAJET SERIES Disassembly Assembly TORQUE 6 SLOTTED WDRIVER 11 32 MAGNE TIZED NUTDRIVER 5 16 amp 7 64 NUTDRIVER ALSO NEEDED n 1 I 1 4 OPEN END 1 4 OPEN BUX END W
135. PTIONS ADVANCED in order to perform this calibration The purpose of the Color Deadband Calibration is to adjust the color cartridges so that they print the straightest lines possible 1 Beginning from this display UTILITIES CALIBRATION Press the UP ARROW twice The display will read UTILITIES MANUFACTURING 2 Press SELECT and the DOWN ARROW The display will read MANUFACTURING COLOR DB 3 Press SELECT The display will read X CURRENT VALUE FOR YELLOW DB X YELLOW DB 4 The plotter will begin printing one row of four 1 2 vertical lines black cyan magenta and yellow 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 5 Ifthe Color Deadband is acceptable proceed to Section 17 0 If it is not acceptable perform the Color Deadband Adjustment in Section 16 1 NOVAJET SERIES 7 63 Calibration 16 1 Color Deadband Adjustment When adjusting the Color Deadband 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 X CURRENT VALUE FOR YELLOW DB X 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 X CURRENT VALUE FOR M
136. SERIES 8 5 Power Media Feed Take Up System 5 The installation is correct if all the tests below work properly refer to Figure Chapter 8 6 as needed a 8 6 Plug the power cord into the Power Cord Jack and then into an outlet Set the Print Cut switch above the Power Cord Jack to Print Stand so that you have a right side view of the printer and turn on the Power Media Feed and Take Up System s power When the system is turned on the following should occur 1 The Feeder Roll Holder should turn counterclockwise right side view for about 8 seconds and then stop 2 The lights on both sensors should be on 3 The Take Up Roll Holder should not turn If it does turn see Step 5 g below and Figure Chapter 8 5 Press the Forward Backward switch on top of the Drive Plate s Supply Side to make sure that the motor is working Press the Forward Backward switch on top of the Drive Plate s Take Up Side to make sure that the motor is working Check that the Feeder Sensor is working properly by blocking the sensor s beam with your hand and then removing your hand The feeder motor should start turning once your hand is removed and stop after about 8 seconds Media must not be loaded for this test to work properly Check that the Take Up Sensor is working properly by blocking the sensors beam with your hand The take up motor should start turning and stop after removing your hand If it does not make s
137. SHAFT middle support SUPPORT SHAFT BOX PLOTTER D SIZE FOAM TOP LEFT FOAM TOP RIGHT ROLL SUPPORT FRAME TENSIONER DISK WINDOWS DRIVER ENCAD CABLE RS422 SPRING COMPRESSION IDLER STOP RETRACTING PAPER SENSOR W FLEX CARRIAGE BOARD KKK KK KOK KKK KK KK ON OFF SWITCH POWER ENTRY MODULE ASSY SERVICE STATION ASSY CABLE SUPPORT SERVICE E SIZE ASSY CABLE TRAILING with bend in cable ASSY ROLLGUIDE LEFT ASSY STABILIZER BRACKET SERVICE E ASSY TOP COVER E SIZE ASSY TOP COVER D SIZE ASSY TOP COVER 50 X lt X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X NOVAJET SERIES Replacement Parts List USED IN PART DESCRIPTION 40 NJ4E NJP 36 NJP 50 204731 SEAL 4 X 204732 WIPER 4 X 204740 SIDEPLATE LEFT X X X 204760 SUPPORT SHAFT X 204763 SPRING EXT SERVICE STATION BOTTOM X 204773 ASSY PINCH ROLLER quantity needed 5 8 8 9 204774 SLIDE SHAFT X X 204849 POWER SUPPLY 24V DC X 204849 1 POWER SUPPLY 24V DC X X X 204898 SIDEPLATE RIGHT X X X X 204903 ASSY CABLE TRAILING with bend in cable X 204906 PLATEN MACHINED X 204916 ASSY BRACKET DRIVE SHAFT left bracket w bushing 204917 1 ASSY LOWER DRIVE SHAFT W GEAR X 204917 31 ASSY LOWER DRIVE SHAFT W GEAR D X 204929 61 ASSY CABLE OUTPUT
138. 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 During Step 10 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 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 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 10 3 below if the Stepper Motor Assembly needs to be removed Otherwise go to Section 10 4 NOVAJET SERIES 6 71 Disassembly Assembly 10 3 Stepper Motor 10 3 1 Removing the Stepper Motor 6 72 If the Stepper Motor needs to be replaced all of the steps from the beginning of Section 10 0 including all subsections must be performed If removing only the Stepper Motor do not remove the Wave
139. Supply Side OG NiO Switch SP3T Supply Side NOVAJET SERIES 8 9 Power Media Feed Take Up System Figure Chapter 8 7 Power Supply 24V DC P N 204849 8 10 NOVAJET SERIES Power Media Feed Take Up System Chapter 8 POWER MEDIA FEED AND TAKE UP SYSTEM 8 1 re eS ee ee 8 1 2 0 Power Media Feed and Take Up System Installation 8 2 2 1 Installation Procedure eet det oed 8 2 2 2 Usage of Media 2 8 8 p HH HC Ip 8 9 TABLES FIGURES Figure 8 1 NJP 50 with Power Feed and Take Up 8 1 FlIgure8 2 Idler Side 8 2 Figure 8 3 Installation of Drive Plate 8 3 Figure 8 4 Installing Rails and Adjustable Roll 8 4 Figure 8 5 Mounting Take Up 020 8 5 Figure 8 6 Fully Assembled Power Media Feed and Take Up System 8 7 Figure 8 7 Power Supply 24V DC P N 204849 8 10 NOVAJET SERIES 8 11 9 REPLACEMENT PARTS LIST 1 0 Introduction This chapter lists the names part numbers for field replaceable parts and ass
140. T PART 3 AFTER CARTRIDGE HEIGHT ADJUSTMENT LEFT CENTER RIGHT NOTE ALL VALUES MUST BE BETWEEN 062 AND 068 PAPER SENSOR VOLTAGE aca NOTE VALUE MUST BE BETWEEN 1 45 TO 1 55 VOLTS DEADBAND VALU BLACK SLOW DEADBAND VALUE DEADBAND FAST VALUE Figure Chapter 7 14 NOVAJET PRO Calibration Worksheet 7 68 NOVAJET SERIES Calibration Chapter 7 CALIBRATION 7 1 TOI sudore Pluie DURUM 7 1 2 0 Required Supplies and Tools A ee 7 2 3 0 Required Documentation and 7 4 4 0 Downloading Files From the 5 7 5 4 1 BBS OG OM Procedure a eem e n p 7 5 4 2 Using the Downloaded Files NJPRO101 EXE and NJPTEST EXE 7 12 5 0 Numbering Sequence of Upper Roller Supports 7 14 6 0 Slide Shaft Profile Adjustment eai eh 7 15 7 0 Cartridge Head Height 00 1 7 20 7 1 Initial Adjustment 7 21 7 2 Fine Adjustment and TOL alie uic e ee a ee 7 22 Fos Encoder SIND cena eq ete creatus 7 25 7 4 Frame Tensioner and Carriage Belt Position 7 25 7 5 Trailing Cable Strain Relief Check 7 25 0 aot dus 7 2
141. Washer Washer and Retaining Ring which are between the end of the Lower Drive Assembly and the Stepper Motor Bracket See Figure Chapter 6 29 Do not remove the 20 Teeth Gear from the Stepper Motor See Figure Chapter 6 29 Do not remove the Bushing from the Stepper Motor Bracket If it should happen to fall out press it back in as far as it will go Do not clean the Oilite Bushing with alcohol Wipe it with a clean lint free dry cloth only See Figure Chapter 6 29 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 6 29 Unscrew the Retainer Spring Post from the Spring Post and remove them from the Stepper Motor Bracket and Stepper Motor Assembly Unscrew the Pivot Screw and Pivot Nut and remove them from the Stepper Motor Bracket and Stepper Motor Assembly Remove the Stepper Motor from the end of the Lower Drive Assembly If you are replacing the Stepper Motor Bracket you will need to remove the Retaining Ring Washer and Wave Washer which are between the end of the Lower Drive Assembly and the Stepper Motor Bracket NOVAJET SERIES Disassembly Assembly Figure Chapter 6 29 Lower Drive Assembly and Stepper Motor Assembly NOVAJET SERIES 6 73 Disassembly Assembly 10 3 2 Reinstalling the Stepper Motor 6 74 If the Oilite Bushing c
142. X XX XX Current time and date settings in use TIME XX XX XX ROM REVISION Shows the plotter model and the plotters current NovaJet PRO 1 00 Revision Level RELEASE INFO Shows the release date of the current firmware REV 1 00 ROM TOTAL MEMORY Shows the number of bytes available XXXXXXXX BYTES MEMORY CONFIG Shows buffer memory bank and raster memory JO 128K RAS 3M available EMULATE LANGUAGE Shows the Emulation Language in use HPGL2 NOVAJET Series plotters are programmed for HP GL and HP GL 2 NOVAJET SERIES 5 11 Troubleshooting EVEN 7BITS PRINT DIRECTION 0 2 U 2 o U ow gt gt gt 8 gt xz 22 DZ 2 ec 5 gt gt zo lt E gt mx m m m PRINT COLOR COLOR cim Sz 5 A 4 5 12 Shows the number of bits per second that are transmitted or received Reports communications failure Allows time for processing hardwire communication f 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 Shows draft normal quality or enhanced line resolution Shows choice of bi directional or uni directional jet firing Shows the method of printing including dots per inch Options are MONO 300X300 GRAY 300X300 COLOR 300X300 MONO and GRAY are available using 1 cartridge only you cannot use 4 cartridges to do MONO and GRAY Shows th
143. Y for the actions to be taken Look down column 7 for the number 1 ACTION for the row containing the number 1 in column7 is CHECK STEPPER MOTOR CONNECTOR JP5 This is the first action which should be performed to correct the condition of the media not loading 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 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 NOVAJET SERIES 5 3 Troubleshooting Table Chapter 5 1 Decision Logic Table One DLT 1 WARNING OBSERVE ALL STANDARD STATIC AND SAFETY PRECAUTIONS REFERENCES CALIBRATION PROCEDURES USER S GUIDE amp SERVICE MANUAL BEGIN WITH ASSUMPTIONS LISTED BELOW EXIT TO THE DECISION LOGIC TABLE INDICATED AT THE END OF THIS TABLE ASSUMPTIONS 1 NOVAJET PRO or NOVAJET 4 SERIES PLOTTER 2 INPUT POWER 5 DOESDISPLAVCOMEON DOESMEMORYCOUNTUP oO o v DOES EPROM REVISION DISPLAY VERIFYBELTPOSIT
144. a in the buffer RAM transfers to the Carriage Assembly electronics and the appropriate jets fire The gate array initiates the DMA transfer of the data for the next firing position Steps 3 to 5 repeat until the entire swath 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 Cartridge Driver Flex Circuit and Paper Sensor Flex Circuit are located in Appendix C NOVAJET SERIES 2 19 Theory of Operation Chapter 2 THEORY OF OPERATION 2 1 2 1 2 0 Mechanical Operation 2 2 2 1 Paper Media Axis 2 2 2 2 Carmage 2 2 2 0 2 lt tee t mtt ot 2 3 3 1 Circuit Assemblies 5 2 3 3 1 1 Main Printed Circuit Board 2 3 31 2 Front Patel ioo ehe 2 3 3 1 3 Carriage Printed Circuit Assembly Carriage 2 4 9 2 estables cett ifo an 2 5 3 3 Power SUPPly cou 2 6 SE MIGIODIOGOSSOF uaa x ea Sato bcd 2 7 3 5 9arteup SedgueliGe te o eiie EE EN 2 8 9
145. able files on the screen press L and then press ENTER again and files will be listed from all possible downloadable areas NOVAJET SERIES 7 9 Calibration 1 ACAD12 EXE 1 158 243 09 07 94 HPGL 2 and RTL print drivers for Keep pressing ENTER until the file you want to download is shown on the screen When you see the file you want type in M and press ENTER You will be asked to enter the number of the file you want the computer to mark Example You want the file BARB DWG Press ENTER 6 and ENTER again Press ENTER until you have marked all the files you want to download When you have found all of the files you want to download press D and ENTER This starts the download process Go into your modem software package and tell it to start the download process from your end You should see a progress bar during download with an estimate on how long the download should take 7 10 NOVAJET SERIES Quit Main 1 Jain A Conf Message Henu Help Level Personal Stats Command Help On A File Goodbye logoff edre rTes File Bead Text File Sysop Menu Conference CAD Questions Time Left 996 Time On 2 File Menu Command gt gt List Files Hew Files Since Download Files Upload Fi bes Edit Hark List Tranzfer Info You are now done You have downloaded the files you wanted Now press and ENTER NOVAJET SERIES
146. able onto the two tapes on the Trailing Cable Support Assembly There must not be any kinks or bends in the Trailing Cable when it is installed on the Trailing Cable Support Assembly and it must be lined up even with the front edge of the Trailing Cable Support Assembly NOVAJET SERIES 6 41 Disassembly Assembly 6 42 10 11 Route the right end of the Trailing Cable through the slot in the Right Side Plate see Figure Chapter 6 32 and connect the Trailing Cable connector at the JP3 location on the MPCB see Figure Chapter 6 5 Be sure to slide both sides of the connector lock shut at the same time Reattach the Right Cover Assembly If the Carriage Assembly was removed from the Slide Shaft go to Section 7 3 Steps 1 and 2 See Section 7 3 Steps 3 7 for instructions for routing the Trailing Cable through the Strain Relief and connecting it to J5 on the Carriage Assembly After the Trailing Cable has been installed on the Carriage Assembly it is very important that you check to make sure that there is clearance between the edges of the Trailing Cable and the side walls of the Strain Relief It must not rub against the side walls Slide the Carriage Assembly back and forth several times to make sure that the Carriage Assembly travels the full length of the Slide Shaft See Section 7 3 Steps 8 10 for instructions for attaching the Electronics Cover to the Carriage Assembly If the Carriage Assembly was removed go t
147. across the motor winding in order to make the actual current match the reference waveform 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 F CURRENT m STEPPER DRIVER SENSE MOTOR Figure Chapter 2 3 Stepper Motor NOVAJET SERIES Theory of Operation 3 12 Servo Motor MOTOR SERVO gt SERVO CARRIAGE aem DRIVER Ec CONNECTOR MOTOR 2 ENCODER ARRAY CARRIAGE K Figure Chapter 2 4 Servo Motor The Carriage Assembly is driven by the Servo Motor The speed of the Carriage Assembly is controlled by varying the duty cycle of the power applied to the controller The microprocessor checks the position of the Carriage Assembly approximately 1 000 times per second during the servo interrupt It then updates the PWM pulse width modulator register in the gate array which sets the duty cycle to make adjustments to the Carriage Assembly speed A linear optical encoder is used to monitor the Carriage Assembly position The optical codestrip runs the length of the Stabilizer Bracket 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
148. ad Calibration also serve as the alignment values for the Color Vertical Head to Head Calibration Three rows of small black boxes will be printed Each box has three short lines on each of its ends The Cyan Cartridge will print three short lines across the width of each box in the first row of boxes The Magenta and Yellow Cartridges will do the same in the other two rows of boxes Look at the Current Heads printout If the colored plus signs each line up horizontally and vertically with the black alignment marks no adjustment is required Proceed to Section 16 0 If the horizontal marks do not line up satisfactorily adjustment is required for Horizontal Head to Head Calibration Proceed to Section 15 1 If the vertical marks do not line up satisfactorily adjustment is required for Vertical Head to Head Calibration Proceed to Section 15 2 NOVAJET SERIES Calibration 15 1 Adjusting the Horizontal Head to Head Calibration 1 NOVAJET SERIES With the display set at CALIBRATION X current alignment value HORIZ YELLOW X press SELECT and then the UP ARROW or DOWN ARROW to select the alignment value matching the best horizontal alignment in the print out for Color Horizontal Head to Head Calibration Once the matching alignment value is reached press SELECT to save the setting If adjustment is also required for Vertical Head to Head Calibration proceed to Section 15 2 If no adjustment is required for Vert
149. adband Calibration compensates for minute differences created when bi directional plotting is used Figure Chapter 7 11 shows how to correct the differences The NOVAJET PRO Service Menu provides for both Slow Deadband and Fast Deadband Calibration NOTE Note Uni directional plotting is not affected by deadband REVISE TO LEFT DECREASE THE VALUE REVISE TO RIGHT INCREASE THE VALUE Figure Chapter 7 11 Deadband Alignment NOVAJET SERIES 7 51 Calibration 14 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 CALIBRATION 3 Press the UP ARROW
150. al for the plot areas for the different media standards 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 NOVAJET Series User s Guide You may also want to refer to Section 11 5 4 in this chapter for further assistance NOVAJET SERIES Troubleshooting 11 13 Plotter is Noisy 1 Noisy operation may be caused by a dirty Slide Shaft Refer to the Slide Shaft Maintenance procedures in Chapter 4 Section 3 0 Check for tightness of the Roller Supports by tightening the hardware See Chapter 7 Section 10 2 The Lower Drive Shaft Rollers may be misaligned Replace the Lower Drive Shaft Assembly See Chapter 6 Section 10 0 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 6 Section 10 0 11 14 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 2 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
151. ame 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 If you did not remove the Stepper Motor Bracket from the Lower Drive Assembly skip Step 1 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 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 Overtightening the Pivot Screw Step 3 below can prevent the Stepper Motor from pivoting as intended DO NOT OVERTIGHTEN If you are replacing the Stepper Motor put the Stepper Motor Bracket onto the Lower Drive Assembly and then put the Wave 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 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 Use the Pivot Screw and Pivot Nut to secure the Stepper Motor Assembly to the Stepper Motor Bracket Torque to 6 IN LB Hook the Extension Spring onto the Spring Post Place the Spring Post through the Stepper Motor Assembly and the Stepper Motor Bracket and secure it with the
152. an Inverkehrbringen dieses Ger tes angezeigt und die Berechtigung zur berpr fung der Serie auf die Einhaltung der Bestimmungen einger umt ENCAD Inc U S A NOVAJET SERIES Material Safety Data Sheet NOVAJET QIS Quality Image Supplies ink is nonhazardous requiring no special disposal handling It can be harmful if swallowed and should be kept away from children To obtain a Material Safety Data Sheet contact ENCAD Inc at 6059 Cornerstone Court West San Diego CA 92121 3734 619 452 4350 International users should contact their local dealer or distributor NOVAJET SERIES PRINTING HISTORY 1st Edition December 12 1995 2nd Edition February xx 1996 vi NOVAJET SERIES 5 CHAPTER 1 55 1 1 GHAPTER2 2 1 CHAPTER 3 INK DELIVERY SYSTEM tri 3 1 CHAPTER 4 4 1 5 TROUBLESHOOTING cnn cottura oak n es ota emen ta 5 1 CHAPTER6 5 5 6 1 CHAPTERS CALIBRATION 7 1 CHAPTER8 FEEDER TAKEUP MECHANISM eem 8 1 CHAPTER 9 REPLACEMENT PARTS LIST 9 1 APPENDIX A EMERGENCY FIRMWARE DOWNLOAD PROCEDURE
153. any obvious obstruction and the media Turn the plotter ON load new media and resend the plot If this same message appears 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 For cut sheet only This display indicates the plotter is ready to generate another copy of the same image aa 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 22 NOVAJET SERIES 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
154. ar the front edge b 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 6 32 Secure the Right Side Plate to the Platen with four screws NOVAJET SERIES 6 79 Disassembly Assembly Figure Chapter 6 32 Routing of Wires and Cables on Right Side Plate and MPCB 6 80 NOVAJET SERIES 10 13 14 15 16 5 5 Disassembly Assembly 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 Make sure the silver fingers are facing up when they are routed through the Right Side Plate See Figure Chapter 6 32 Route the Trailing Cable with the silver fingers facing up through the top slot in the Right Side Plate Secure the to the Right Side Plate using three screws See Section 4 3 2 and Figure Chapter 6 32 Make sure the Trailing Cable is not pinched between the stand off and the MPCB Bring the Trailing Cable around the bottom of the MPCB Connect it at the JP3 connector Make sure the silver fingers face down when the Trailing Cable is inserted into the connector 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
155. arriage PCB from the slot in the Carriage Assembly 6 See Section 7 10 for installation instructions Figure Chapter 6 19 Removing the Carriage PCB 6 46 NOVAJET SERIES Disassembly Assembly 7 10 Installing the Carriage PCB 1 Put the tab on the left end of the Carriage PCB into the slot in the left side of the Carriage Assembly See Figure Chapter 6 19 2 Make sure that no flex cables are underneath the Carriage PCB 3 Push down the right end of the Carriage PCB until the latch snaps into place 4 Reattach all flex cables on the Carriage PCB in this order J6 J4 J2 J7 andJ1 See Figure Chapter 6 19 5 Follow all procedures in Sections 7 3 and 7 4 in this chapter to reinstall the Carriage Assembly NOVAJET SERIES 6 47 Disassembly Assembly 7 11 Removing the Paper Sensor or the Encoder 1 Follow all procedures in Sections 7 1 and 7 2 in this chapter to remove the Carriage Assembly from the Slide Shaft 2 Toremove the Paper Sensor a Unlock the connector at J6 and remove the flex cable See Figure Chapter 6 19 b the Carriage Assembly over and hold it in one hand while firmly grasping the Paper Sensor between thumb and index finger See Figure Chapter 6 20 Pull straight up on the Paper Sensor and remove it from the Carriage Assembly 3 To remove the Encoder a Unlock the connector at J7 and remove the flex cable See Figure Chapter 6 19 b Turn the Carriage Assembly
156. ation of Drive Plate NOVAJET SERIES 8 3 Power Media Feed Take Up System 3 Install the Rails into the Cradles make sure the Rails are all the way against the Drive Plate and tighten the screws which hold the Rails in place Then slide the Adjustable Roll Guides onto the Rails See Figure Chapter 8 4 i S d ey EX d meres 2 TIGHTEN 4 PHILLIPS WHICH HOLD E RAILS 5 SLIDE THE ADJUSTABLE ROLI ONTO THESRAI S C J Figure Chapter 8 4 Installing Rails and Adjustable Roll Guides 8 4 NOVAJET SERIES Power Media Feed Take Up System Loosen the Phillips screws on the pre assembled Take Up Reflector Bracket and Bracket Mount enough so that the Bracket Mount slides back and forth Install the Take Up Reflector Bracket at the front foot of the right leg behind the caster wheel See Figure Chapter 8 5 There should be about 8 1 4 between the back edge of the bracket and the front side of the printer stand s vertical leg The reflective surface should face towards the inside of the stand After the bracket is in position tighten the Phillips screws UN gt Gay e B Figure Chapter 8 5 Mounting Take Up Reflector NOVAJET
157. because the Ink Delivery Line connected to the Black Cartridge cannot reach to the Cyan slot without a risk of damage to the tubing REMINDER Once the cause of the misfiring has been determined and corrected be sure to perform the Color Calibration procedure before plotting See Chapter 8 Section 15 0 of this Service Manual NOVAJET SERIES 5 49 Troubleshooting Table Chapter 5 8 NOVAJET 4 Cartridge Swapping Procedure The purpose of this procedure is to identify the cause of misfiring by a NOVAJET 4 Cartridge CAUSE SYMPTOM SOLUTION Defective Cartridge A defective Cartridge will misfire with Replace Cartridge the same pattern regardless of which slot it occupies in the Carriage Assembly Defective slot in the A Cartridge which is not defective will Return to the next Carriage Assembly misfire only if it is in a slot in the step in Table Chapter Carriage Assembly which is defective 5 6 PROCEDURE Put the suspected Cartridge in the slot to its right as described below If suspected Cartridge is REMINDER Once the cause of the misfiring has been determined and corrected be sure to perform the Color Calibration procedure before plotting See Chapter 8 Section 15 0 of this Service Manual 5 50 NOVAJET SERIES 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 c
158. bushing 204916 X X X X ASSY CABLE OUTPUT E SIZE 204929 1 X X ASSY CABLE OUTPUT D SIZE 204929 31 X ASSY CABLE OUTPUT E SIZE 204929 61 X ASSY CABLE SUPPORT SERVICE D SIZE 205875 31 X ASSY CABLE SUPPORT SERVICE E SIZE 205875 1 X ASSY CABLE SUPPORT SERVICE E SIZE 204641 1 X ASSY CABLE TRAILING with bend in cable 204695 X ASSY CABLE TRAILING with bend in cable 204903 X ASSY CABLE TRAILING D SIZE 205179 X ASSY CABLE TRAILING E SIZE 205697 X X ASSY CARRIAGE complete 204966 X ASSY CARRIAGE complete 204996 X X X ASSY COVER LEFT includes Ink Reservoirs 205026 X X ASSY COVER LEFT 203533 1 X X ASSY COVER RIGHT 203476 4 X X X X ASSY ENCODER W FLEX 204999 X X X X ASSY FAN 203443 X X X X d ASSY HARDWARE KIT SERVICE 205440 X X X X ASSY IDLER 203405 1 X X X X ASSY KEYPAD TOP 203487 6 X X X ASSY KEYPAD TOP 203488 1 X X X X ASSY KIT HEIGHT GAUGE 205660 X X X X ASSY LEGS 203484 3 X X ASSY LEGS AND BASKET 203769 4 X ASSY LEGS AND BASKET 203484 6 X ASSY LOWER DRIVE SHAFT W GEAR 204917 1 X X ASSY LOWER DRIVE SHAFT W GEAR 205122 X ASSY LOWER DRIVE SHAFT W GEAR D 20491 7 31 X ASSY MPCB 205853 1 X X X ASSY MPCB 206372 X ASSY PINCH ROLLER quantity needed 204773 5 8 8 9 ASSY ROLLGUIDE LEFT 204969 3 X X X X ASSY ROLLGUIDE RIGHT 203477 6 X X X ASSY SERVICE BOTTLE 1 Ink Reservoir 206376 X X ASSY SERVICE STATION 204629 X X X X ASSY SERVO MOTOR 203496 1 X X X X NOVAJET SERI
159. ce with the instructions may cause harmful interference to radio communications User Instructions V 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 e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Consult the dealer an experienced radio TV technician for help Changes or modifications not expressly approved by ENCAD Inc could void the user s authority to operate the equipment Note This product was FCC certified under test conditions that included the use of shielded cables and connectors between system components To be in compliance with FCC regulations the user must use shielded cables connectors and install them properly NOVAJET SERIES iii VDE Statement Hiermit wird bescheinigt daB der NOVAJETPRO und NOVAJET 4 in bereinstimmung mit den Bestimmungen der BMPT AmstblIVfg 234 1991 funkentst rt ist Der vorschriftsmaBige Betrieb mancher Ger te z B MeBsender kann allerdings gewissen Einschr nkungen unterliegen Beachten Sie deshalb die Hinweise in der Bedienungsanleitung Dem Zentralamt f r Zulassungen im Fernmeldewesen w rde d
160. ck Extension Not used Calibration Jo Block 1 434 Not used NOVAJET SERIES 7 15 Calibration Plastic Gauge Card 0 011 Not used Modified Cadjet Black Cartridge Not used Modified Novajet 1 2 3 Cartridge Not used There are two basic measurements that are to be made using this kit ensure power is off prior to performing these procedures 1 Carriage Shaft Profile Measurement 2 Carriage Cartridge Height Setting SLIDE SHAFT HEIGHT ADJUSTMENT The Novajet series shaft height is not held at any specific value only ageneral range The shaft itself should remain relatively perpendicular to the platen surface The Novajet series shaft height can vary anywhere from 1 390 to 1 440 average will be around 1 418 with respect to the platen surface Procedure 1 Connect the dial gauge micrometer to the Shaft mounting block as shown below Dial Gauge Micrometer Tighten Set Screw Not seen Shaft Mounting Block 2 Place gauge against left side of shaft assembly allowing micrometer tip to rest directly on top of shaft Zero the gauge this is reference 7 16 NOVAJET SERIES Calibration 3 Measure the right side next to media alignment mark and note the difference on the calibration worksheet below Divide this amount by two and record 4 Measure just off the center of the slide shaft and adjust the center turnbuckle with an open ended wrench if required for the average value
161. d on Power Supply 3 ON OFF Switch None On back left side of Platen One SIMM socket 4 MB permanently installed upgradeable to 32 MB plus two 72 pin 32 bit wide DRAM SIMM sockets upgradeable with 4 8 16 or 32 MB with 70 ns or faster SIMMS ENCAD approved See Chapter 2 Section 3 8 Flash EEPROM Replaceable New type of Flash EEPROM 1 permanently mounted 1 socket for expansion Resolution 300 x 300 dpi color 300 x 300 color 600 x 300 dpi monochrome monochrome or gray only Ink Counting Available NJP 36 NJP 50 Not available because of the extended ink supply NJ 4 Available Plot Nesting Not available Standard Auto Rotation Not available Standard 1 6 NOVAJET SERIES FEATURE NOVAJET 5 Extended Ink Supply Refillable Cartridges Not available Not available 6 Carriage Assembly ENCAD Cartridge Covers Entire assembly must be replaced in the event of PCB Encoder or Bushing failure Mechanical Paper Sensor No tubing 7 Trailing Cable Support Bracket Carries only the Trailing Cable 8 Encoder Strip Encoder Strip mounted on Y Arm Assembly 9 Stepper Motor Requires manual backlash adjustment NOVAJET SERIES Uses HP Cartridges filled by General Information NJP 36 NJP 50 and NJ 4 NJP 36 NJP 50 only Standard NJ 4 only Standard Uses ENCAD Cartridges designed specifically for this Carriage Assembly No Cartridge Covers New
162. dge in 3 14 Releasing Ink Reservoir 3 19 Purging Ink Delivery 2020244400 3 21 Removal of Left Cover Assembly 3 23 Left Cover Assembly with Ink Reservoirs in Packing Foam 3 24 Removing Black Foam 3 26 CHAPTER 4 MAINTENANCE Number Figure 4 1 Title Removal of Service Station enne 4 6 CHAPTER 5 TROUBLESHOOTING Number Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Title Page PE DRG YS Od 5 18 GYDA trat a t Rn tart oe 5 19 Cable and Schematic for Parallel and Serial Loop Back Tests 5 29 Correct Usage of Cable for Parallel and Serial Loop Back Tests 5 30 6 DISASSEMBLY ASSEMBLY Number Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 6 9 Figure 6 10 Title Page NOVAJET PRO Hardware Kit 6 5 NOVAJET PRO Final Assembly 6 6 Removing Tie Wrap and Foam 6 8 Removing Cardboard Wedge
163. e Figure Chapter 3 15 3 If you are shipping the plotter to ENCAD DO NOT return the Left Cover Assembly and the Ink Reservoirs replacement plotter will come with a different type of Left Cover Assembly the replacement plotter s Left Cover Assembly and attach it to the plotter you are shipping to ENCAD Attach your Left Cover Assembly with the Ink Reservoirs to the replacement plotter 3 3 1 Preparing the NOVAJET PRO for Shipment to ENCAD 1 Remove all four Cartridges and drain all four lines before removing the Left Cover Assembly See Section 3 1 and or Section 3 2 as needed Do not remove the rubber caps on the Ink Reservoirs 2 Three Phillips screws hold the Left Cover Assembly onto the Left Side Plate One of them is on the bottom of the Left Cover Assembly The other two are on the inside of the Left Side Plate See Figure Chapter 3 14 3 Use a 2 Phillips screwdriver to remove the three screws while someone holds the Left Cover Assembly to keep it from falling Hold it level so ink does not spill out of the air vents in the top of the Ink Reservoirs 4 Once the Left Cover Assembly has been removed place it in the Left Cover packing foam that came with the plotter so that the ink does not leak out of the air vents in the top of the Ink Reservoirs See Figure Chapter 3 15 3 22 NOVAJET SERIES Ink Delivery System SCREW IS UNDERSI
164. e red with patch cord red Patch cord alligator to banana black Calculator magnifier and flash light 7 3 Calibration Documentation and Files The following documentation and files will be necessary in order to perform the procedures described in this chapter e NOVAJET PRO Users Guide e Emergency Flash ROM Boot Procedure refer to Appendix A of the NOVAJET PRO Service Manual for this procedure The files for this procedure are available on the NOVAJET PRO 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 download the Utilities Disk file name NJPRO101 EXE this is a self extracting file 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 s Flash EEPROM is blank or corrupt e Printer Firmware Upgrade Procedure refer to Appendix B of the NOVAJET PRO Service Manual The files for this procedure are included on the NOVAJET PRO Utilities Disk This procedure is used to download the firmware if the plotter does not have the current version of the firmware i e the Flash EEPROM is not blank or corrupt e Line Quality Acceptance Standards Section 17 0 gives the instructions for performing the Line Quality Plot Computer Test order to perform this test you will ne
165. e 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 indicated by the Warning symbol at the left The warning text is in bold italics type and is enclosed in a box NOVAJET SERIES General Information 3 0 ENCAD Technical Support amp 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 amp Service Dept 6059 Cornerstone Court West San Diego 92121 Help Desk Telephone 619 452 4350 Help Desk FAX 619 546 0659 Additional information is available ENCAD s bulletin board and through Internet ENCAD BBS 619 452 2653 or 619 452 3768 Internet WEB Page Address http www encad com NOVAJET SERIES 1 5 General Information 4 0 Comparison of NJ IIl with NJP 36 NJP 50 and NJ 4 Table Chapter 1 1 Comparison of NJ IlI with NJP 36 NJP 50 and NJ 4 FEATURE NJ 111 NJP 36 NJP 50 and NJ 4 1 Power Supply External Internal inside left end of Platen 2 Fue Located on MPCB Locate
166. e Length The following information for the NOVAJET plotters clarifies the amount of acceptable variation for Figure Chapter 1 4 plotting accurately See 1 HEORETICA SPECIFIED Le L 0 2 L L 0 2 L LENG L 1 0 2 L 1 0 2 L PS DRAWN LINE 1 Y MEDIA PERIMETER L Figure Chapter 1 4 Line Length Accuracy 1 drawn line length Lw is to be within 0 2 of the length specified Ly typically is constant on the top and bottom of the plot 2 Line length LL ang LR 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 gt 4 2 2 4 L LR LL AL AL lt 0 4 of L Example If L specified 45 Then AL left and right must be 4 of 45 NOVAJET SERIES General Information AL lt 0 18 inches NOVAJET SERIES 1 19 General Information If the media loading instructions have been correctly implemented these figures are conditions for variable paper movement during plotting See Figure Chapter 1 5 QE PE REFERENCE RECTANGLE OUTPUT 7 i 3 Ne N L5 L1 S N L x J Y N N
167. e Plotter on the 4 2 6 9 Right Cover Assembly MPCB and 51 6 10 4 1 Removing the Right Cover Assembly 6 10 4 2 Removing the MPCB Connectors sese 6 12 4 3 oe 6 14 4 3 1 rrr rrr 6 14 4 3 2 Reinstalling the 6 15 4 4 Reinstalling the MPCB 6 16 4 5 Extra Memory tete ttr 6 17 4 5 1 Extra Memory SIMM 6 17 4 5 2 Extra Memory SIMM Installation 6 18 Reinstalling the Right Cover 6 19 forro 6 20 5 1 Removing the Servo MOIOF o e o les 6 20 5 2 Replacing the Servo 6 24 Display tie eel ee 6 26 6 1 Removing the Display Assembly 6 26 6 2 Reinstalling the Display 6 27 Left Cover Assembly Left Side Plate Carriage Assembly and components Trailing Cable Carriage Belt and Tubing Chain Assembly 6 28 7 1 Removing the L
168. e Tensioner See Figure Chapter 6 17 for part names if necessary Figure Chapter 6 17 Left End of Y Arm 13 Remove the Carriage Assembly from the end of the Slide Shaft 14 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 To replace Trailing Cable see Section 7 5 2 To replace Carriage Belt see Section 7 7 3 To replace Carriage PCB Paper Sensor Encoder or Bushings see Sections 7 8 through 7 13 4 NOVAJET PRO only To replace Tubing Chain Assembly see Section 7 14 6 34 NOVAJET SERIES Disassembly Assembly 7 3 Reinstalling the Carriage Assembly NOTE NOVAJET SERIES 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 See Chapter 4 Section 3 0 Never use Isopropyl Alcohol to clean the brass bushings on the Carriage Assembly Use only a dry cloth When you slide the Carriage Assembly onto the Slide Shaft make sure that the Encoder Strip fits into the slot in the Encoder which is on the Carriage Assembly Make sure the left end of the Trailing Cable extends out beyond the left end of the Trailing Cable Support Assembly Slide the Carriage Assembly onto the left end of the Slide Shaft making sure that the Encoder Strip fits into
169. e Upper Roller Support the floor on the head of each mounting screw will not be perfectly level at the same time as you loosen or tighten the and will not perform its screw function properly Each mounting screw must be completely at the bottom edge of its hole in the back of the Y Bracket as you loosen or tighten the screw See Figure Chapter 7 5 4 f you loosen one of the mounting screws and the roller moves in one direction and you need to move the roller in the opposite direction tighten the screw that was loosened to its maximum torque 3 in Lbs 0 5 BEFORE loosening the other screw to move the roller in the opposite direction NEVER LOOSEN OR TIGHTEN BOTH MOUNTING SCREWS AT THE SAME TIME ON THE SAME UPPER ROLLER SUPPORT 5 Following all of the information in Section 10 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 7 5 7 34 NOVAJET SERIES Calibration WNWARD PRESSURE ENING TIGHTENING G SCREW Le UNTING SCREW PINCH ROLLER ASS PINCH ROLLER ASSEMBLY MUST TOUCH Y ARM IN THE AREA SHOWN Figure Chapter 7 5 Correct Positioning of the Spring in the Upp
170. e connector lock and remove the flex cable from the connector 2 Disconnect the Trailing Cable connector at the JP3 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 6 12 NOVAJET SERIES Disassembly Assembly and pull straight out At this point all 6 connectors should be disconnected NOVAJET SERIES 6 13 Disassembly Assembly ooo pas lt nnnnnnni cgo inn GO O ARAR nm 20 HULLS HHHH Figure Chapter 6 5 MPCB Connectors NOVAJET SERIES Disassembly Assembly 4 3 Power must be disconnected Integrated circuits can be weakened or inactivated by electrical discharge You must be grounded to a static station by an ESD wri
171. e current speed at which the ink is fired onto the media 100 Hz increments from 3000 Hz to 10 000 kHz NOVAJET SERIES PWM POSITION 14 84 0 PWM SATURATION 0 245 0 1 STOP MAX DISABLE 0 50 0 5 5 Troubleshooting 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 w
172. e holes in the Left Cover Assembly with the holes in the Left Side Plate b Insert the three screws and tighten with a 2 8 Phillips screwdriver until snug using a torque screwdriver torque to 15 In Lb Putthe Top Cover back on NOVAJET PRO only a Have your assistant hold the Left Cover Assembly level and align the holes in the Left Cover Assembly with the holes in the Left Side Plate Ink may spill from the Ink Reservoirs if they are not kept level b Insert the two top screws first and tighten them until snug Use a 2 Phillips screwdriver c Insert the bottom screw and tighten until snug If using a torque screwdriver torque to 15 In Lb d Putthe Top Cover back on e Reload the Ink Delivery System according to the procedures in Chapter 3 Section 2 0 6 38 NOVAJET SERIES Disassembly Assembly 7 5 Removing the Trailing Cable Handle the Trailing Cable with care Do not twist or turn the cable Perform this procedure only if the Trailing Cable is being replaced If you are replacing only the Trailing Cable it is not necessary to remove the Carriage Assembly from the Slide Shaft but you will need to remove the Cartridges and on NOVAJET PRO s drain the Ink Delivery Lines see Chapter 3 Sections 3 1 and 3 2 and you will need to perform Steps 2 9 of Section 7 2 of this chapter If you have already removed the Carriage Assembly from the Slide Shaft in order to replace the Carr
173. e 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 A D A converter is used to generate a sine wave output This signal is fed into a amplifier that is measuring the current through the winding of the stepper motor If the current is too low a pulse of 24V is generated When the current goes above the output of the D A the pulse turns off Every time the output of the D A converter is changed by the microprocessor the motor moves 1 micro step NOVAJET SERIES 2 13 Theory of Operation Each circuit contains four main blocks see Figure Chapter 2 3 1 CONVERTER 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 Motor current sense The voltage across a series current sense resistor is measured and level shifted so that it is centered around 5V 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
174. e of the Platen will drip down onto the internal Power Supply and cause damage If any liquid spills onto the Platen immediately blot it up with a dry cloth Do not wipe across the vacuum holes wipe away from them This chapter contains the NOVAJET PRO NOVAJET 4 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 DLT The Service Menu and the Front Side Panel figures aid in the understanding of the plotter tests and how to scroll through the menu Troubleshooting information for the Power Media Feed and Take Up System is located in Chapter 8 NOVAJET SERIES 5 1 Troubleshooting 5 2 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 be ans
175. e way while the Right Cover Assembly is being removed Move the Carriage Assembly to the middle of the Platen 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 6 4 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 6 11 Disassembly Assembly 4 2 Removing the MPCB Connectors Power must be disconnected Reference Figure Chapter 6 5 for the locations of the connectors Grasp the connector not the wires to remove the cables Do not pull the cables from the connectors on the J1 location Keypad Cable and JP3 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 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 6 5 for positions of the connectors as follows 1 Disconnect the Keypad Cable connector at the J1 location Use the reamer to pull forward on th
176. ection 15 0 of this Service Manual NOVAJET SERIES Ink Delivery System 4 1 2 Refilling a Used NOVAJET 4 Cartridge 1 Press the ACCESS CARTRIDGES key to move the Carriage Assembly away from the Service Station Remove the Cartridge from the Carriage Assembly by pulling the top of the Cartridge toward you and lifting up Be careful not to touch the Flex Contacts see Figure Chapter 3 1 or the jet area Remove the cap from the needle on the 30 ml ink bottle careful not to squeeze the ink bottle or ink may squirt out Insert the needle into the refill hole at the top front of the Cartridge See Figure Chapter 3 17 EFILI HOLE NOVAJET 4 CARIRIDGE Figure Chapter 3 17 Refilling the NOVAJET 4 Ink Cartridge 5 Gently squeeze the ink bottle until it is empty Do not release pressure on the ink bottle until you remove the spout from the Cartridge NOVAJET SERIES DO NOT OVERFILL the Cartridge The Cartridge is overfilled if ink begins to surface from the refill hole Stop squeezing release pressure on the ink bottle and allow it to slightly reinflate This will draw some of the ink back into the bottle and prevent overflowing DO NOT SQUEEZE AIR INTO THE CARTRIDGE Air bubbles in the Cartridge may cause quality defects 3 29 Ink Delivery System 12 Slowly remove the needle from the Cartridge Allow the ink bottle to completely reinflate Recap the
177. ectronic 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 Adjusting the size of an image to fit onto the desired plot area 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 NOVAJET SERIES SERVO SHEET MEDIA SKEW STEPPER MOTOR STOP BIT UART General Information A self correcting closed loop electromechanical system that adjusts an output signal based on an input and feedback signal Media that is 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 See Section 10 0 of this chapter for i
178. ed to download the following file from the BBS NJPTEST EXE e Production Gold Standard Computer Test Section 18 0 gives the instructions for performing the Production Gold Standard Computer Test In order to perform this test you will need the file PRODGS RTL This file is too large to download from the BBS It is currently available on floppy diskettes and may soon be available on CD To order see Chapter 1 Section 3 0 7 4 NOVAJET SERIES Calibration 4 0 Downloading Files From the BBS This section provides the information necessary for downloading files from the ENCAD Technical Support and Service BBS It also gives information concerning the following files e NJPRO101 EXE NOVAJET DOS Utilities Disk NJPTEST EXE Line Quality Acceptance Standards 4 1 BBS Logon Procedure NOTE Before you call Set your modem up to dial the phone number 1 619 452 2653 or if busy set to the second line 1 619 452 3768 If also busy try again in 30 minutes Set your modem download protocol to Z Modem if it is available Otherwise choose X Modem Modem protocols are 8 bits per character 1 stop bit no parity and X on off flow controls NOVAJET SERIES 7 5 Calibration In the example below the fictitious name Steve Parinski is used a new user that is calling the ENCAD BBS for the first time Press the ENTER key until you see the prompt at the left NOVAJET SERIES Calibration Default
179. editor mode Which default download protocol do you want to use We suggest that you choose S elect to indicate you will make a choice prior to each download This will allow you to use additional external protocols for file transfers or to quickly see and change choices as new external protocols are added Please select a protocol S elect the protocol at time of transfer A Ascii X Xmodem C Xmodem CRC Xmodem 1K F Xmodem 1K G Y Ymodem G Ymodem G Z Zmodem Kermit M Select SA XCOFYGZKM Press the ENTER key until you see the above window If you have Z modem available in your modem software use Z modem as your download protocol To do this type 2 and press ENTER Make sure you make the change in your modem software download specifications Otherwise type X and press ENTER Pressing X selects X modem as a download protocol Would you like to view it Y n When logging on for the first time press FLL FTL FLL ETT LLL TLL LL LLL LLL Rd when asked to view any newsletters Bulletin Menu Wildcat v4 and the ENTER key to scroll through lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt 0 unfamiliar screens Press ENTER until 1 BBS Glossary of Terms you are in a familiar area Be patient you 2 NEW VERSION 2 2 WINDOWS DRIVERS will soon get to the 3 NEW FIR
180. ee Section 4 0 of this chapter if you do not already have this file Whenever the Production Gold Standard Computer Test is performed the plotter s Print Mode should be set to ENHANCED 3 or 4 PASS and Printer Setup to CONTROL HARDWARE To perform the test 1 Press the MENU key followed by the SELECT key When the equals sign blinks press the UP ARROW key until the display reads MAIN MENU MODE ENHC 3 4 PASS 2 Press the SELECT key The equals sign will stop blinking The plotter is now set to the desired mode 3 Load the QIS Photoglossy media on the Plotter with the 36 side against the Upper Rollers 4 Atthe C prompt type on the computer s keyboard GO PRODGS RTL 5 Press the ENTER key to send the plot file to the Plotter The computer s screen will show SENDING On the Plotter the display will read PROCESSING K 6 After the plot is completed the Carriage will move to actuate the Cutter 7 Do not touch the printed surface Remove the plot and let the ink dry for 2 minutes 8 Examine the plot for the quality of the color and for the interaction between the ink and the media NOVAJET SERIES 7 67 Calibration SERIAL MODEL 880 SOFTWARE REVISION PART 1 SLIDE SHAFT PROFILE ADJUSTMENT LEFT CENTER RIGHT E E SHAFT HEIGHT LEFT ACTUAL RIGHT 1 SUM _ DIVIDED BY 2 AVERAGE PART 2 BEFORE CARTRIDGE HEIGHT ADJUSTMENT LEFT CENTER RIGH
181. ee cloth that has been moistened with distilled or R O water to remove any ink 4 Replace the Cartridges in the Carriage Assembly 5 Move the Carriage Assembly back to the Service Station Make sure the Cartridges are properly capped in the Service Station 6 NOVAJET PRO only Make sure that the Tubing Clamps on the Delivery Lines are left open 7 When you are ready to use the plotter again you may need to run the PRIME plot several times Refer to the troubleshooting procedures in Chapter 5 if the PRIME plot is unsatisfactory NOVAJET PRO only If the plotter is going to be out of service more than 30 days the entire Ink Delivery System Cartridges Ink Delivery Lines and Ink Reservoirs should be drained so that ink does not dry up and cause clogging See Chapter 3 Section 3 0 for the procedure NOVAJET 4 only If the plotter is going to be out of service more than 30 days remove the Cartridges from the plotter Blot the jet area as described in Step 3 above If it is available place the blue tape which was originally on the jet area back over the jet area do not substitute any other type of tape it may damage the jets Place the Cartridge in a sealed plastic bag conditions If the plotter is in a location with very high note The rate at which ink dries up is affected by environmental temperatures or low humidity the ink will dry up faster than in an area with low or average temperatures The 30 day time period men
182. eet Figure Chapter 7 14 at the end of this chapter Whenever you move the Carriage with the Height Gauge installed lift up the gauge tip to prevent damage to the gauge NOVAJET SERIES 7 1 Calibration 2 0 Required Supplies and Tools e Media Architectural 4 mil 24 LBS opaque 36 x 48 D 36 x 24 and B 11 x 17 sizes QIS Photoglossy media D 36 x 24 cut sheet or 36 wide x 2 5 O D Rolled e ENCAD NOVAINK 55 KITS 1 each of Yellow Magenta Cyan and Black e ENCAD NOVAJET PRO MAINTENANCE containing Suction Bulb Priming Pump Priming Depriming Attachments rubber gloves e U S A 110V power cord P N 205757 e 36 long precision ruler 1 4 open and box end wrench 110 thick e Static Station with wrist strap e Torque screwdriver pre set at 12 in Ibs with 3 32 Allen bit e Torque screwdriver pre set at 15 in Ibs with 2 Phillips bit e Torque screwdrivers pre set at 3 in Ibs with PO Phillips bilts e Screwdriver 1 6 mm flat blade and GLIPTAL e Compatible Computer 386SX 16 MHz 2 MEG OF RAM 40 MEG HD MINIMUM e Parallel Cable e Special firmware download Serial Cable P N 203977 e Ultrasonic Cleaner 7 2 NOVAJET SERIES NOVAJET SERIES Calibration Two regular NOVAJET PRO Cartridges each of which has exactly 20 ml of ink in it Height gauge kit assembly P N 205660 Multimeter BECKMAN IND DM15XL or equivalent Adapter Flexibl
183. eeze Bottle Figure Chapter 3 7 Item 1 which is enough to fill the Cartridge approximately half full 2 Remove the cap on the Squeeze Bottle 3 Insert the needle of the Squeeze Bottle into the hole on the top of the empty Cartridge Figure Chapter 3 7 Item 2 4 Slowly squeeze the Squeeze Bottle to pour all of the ink into the Cartridge 5 Remove and recap the Squeeze Bottle and save it for possible future use 6 Proceed to Section 2 4 NOVAJET SERIES 3 9 Ink Delivery System SQUE Je Tos 20 M gt EMPTY CARI RIDGE Figure Chapter 3 7 Initial Filling of NOVAJET PRO Cartridge NOVAJET SERIES Ink Delivery System 2 4 Installing and Priming NOVAJET PRO Cartridges When you handle the Cartridges do not touch the Flex Contact area of the Cartridge See Figure 3 1 Always thoroughly rinse and dry the Suction Bulb before working with the next color to prevent colors from becoming mixed Leave the blue tape on the jet area on the bottom of the Cartridge see Figure 3 8 until you are ready to install the cartridge on the Carriage Assembly and hold the Cartridge upright This will prevent ink from coming out of the jet area or out of the opening in the top of the Cartridge Prior to releasing the Tubing Clamps take care not to invert the Cartridges or to have the Cartridges located above horizontal plane of the Tubing Clamps Failure to do so can ca
184. eft Cover Assembly and Left Side Plate 6 28 7 2 Removing the Carriage Assembly 6 29 7 3 Reinstalling the Carriage 6 33 7 4 Reinstalling the Left Side Plate and Left Cover Assembly 6 36 NOVAJET SERIES Table of Contents CHAPTER 6 DISASSEMBLY ASSEMBLY continued 7 5 Removing the Trailing 6 37 7 6 Reinstalling the Trailing 6 39 7 7 Removing the Carriage Belt from Carriage Assembly 6 41 7 8 Installing the Carriage Belt on Carriage Assembly 6 42 7 9 Removing the Carriage 6 43 7 10 Installing the Carriage PGB 5 eet 6 44 7 11 Removing the Paper Sensor or the Encoder 6 45 7 12 Installing the Paper Sensor or the Encoder 6 47 7 13 Replacing the Carriage 5 6 49 7 14 Removing the Tubing Chain 6 50 7 15 Installing the Tubing Chain 6 52 8 0 Power Supply and ON OFF 6 53 8 1 Removing the Power Supply and ON OFF Switch
185. emblies of the NOVAJET PRO 36 NOVAJET PRO 50 NOVAJET4 Color Inkjet Plotters Section 2 0 is the numerical listing Section 3 0 is the alphabetical listing and Section 4 0 is an alphabetical listing with drawings 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 NOTE The part numbers are subject to change without notice NOVAJET SERIES 9 1 Replacement Parts List 2 0 Numerical Listino USED IN 40 NJ4E NJP 36 NJP 50 PART 200172 202010 202512 202513 203037 203228 203405 1 5 203440 3 203443 5 203457 203476 4 203477 6 203479 2 203480 1 203481 1 203484 3 4 203485 2 203487 6 5 203488 1 203496 1 203533 1 203556 2 203565 2 203772 2 203788 1 203789 1 203868 2 203870 1 203957 3 203977 203999 204246 1 204559 204562 204599 204629 204641 1 204695 204696 3 204699 a 204711 1 a 204711 31 a 204711 61 9 2 DESCRIPTION LOCTITE BLACK MAX SPRING COMPRESSION TOP COVER CASTER NON LOCKING TWIN CASTER LOCKING TWIN BELT 312 WIDE D SIZE BUSHING CARRIAGE 2 ASSY IDLER KEYPAD BOTTOM ASSY FAN CABLE KEYPAD ASSY COVER RIGHT ASSY ROLLGUIDE RIGHT BOX PLOTTER E SIZE FOAM BOTTOM LEFT FOAM BOTTOM RIGHT ASSY LEGS AND BASKET SCREWS STAND 10 KEYPAD TOP ASSY KEYPAD TOP ASSY SERVO MOTOR ASSY COVER LEFT NJ 4 SUPPORT DRIVE
186. en turn it on again so that the plotter resets Try the DIAGNOSTICS KEYPAD test again NOVAJET SERIES 5 59 Troubleshooting 5 60 For the LCD keys If the key still does not beep remove the Keypad Top Assembly see Chapter 6 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 Top Assembly For the LED keys If the key still does not beep remove the Right Cover Assembly see Chapter 6 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 6 Section 4 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 6 Section 4 3 NOVAJET SERIES Troubleshooting 11 18 LCD Keypad Display Inoperative If there are no characters displayed on the LCD Display but other plotter functions are correct perform the following actions until the problem is corrected 1 NOVAJET SERIES Keypad Display cable connections may be bad Check t
187. er 1 Section 3 0 3 The plotter has passed the PRIME test if misfiring is not observed f PRIME 4 Proceed to Section 13 0 NOVAJET SERIES 7 45 Calibration NOTE Note During these tests check the overall functioning of the plotter Listen for any loud sounds from the Stepper Motor Assembly squeaking from the Roller Assemblies rubbing noises from the Drive Shaft 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 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 7 46 NOVAJET SERIES Calibration 13 0 XY Calibration NOVAJET SERIES 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 The XY Calibration values are only used when the USE XY CALIBRATION option is set to ON When you set the XY Calibration values all subsequent images are plotted using the new values until you manually reset the calibration XY calibration should not be used for merged vector raster images 7 47 Calibrat
188. er 6 Section 4 0 for the procedure NOVAJET SERIES 5 5 Troubleshooting For the RAM test a read out of RESULT ERROR could indicate 1 Any extra SIMM may be installed incorrectly or not fully seated See Chapter 6 Section 4 0 for the procedure The extra SIMM may be defective or not compatible with the plotter circuits See the Users Manual for information concerning the acceptable SIMM sizes See Chapter 6 Section 4 0 for the replacement procedure The socket on the MPCB may be defective Replace the MPCB See Chapter 6 Section 4 0 for the procedure 5 41 Troubleshooting 11 6 Media Cutting Problems Media which is very abrasive such as canvas may shorten the life of the Cutting Knife nore Note Certain media is more abrasive than other types of media If the cut edges of the media are ragged or the cut is not complete across the media you need to replace the Cutting Knife This part is available from your local authorized dealer or directly from ENCAD 5 42 NOVAJET SERIES Troubleshooting 11 7 Ink Delivery System Troubleshooting NOVAJET SERIES 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 unless the power is turned off Damage to the Carriage may result NOVAJET 4 only Do not fi
189. er Roller Support NOVAJET SERIES 7 35 Calibration 10 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 small as possible and 2 a 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 7 6 Avoid adjusting the Upper Roller Supports so that they touch the Y Arm s cut outs Le WE THE MINIMUM ACCEPTABLE E MINIMUM ACCEPTABLE GAP BETWEEN THESE TW BETWEEN THESE TWO POINTS EQUALS THE THICKNESS POINTS EQUALS THE THICKNESS OF A PIECE OF BOND PAPER OF A PIECE OF BOND PAPER Figure Chapter 7 6 Test for Minimum Acceptable Gap 7 36 NOVAJET SERIES Calibration 10 4 Adjustment of Upper Roller Supports NOTE Be sure to perform the adjustment according to the sequence given in Section 10 1 When adjusting with paper if the right edge of the paper drifts to the right side of the Media Alignment Mark the Upper Roller Supports will need to be adjusted to the right
190. es smoothly NOVAJET SERIES 5 5 Disassembly Assembly Because you have replaced the Upper Roller Supports perform the following Calibrations in Chapter 7 Section 9 0 Paper Skew Setup e Sections 10 0 through 10 5 Paper Skew Adjustment Section 13 1 Calibrating the X Axis Paper Axis or Vertical Axis Calibration e lf the Carriage Belt was loosened during this procedure you will need to perform all the Calibrations in Chapter 7 Sections 6 0 through 18 0 Replace the Top Cover after you have finished Step 6 6 87 Disassembly Assembly Chapter 6 DISASSEMBLY ASSEMBLY 6 1 A MA m ahs RN NEM E 6 1 2 0 Tools and Equipment Md PRA D M 6 4 T 6 6 3 1 Removing the Plotter from the 6 6 3 2 Placing the Plotter on the 6 9 4 0 Right Cover Assembly MPCB and 6 10 4 1 Removing the Right Cover Assembly eese 6 10 4 2 Removing the MPCB Connectors sse 6 12 4 9 MPOB ieu atm td ND add dni dd nd Quei d DAC sid 6 15 4 3 1 REMOVING ti WP CB oq e o EU e ER Rd trs 6 15 4 3 2 Reinstalling the MPCB 6 16 4 4 Reinstalling the Connectors 6 17 4 5 Extra Memory SIMM
191. fect Disassembly Assembly procedures Table Chapter 6 1 Plotter Differences Affecting Disassembly Assembly Procedures of screws holding Trailing Cable 4 5 4 3 Support Assembly on Y Arm of screws holding Stabilizer 3 4 3 3 Bracket on Y Arm of Rollers amp Upper Roller Supports of Turnbuckles 3 3 5 2 Assistant needed when removing NO POSSIBLY NO NO replacing Carriage Belt Assistant needed when purging YES YES N A N A Ink Delivery Lines Calibration procedures are in Chapter 7 and replacement parts are listed in Chapter 9 Disassembly Assembly information for the Power Media Feed and Take Up System is in Chapter 8 NOVAJET SERIES 6 1 Disassembly Assembly 6 2 Whenever components or parts are removed and replaced calibration of the plotter is necessary Calibration Procedures are in Chapter 7 Also refer to Chapter 1 Sections 9 0 and 10 0 for information on Line Length Accuracy and Skew Removal of the following parts will require the indicated calibrations after reassembly Cartridges Color Calibration Chapter 7 Section 15 0 Servo Motor Assembly or Idler Tensioner Assembly Y Axis Carriage Axis Chapter 7 Section 13 2 Deadband NJPTEST PLT Chapter 7 Section 14 0 Test Plots PRODGS RTL Chapter 7 Sections 17 0 amp 18 0 MPCB ALL CALIBRATIONS except Slide Shaft Profile Chapter 7 Section 6 0 Cartridge Head Height Chapter 7 Section 7 0 Paper Skew Chapter 7 Sections 9 0
192. ffer 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 l O 128K and Raster 1M If you are sending Raster files increase the size of the buffer to decrease the transfer time freeing up the computer sooner lf 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 MEMORY CONFIG gt Press SELECT to go to MEMORY CONFIG 1 0 128K RAS 1M NOVAJET SERIES Troubleshooting Press SELECT Try increasing the amount of memory allocated to the 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 NOVAJET Series 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
193. front of the Slide Shaft 3 Use the 1 Phillips Screwdriver to remove the screws which hold the one of the Upper Roller Supports on the Y Bracket The screws are located on the back of the Y Bracket See Figure Chapter 6 33 MAKE SURE YOU ARE LOOSENING THE CORRECT SCREWS AND NOT THE ONES WHICH HOLD ON THE STABILIZER BRACKET see Figure Chapter 6 24 4 Using your fingers pull the Upper Roller Support slightly forward and if necessary use the tip of a screwdriver to turn it sideways 5 Use a pair of needlenose pliers to grasp the long flat part of the Upper Roller Support and lift it out over the Slide Shaft 6 Repeat this procedure for all the other Upper Roller Supports 6 84 NOVAJET SERIES Disassembly Assembly 11 2 Installing the Upper Roller Supports Make sure that you do not install the Upper Roller Supports upside down See Figure Chapter 6 33 for the correct orientation of the Upper Roller Supports Note Do not overlook the instructions regarding Calibration given in Step 6 of this section 1 Turn an Upper Roller Support sideways and put it into place in the Y Bracket 2 Use the tip of a screwdriver to maneuver it into the correct position Make sure the point on top back of the Upper Roller Support is in its hole in the Y Bracket See Figure Chapter 6 33 Figure Chapter 6 33 Positioning Upper Roller Supports NOVAJET SERIES 6 85 Disassembly Assembly 3 4 6 86 Keep pres
194. gainst the tensioning mechanism The belt must always clear the Frame Tensioner The spring must be engaged in the assembly If the Carriage Belt is misaligned refer to Chapter 6 Figure 6 17 and 6 18 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 7 5 Trailing Cable Strain Relief Check 1 NOVAJET SERIES Slide the Carriage Assembly all the way to the Left Side Plate so that the top of the Strain Relief can be viewed Visually check that clearance exists between the edges of the Trailing Cable and the Strain Reliefs side walls Make sure that the Trailing Cable does not rub against the side walls Proceed to Section 8 0 Firmware Download and Paper Sensor Adjustment 7 25 Calibration oer Sensor Adjustment IF THE MACHINE DOESN T POWER UP IT MUST BE TURNED OFF IMMEDIATELY TO ELIMINATE ANY DAMAGE UNTIL THE PROBLEM CAN BE RESOLVED For static control you must be grounded to a static station by a wrist strap whenever you are working with EPROM s the Carriage Assembly and the MPCB when power to unit is off Do not slide the Carriage at any time unless using the ACCESS CARTRIDGES key function and then only mo
195. h the menus and options e 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 e Submenu items with an arrow gt have additional submenus MAIN MENU PRINT MODE SELECT Vs Figure Chapter 5 2 LCD Keypad 5 20 NOVAJET SERIES 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 7 2 Drying Plot DRYING PLOT x MIN x SEC 7 3 Insert Media INSERT MEDIA USE LOAD KEY 7 4 Memory Full MEMORY FULL PRESS ANY KEY NOVAJET SERIES 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 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 elapse
196. hapter and to Figure Chapter 6 24 while performing this procedure 1 2 NOVAJET SERIES Remove the Top Cover The Carriage Assembly must be removed from the Slide Shaft Follow all procedures in Sections 7 1 and 7 2 of this chapter After the Carriage Assembly is removed from the Slide Shaft remove the Right Cover Assembly and disconnect the Trailing Cable from the JP3 connector on the MPCB See Section 4 1 and Figure Chapter 6 6 The Trailing Cable Support Assembly must be removed Use a 2 Phillips screwdriver to remove the Phillips screws on the back of the Trailing Cable Support Assembly See Figure Chapter 6 13 for identification of the screws There are three screws on the NJ 4 D Size four screws on the NJ 4 E Size and the NJP 36 and five screws on the NJP 50 Lift straight up on the Trailing Cable Support Assembly and remove it from the Y Bracket Use a 7 64 Hex Nut Driver to remove the Allen Head 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 6 24 6 61 Disassembly Assembly Reinstalling the Stabilizer Bracket Be very careful not to damage the Encoder Strip as you install the Stabilizer Bracket 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 5 Alcohol to clean the Slide Shaft but you should NOT use i
197. hardclip limits are set accordingly Pre cut media uses different maximum plotting areas than roll media Equal margins on all four sides are available for roll media Serial and Centronics parallel interfaces are provided Commands sent from the host computer in several forms are understood including HP GL HP GL 2 and HP RTL Hewlett Packard Graphics Language NOVAJET SERIES 1 1 General Information 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 plotters permanent memory 2 1 Related Publication The following publication contains additional information which may be useful in servicing the ENCAD Inc NOVAJET Color Inkjet Plotters e ENCAD Inc NOVAJET Series User s Guide P N 205883 Copies of this and other ENCAD Inc publications may be obtained by contacting your nearest authorized ENCAD Inc dealer or by contacting ENCAD s Technical Support and Service Department 1 2 NOVAJET SERIES 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
198. he connection at J1 on the MPCB see Chapter 6 Figure 6 6 and J1 on the Keypad PCB see Chapter 6 Section 6 0 The Display Cable may have been installed backwards Check the orientation of the flex fingers See Chapter 6 Section 6 2 Try reprogramming the Flash EEPROM See Appendix A The Keypad Display has failed Replace the Keypad Top Assembly See Chapter 6 Section 6 0 The Main Printed Circuit Board circuitry has failed Replace the Main Printed Circuit Board see Chapter 6 Section 4 0 and reprogram the EPROM EEPROM or Flash EEPROM failure Replace the MPCB See Chapter 6 Section 4 0 5 61 Troubleshooting Chapter 5 TROUBLESHOOTING 5 1 mr e 5 1 2 0 Decision Logic Tables 5 2 2 1 Procedure for Using Decision Logic 5 2 2 2 Decision Louie Tables IER DR RR ORA 5 3 3 0 Service Menu 5 9 4 0 Service Menu DescriptiOti o oo ccc reuerti nenne nene nnne edem dene annexa 5 10 4 1 SEMVICe IMONMANON costi CROP dr ec E 5 11 4 1 1 Information Display 0 5 11 4 1 2 Information Print SHINS eee 5 14 4 2 Service 2 04000000000 eene nnne neni nnn 5 15 4 3 Service Calibration
199. he unit being shipped to ENCAD See Figure Chapter 6 3 13 NOVAJET PRO only Attach the replacement plotter s Left Cover Assembly to the plotter you are shipping to ENCAD 14 NOVAJET PRO only Open the Tubing Clamps on the Ink Delivery Lines on the plotter you are shipping to ENCAD 15 Close the Top Cover and place a rubber band around each end of the unit to hold the Top Cover in place during shipping 6 8 NOVAJET SERIES 16 17 18 19 20 Disassembly Assembly 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 Remove the eight screws which hold the plotter on the stand 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 Use the factory box and packing from the replacement unit Put the plotter upside down in the box If you are returning the unit because of bad line quality and misfiring please send us the following items a the actual drawing Please include a note indicating the media type mode of operation and DPI b the plot file if available When your RA number is issued we will fax you a Mailing Label Please photocopy it and attach the photocopy to the outside of the box The printing on the fax paper used by some customer s fax machines fades if
200. he V shaped groove in the Frame Tensioner 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 Fit the Compression Spring over the post at the back of the Y Arm Fit the notch in the front end of the Frame Tensioner over the notch in the front of the Y Bracket Depress the back of the Frame Tensioner with your left hand and slip the Carriage Belt over the Servo Motor pulley Make sure that the guides in the Carriage Belt are properly fitted over the Servo Pulley NOVAJET PRO 50 only you may need to have an assistant compress the Frame Tensioner Gently move the Carriage Assembly from end to end and make sure that the Carriage Belt is not rubbing against any other parts Proceed to Section 7 4 6 37 Disassembly Assembly 7 4 Reinstalling the Left Side Plate and Left Cover Assembly V NOVAJET PRO only Note 1 You will need someone to help you reinstall the Left Cover Assembly 2 You may want to protect the floor with newspaper or a plastic drop cloth in case any ink spills 3 Keep the Left Cover Assembly as level as possible at all times so that ink does not spill out of the Ink Reservoirs 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 If using a torque screwdriver torque to 15 In Lb 2 NOVAJET 4 only a Align th
201. he copper area on the Cartridges must be in contact with the flex cables on the Carriage Assembly Check for a loose interface Trailing Cable at the Carriage Assembly or at the Main PCB See Chapter 6 Section 7 6 for correct installation procedures 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 Verify communication between the plotter and the computer by transmitting the following ASCII 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 Run the COLOR TEST from the SERVICE DIAGNOSTICS menu Advanced Options on the plotter If the plot runs correctly the problem is not in the plotter NOVAJET SERIES 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
202. he edge of the media if the preprinted border is too wide Use the Manual Load function see Chapter 2 in the NOVAJET Series User s Guide for instructions if this should occur Certain media types may cause difficulty in loading Use the Manual Load function see Chapter 2 in the NOVAJET Series User s Guide for instructions The paper sensor may be defective As an intermediate measure use the Manual Load function See Chapter 2 in the NOVAJET Series User s Guide for instructions In order to test the paper sensor see Chapter 7 Section 8 0 for the Paper Sensor Potentiometer Adjustment it fails this adjustment replace the Paper Sensor See Chapter 6 Section 7 0 for the removal and installation procedures NOVAJET SERIES 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 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 2 or 1 3 in Chapter 1 for acceptable sizes Example Set the plotter to MEDIA ARCH if you use
203. he 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 PO bit to adjust the Upper Roller Support mounting screws The maximum torque requirement is 3 in Lbs 0 5 NOTE Note 1 Use the sequence given in Section 10 1 as you do the steps given in Section 10 4 2 Read and follow ALL of the information in Sections 10 1 10 2 and 10 3 before you begin Section 10 4 NOVAJET SERIES 7 31 Calibration 10 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 7 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 10 4 2 Load a sheet of D Size paper and adjust Rollers 5 and 4 following the directions in Section 10 4 3 Load a sheet of E Size paper and adjust Rollers 3 2 and 1 following the directions in Section 10 4 7 32 NOVAJET SERIES Calibration 10 2 Mounting Screw Information Section 10 4 Make sure you understand this material before note Note 1 Read everything Section 10 2 before beginning you proceed to Section 10 4 NEVER LOOSEN TIGHTEN BOTH MOUNTING SCREWS AT THE SAME
204. her screws NJ 4 D Size remove 2 screws NJ 4 E Size remove 3 screws NJP 36 remove 3 screws NJP 50 remove 4 screws 5 While holding up the Trailing Cable Support Assembly lift up on the Electronics Cover and remove it from the Carriage Assembly 6 Lift up on the connector lock to unlock the Trailing Cable connector 45 on the Carriage PCB and remove the end of the Trailing Cable See Figure Chapter 6 16 6 32 NOVAJET SERIES Disassembly Assembly 7 Remove the Trailing Cable from the triangular portion of the Strain Relief 8 Lift up on the short end of the tape and unfold the bend in the Trailing Cable 9 Push the Trailing Cable down through the opening in the Strain Relief AS Figure Chapter 6 16 Strain Relief and Trailing Cable on Carriage Assembly 10 Move the Carriage Assembly away from the left end of the Slide Shaft Compress the back of the Frame Tensioner with your left index finger and use the end of a screwdriver to remove the Carriage Belt from the Servo Motor pulley See Figure Chapter 6 10 and Figure Chapter 6 11 NOVAJET PRO 50 only you may need to have an assistant compress the Frame Tensioner NOVAJET SERIES 6 33 Disassembly Assembly 11 Remove the Compression Spring from the Frame Tensioner and set it aside 12 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 Fram
205. iage Assembly and you are replacing the Trailing Cable as well you will need to do only Steps 3 6 of this section The placement of the two pieces of double sided tape 2 0 x 3 4 which hold the Trailing Cable to the Trailing Cable Support Assembly is important for proper movement of the Carriage Assembly Before removing the old tapes draw a line around them to mark their location and place the new tapes in the same places 1 Remove the Top Cover 2 f you have not already removed the Carriage Assembly from the Slide Shaft you will need to remove the Cartridges and on NOVAJET PRO s drain the Ink Delivery Lines see Chapter 3 Sections 3 1 and 3 2 and you will need to perform Steps 2 9 of Section 7 2 of this chapter in order to remove the Electronics Cover and release the left end of the Trailing Cable from the Strain Relief See Figure Chapter 6 16 3 Remove the Right Cover Assembly See Section 4 1 NOVAJET SERIES 6 39 Disassembly Assembly 4 Disconnect the Trailing Cable connector at the JP3 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 6 5 if necessary 5 Pull the Trailing Cable away from the double sided tape on the Trailing Cable Support Assembly Remove the Trailing Cable from the plotter unit 6 Draw a line around the old tapes to mark their location on the Trailing Cable Support Asse
206. iage 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 4 of this manual for the cleaning procedure Be very careful when working near the Encoder Strip so that it is not damaged INK DELIVERY SYSTEM NOVAJET PRO only Use only warm water to clean the inside of the Ink Delivery Reservoirs and Tubing 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 with the Carriage Assembly bushings will cause damage START UP If the plotter doesn t power up it must be turned off immediately to eliminate any damage until the problem can be resolved 1 12 NOVAJET SERIES General Information 7 0 Plotter Features The major features of the NOVAJET PRO 36 and NOVAJET 4 plotters are identified in Figure Chapter 1 1 Figure Chapter 1 2 and Figure Chapter 1 3 See Chapter8 for an illustration of a fully assembled NOVAJET 50 gt NU DISPLAY T MEDIA NMENT MARK RIDGES ASSEMBLY
207. ibration 14 2 Fast Deadband Height Calibration 7 54 The FAST DEADBAND also called the HEIGHT CALIBRATION shows the region dependent Carriage height at 16 regions across the Platen with the values shown mils 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 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 5 of the Calibration Worksheet NOVAJET SERIES Calibration 14 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 7 11 Adjustment is made by increasing or decreasing the value for DEADBAND as follows 1 NOVAJET SERIES Press the UP ARROW or DOWN ARROW to change the number to a higher or lower value Once the desired value is reached usually 54 66 or 71 but not limited to these values press SELECT Press SELECT again The plotter will print a new set of lines visually
208. ical Head to Head Calibration press MENU and press SELECT again The plotter will print a new set of three patterns The new Current Heads 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 If the new Current Heads pattern satisfactory proceed to Section 16 0 7 61 Calibration 15 2 Adjusting the Vertical Head to Head Calibration 7 62 1 With the display set at CALIBRATION HORIZ YELLOW X press the DOWN ARROW to change the display to CALIBRATION VERT YELLOW X X 2 current alignment value Press SELECT and then the UP ARROW or DOWN ARROW to select the alignment value matching the best vertical alignment in the print out for Color Vertical Head to Head Calibration Once the matching alignment value is reached press SELECT to save the setting Press MENU and press SELECT again The plotter will print a new set of three patterns The new Current Heads 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 s until satisfactory results are obtained Then proceed to Section 16 0 NOVAJET SERIES Calibration 16 0 Color Deadband Calibration NOTE Note You must have UTILITIES OPTIONS set O
209. igure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Title Page Major Functional Areas of the 2 5 2 12 Stepper MOLIOR ue ebrei 2 14 SEVO eoe atta e cave ec aea 2 15 Parallel and Serial Ports nta 2 16 Keypad DIS play e iti oe Iu E ER ERU EEUU ER EE EH 2 17 Carriage Assembly CIFCUNS seca eb E nal 2 18 CHAPTER 3 INK DELIVERY SYSTEM Number Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Title Page Correct Handling of Filled 3 2 NOVAINK ACCESSORY KIT 3 4 Filling Ink HeSeFVOIES 3 5 Closing and Opening Tubing 3 6 Priming the Delivery rrr irt 3 8 Initial Filling of gt oett eerte 3 10 Connecting Cartridge to Ink Delivery 3 11 Removing Blue Tape from Cartridge Jet Area 3 12 Priming Cartridge Prior to Installation in Carriage Assembly 3 13 NOVAJET SERIES xxi Table of Contents CHAPTER 3 Number Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Figure 3 14 Figure 3 15 INK DELIVERY SYSTEM continued Title Page Installing Cartri
210. ill ensure the highest quality printed images nore Each time you install a Cartridge in the plotter you should NOVAJET SERIES 3 27 Ink Delivery System 3 28 NOVAJET 4 Refillable Cartridges are full when shipped to the customer Each refill kit includes a new Cartridge and three 30 ml bottles of ink 4 1 1 Installing a New NOVAJET 4 Cartridge 1 Press the ACCESS CARTRIDGES key to move the Carriage Assembly away from the Service Station Remove the blue tape from the jet area of the Cartridge Be careful not to touch the Flex Contacts see Figure Chapter 3 1 or the jet area itself Put the bottom of the Cartridge into the correct position in the Carriage Assembly Then press the top of the Cartridge toward the Carriage Assembly to snap it into place Be sure to match the Cartridge color to the color bars on the Carriage Assembly Cartridge positions from left to right are Yellow Magenta Cyan and Black After all four Cartridges are installed press the PRIME key to run the Prime plot Check the Prime plot to see if the Cartridges are firing properly The bands should be smooth without dark streaks or white lines The diagonal lines should not look fuzzy or contain gaps You may need to run the Prime plot more than once If a Cartridge is not firing properly see Chapter 5 Section 11 7 for troubleshooting information Once all the Cartridges are firing properly perform the Color Calibration in Chapter 7 S
211. ill 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 5 13 Troubleshooting If an error occurs this display provides information ERROR CMD POS 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 Records the time used on plotter XX XX XX 4 1 2 Information Print Settings This option prints all eight stored User Settings INFORMATION Media must be loaded in order to print them PRINT SETTINGS 5 14 NOVAJET SERIES I SERVICE DIAGNOSTICS DIAGNOSTICS PAPER SENSOR DIAGNOSTICS SERIAL PORT DIAGNOSTICS PARALLEL PORT DIAGNOSTICS CARTRIDGE DIAGNOSTICS CARRIAGE VIBRATE NOVAJET SERIES Troubleshooting 2 Service Diagnostics This level contains the following firmware tests to detect and isolate plotter malfunctions e Paper Sensor e LED e Serial Port e ROM e Parallel Port e RAM e Cartridge e Speaker e Carriage Vibrati
212. in place follow the same sequence and remove each screw one at a time and apply a small drop of Loctite 222 to the threads of the screw Then reinsert the screw into the support bracket and tighten slightly using a 2 6 or 8 Phillips screwdriver Following the sequence of right support left support and middle supports bring up all the screws a little at a time so that the Lower Drive Shaft does not bind If using a torque screwdriver torque the screws evenly across the unit to 6 In Lb 6 76 NOVAJET SERIES Disassembly Assembly 5 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 6 28 Align the Foam Block as shown in Figure Chapter 6 30 Make sure it is not tilted at an angle Figure Chapter 6 30 Alignment of Foam Block Lower 6 Turn the Platen onto its back NOVAJET SERIES 6 77 Disassembly Assembly Do not overtighten the screws which hold the Fan Assembly in place The threads in the screw holes will strip very easily 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 f necessary push the Power Supply Cable up towards the front edge of the Platen so that it is out of the way of the
213. ings to clean them See Chapter 6 Section 7 13 for the procedure for removing the Carriage Bushings If cleaning the bushings does not resolve the problem replace the Carriage Assembly After replacing the Carriage Assembly see Chapter 7 Section 7 0 for the Cartridge Head Height Adjustment 8 The Slide Shaft Height or the Cartridge Head Height may be too low causing the Cartridges to drag on the media or hit the Upper Roller Supports Refer to the procedures Chapter 7 Sections 6 0 and 7 0 for the Slide Shaft Profile Adjustment and the Cartridge Head Height Adjustment NOVAJET SERIES 5 57 Troubleshooting 11 16 Media Movement Erratic 5 58 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 6 Figure 6 6 Drive circuits may be faulty Replace the Stepper Motor see Chapter 6 Section 10 3 You may also need to replace the MPCB be sure to reprogram the Flash EEPROM See Chapter 6 Section 4 0 and Appendix A 3 The media may be slipping due to a Upper Roller Supports are not in proper adjustment See Chapter 7 Sections 9 0 and 10 0 for the Paper Skew Adjustment b Upper Rollers and or Lower Rollers are dirty To clean the rollers see Chapter 4 Section 7 0 Upper Rolle
214. 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 Press SELECT and the DOWN ARROW twice The display will read CALIBRATION VERTICAL LINES ALL 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 7 12 for a sample Figure Chapter 7 12 Vertical Lines All 7 55 Calibration 7 56 3 0 10 Press the UP ARROW The display will read CALIBRATION VERTICAL LINES ONE Press SELECT The plotter will draw 16 single 1 5 high vertical lines one line at a time uni directional mode See Figure Chapter 7 13 for a sample Figure Chapter 7 13 Vertical Lines One Visually inspect the lines and compare against the printout of the Line Quality Acceptance Standards files NJPTEST PLT see Required Documentation and Files in Section Two regular NOVAJET PRO Cartridges each of which has exactly 20 ml of ink in it e Height gauge kit assembly P N 205660 e Multimeter BECKMAN IND DM15XL or equivalent e Adapter Flexible red with patch cord red e Patch cord alligator to banana black e Calculator magnifier and flash light of this chapter If sub standard lines at various regions exist repeat Steps
215. ion 13 1 Calibrating the Y Axis Carriage Axis or Horizontal Axis Calibration 1 7 48 With a sheet of D Size paper 24 side against the rollers still loaded press DOWN ARROW The display will read MAIN MENU UTILITIES Press SELECT The display will read UTILITIES CALIBRATION Press SELECT The display will read CALIBRATION COLOR Press DOWN ARROW The display will read CALIBRATION USE XY CALIB NO Press SELECT DOWN ARROW and SELECT The display will read CALIBRATION USE XY CALIB YES Press DOWN ARROW The display will read CALIBRATION XY ENGLISH Press DOWN ARROW The display will read CALIBRATION PAPER AXIS NOVAJET SERIES NOVAJET SERIES Calibration Press DOWN ARROW The display will read CALIBRATION CARRIAGE AXIS 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 Press FEED MEDIA and DOWN ARROW to unload the paper and measure the line that was drawn the line 1 21 00 0 05 long proceed to Section 13 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 0
216. itch 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 6 58 NOVAJET SERIES Disassembly Assembly 8 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 2 Connect the ground wire to the inside of the Platen see Figure Chapter 6 31 Connect the Power Cable coming from the MPCB to the connector on the Power Supply If the Power Cable has a Grounding Braid make sure that it is still connected to the inside of the Platen at the same location as the ground from the ON OFF Switch see Figure Chapter 6 31 Insert the Power Supply part way into the Platen Connect the Power Switch cable to the connector on the Power Supply Supply if you turn the Platen onto its back side Note You may find it easier to align the screws with the Power 5 6 7 NOVAJET SERIES 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 Reattach the Plotter to the Stand See Section 3 2 if necessary NOVAJET 4 only Reinstall the Left Side Plate Left Cover A
217. ith NJP 36 NJP 50 and NJ 4 1 6 5 0 Media Sizes and Plotting 20 40000 1 9 6 0 General Prod ct Not e Md 1 12 911218 REM 1 13 8 0 Plotter Specifications odore b bre Hp HE pa 1 16 9 0 Linie Length AOCUIACY Ha td cit etched ieu eR beds 1 18 1 20 11 0 Acronyms and 1 22 T1230 GIoSSal Y enn 1 23 TABLES Table 1 1 Comparison of NJ with NJP 36 NJP 50 1 6 Table 1 2 Media Sizes and Maximum Plotting Areas for Rollfeed Media 1 10 Table 1 3 Media Sizes and Maximum Plotting Areas for Sheet Media 1 11 FIGURES Figure 1 1 Front View of Plotter epe dac susce qe pa ts 1 13 Figure 1 2 Back View of NOVAJET PRO ir rr Rer 1 14 Figure 1 3 Back View of NOVAJET ecce eer natn es ee t out 1 14 Figure 1 4 Line Length Accuracy atia prestato tx qua enn stet creta eec 1 18 Figured soto ipo 1 20 1 30 NOVAJET SERIES Chapter 2 THEORY OPERATION 1 0 Introduction This chapter explains the mechanical and electrical theory of operation of the ENCAD NOVAJET PRO 36 NOVAJET 50 and NOVAJET 4 D and E Size Color Inkjet plotters The NOVAJET is a 68340 microprocessor based digi
218. k and may affect plotting quality You should open only one Ink Reservoir at a time so that no ink CAUTION spills into any other Ink Reservoirs wr Note 1 When you refill an Ink Reservoir you will not need to drain the Reservoir or the Ink Delivery Line Different lots of NOVAINK can be mixed since ENCAD will not release any ink lots which do not meet our specifications for color matching The length of time that an Ink Cartridge can be used may vary Current data suggests that one Cartridge can be used per one filling of the Ink Reservoir However if the Cartridge is not firing properly it should be replaced if normal troubleshooting procedures cannot restore proper functioning You may wish to save the 500 ml ink bottle and the Pouring Cap in case you ever need to drain the Ink Reservoir and store the ink If so be sure to thoroughly rinse with distilled water or water Reverse Osmosis dry the bottle and the cap NOVAJET SERIES 3 3 Ink Delivery System 3 4 Refer to Figure Chapter 3 2 Figure Chapter 3 3 and Figure Chapter 3 4 during this procedure 1 00 ML INK BOTTLE Remove the rubber cap from the Ink Reservoir you want to fill Figure Chapter 3 4 1 Select the 500 ml ink bottle Figure Chapter 3 2 with the color of ink appropriate for that Ink Reservoir The color for each reservoir is indicated by the colored labels on the front and back of the Left Cover
219. ke 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 Install the Lower Drive Assembly support brackets as follows NOVAJET 4 D and E Sizes and NOVAJET PRO 36 only a Apply a small drop of Loctite 222 to the threads of the screws and put the screws into the three support brackets Use a 2 6 or 8 Phillips screwdriver to tighten them slightly Install the brackets in this sequence right support bracket by the Stepper Motor left support bracket 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 6 27 middle support bracket insert through the Snap Plug opening see Figure Chapter 6 27 6 75 Disassembly Assembly b Tighten all the screws in the supports until they are snug If using a torque screwdriver torque to 6 In Lb NOVAJET 50 only a Put all the screws loosely finger tight into all four support brackets in this sequence right support bracket by the Stepper Motor left support bracket 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 6 27 middle support brackets insert through the Snap Plug openings see Figure Chapter 6 27 b Once all the screws are
220. l Cartridge and run the PRIME plot Table Chapter 4 2 NOVAJET 4 Cartridge Jet Area Cleaning Procedures 4 10 NOVAJET SERIES Maintenance METHOD PROCEDURE 1 Blotting Remove the Cartridge from the Carriage Assembly Gently blot press lightly against the jets to remove any excess ink before reinstalling the Cartridge Reinstall the Cartridge and run the PRIME plot If the plot is unsatisfactory repeat this procedure one more time before proceeding to Method 3 3 Ultrasonic Cleaner Remove the Cartridge from the Carriage Assembly Put a small amount of distilled water or R O water into the ultrasonic cleaner Hold the bottom end jet area of the Cartridge in the water Do not allow the Cartridge to rest on the bottom of the ultrasonic cleaner Set the timer for 10 20 seconds then remove the Cartridge Dry the Cartridge body with a clean lint free cloth avoid touching the jet area or the Flex Contacts Reinstall Cartridge and run the PRIME plot NOVAJET SERIES 4 11 Maintenance 6 2 Extended Periods of Inoperation If the plotter is not used for a period of time up to about 30 days the Cartridges should remain in the plotter with the Carriage Assembly parked at the Service Station Do the following 1 Unplug the plotter s power cord 2 Move the Carriage Assembly out of the Service Station 3 Remove each Cartridge from the Carriage Assembly and blot the jet area with a lint fr
221. l Ready Enquire Fahrenheit Federal Communications Commission Gravity defined as 9 82 m s or 32 ft s grams Ground Hewlett Packard Graphics Language older standard Hewlett Packard standard Graphics Language Hz INIT ISO KB kHz LCD LED MANF MAX MB MIN mm MPCB PC PD PLL PROM PU PWM RAM ROM RTS RXD SG SIMM SRXD STXD TXD TXDO UART Vac Vdc Hertz cycles per second Initialize International Standards Organization Kilobytes Kilo One Thousand Hertz Liquid Crystal Display Light Emitting Diode Manufacturer s Maximum Megabyte Minimum Millimeter Main Printed Circuit Board Personal Computer Pen Down Phase Locked Loop Programmable Read Only Memory Pen Up Pulse Width Modulation Random Access Memory Read Only Memory Ready to Send Receive Data Signal Ground Single Inline Memory Module Secondary Receive Data Secondary Transmit Data Transmit Data Transmitter Signal Data Output Universal Asynchronous Receiver Transmitter Volts Volts Alternating Current Volts Direct Current Watts NOVAJET SERIES General Information ASCII ASYNCHRONOUS BANDING BASIC BAUD BIT BI DIRECTIONAL PRINTING BINARY BITMAP BYTE BUFFER NOVAJET SERIES American Standard Code for Information Interchange An information scheme used by computers to represent letters numbers and symbols Data transfer which occurs at a known rate so that
222. laten 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 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 microprocessors 32KHz crystal oscillator is not working it will hold RESET low NOVAJET SERIES 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
223. le which is between the inside of the Right Side Plate and the end of the Trailing Cable Support Assembly This will give you about 1 of slack NOVAJET PRO only In Steps d and e do not pull up too hard on the Trailing Cable Support Assembly or the Chain Tube Assembly may pull loose from the Carriage Assembly d Lift up gently and hold the right end of the Trailing Cable Support Assembly e Use 2 6 Phillips screwdriver to remove the back screw on the Servo Motor See Figure Chapter 6 11 Your screwdriver will be at a slight angle Be careful not to strip the head of the screw f Lowerthe Trailing Cable Support Assembly back into place 6 24 NOVAJET SERIES Disassembly Assembly 10 Hold your hand under the Servo Motor and remove the front screw on the Servo Motor See Figure Chapter 6 11 During the removal of the Servo Motor do not accidentally cut the Servo Motor wires on the opening in the bottom of the Platen 11 Tilt the bottom of the Servo Motor towards the back of the Platen and carefully lower the cable connector through the opening in the bottom of the Platen Then move the bottom of the Servo Motor towards the front of the Platen and lower the motor out of the opening 12 Unlock the cable connector from the Servo Motor and finish removing the motor NOVAJET SERIES 6 25 Disassembly Assembly 5 2 Replacing the Servo Motor While reinstalling the Servo Motor do not accidentally cut
224. ll used Cartridge with different type of ink or a different color of ink There will still be some of the previous ink left in the Cartridge and if it mixes with the new ink plotting quality may be affected NOVAJET PRO only Do not fill a used Ink Delivery Line ora used Ink Reservoir with a different type of ink or a different color of ink The ink which was in the system has permeated the surface of the Line and Reservoir If a different type of ink or different color of ink is used in them particles of the previous ink will mix with the new ink and may affect plotting quality 5 43 Troubleshooting Table Chapter 5 5 NOVAJET PRO Extended Ink Supply Troubleshooting Table 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 A NOVAJET PRO CARTRIDGE CONDITIONS ACTIONS The Cartridge does not fire after initial installation or stops firing after it has been in use 2 One nozzle stops firing 5 44 Make sure the Tubing Clamp on the Carriage Assembly is open Make sure that the blue tape has been removed from the Cartridge s jet plate Make sure that there is ink in the Ink Reservoir Make sure that ink is still being fed through the Ink Delivery Line is the line still full If not use the Priming Pump to establish the siphon See Chapter 3 Section 2 2 Use the Suction Bulb to dra
225. lled on carpeting or other floor covering NOVAJET PRO and NOVAJET 4 blue tape should remain on the jet area on the bottom of the Cartridge see Figure Chapter 3 9 until you are ready to install it on the Carriage Assembly and the Cartridge should be held upright This will prevent ink from coming out of the jet area or out of the opening in the top of the Cartridge NOVAJET PRO and NOVAJET 4 If you lay down a Cartridge with ink in it lay it on its front side so that the Flex Contacts are facing up see Figure Chapter 3 1 This will prevent the ink from leaking out of either the opening in the top or out of the jet area on the bottom ij UC FLEX CONTACTS KEEP FLEX CONTACTS WHEN FILLED CARTRIDGE IS LAID Figure Chapter 3 1 Correct Handling of Filled Cartridge 3 2 NOVAJET SERIES Ink Delivery System 2 0 Loading the NOVAJET PRO Extended Ink Suppl 2 1 Filling the Ink Reservoirs Use of any inks other than those supplied by ENCAD Inc will void the warranty Do not fill a used Ink Reservoir or a used Ink Delivery Line with a different type of ink or a different color of ink The ink which was in the system has permeated the surface of the Line and Reservoir If a different type of ink or different color of ink is used in them particles of the previous ink will mix with the new in
226. logged 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 and a series of segmented sloping lines Each segment in the sloping lines represents one jet The bands should be smooth without 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 at least three more times If you still see discrepancies after priming the plotter several times you should clean the Cartridges See Chapter 4 Section 6 1 2 for cleaning procedures Repeat the PRIME plot 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 NOVAJET SERIES 5 51 Troubleshooting 11 9 Memory Full 5 52 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 and the Raster The bu
227. ly 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 until the Cutter is engaged the knife drops down into the groove in the Platen 8 NOVAJET PRO only After the Cartridges and the Top Cover are reinstalled you will need to reestablish the siphon in the Ink Delivery Lines Follow the procedures in Chapter 3 Sections 2 2 and 2 4 NOVAJET SERIES 6 63 Disassembly Assembly 10 0 Lower Drive Assembly Fan Assembly and Stepper Motor Assembly Inner Platen 15 Inner Platen contains the Lower Drive Assembly the Fan Assembly the Stepper Motor Assembly the Drive Shaft Supports and the Foam Block Lower See Figure Chapter 6 25 and Figure Chapter 6 26 These parts are referred to collectively as the Inner Platen Parts Replacement procedures for the Power Supply ON OFF Switch and Servo Motor are given in previous sections of this chapter 6 64 NOVAJET SERIES Disassembly Assembly Figure Chapter 6 25 Inner Platen Parts NOVAJET SERIES 6 65 Disassembly Assembly gt HEAT SHRINK d fox Figure Chapter 6 26 Details of Figure 6 25 6 66 NOVAJET SERIES Disassembly Assembly 10 1 Disassembly of Plotter Before Removing the Inner Platen Parts Do not remove the Trailing Cable Carriage Assembly the Trailing Cable Support Assembly the Stabilizer Bracket Assembly or the Y Arm Assembl
228. m drying out and clogging the Ink Delivery Lines Be sure to open the Tubing Clamps on the Ink Delivery Lines This will help the Ink Delivery Lines remain flexible so that they function properly This procedure should also be followed if you plan to transport the plotter to another site This will avoid any ink spills which could cause damage to other parts of the plotter Do not fill a used Ink Reservoir or a used Ink Delivery Line with a different type of ink or a different color of ink The ink which was in the system has permeated the surface of the Line and Reservoir If a different type of ink or different color of ink is used in them particles of the previous ink will mix with the new ink and may affect plotting quality 1 Remove all four Cartridges and drain all four lines before removing the Left Cover Assembly See Section 3 1 and or Section 3 2 as needed Do not remove the rubber caps on the Ink Reservoirs 2 Three Phillips screws hold the Left Cover Assembly onto the Left Side Plate One of them is on the bottom of the Left Cover Assembly The other two are on the inside of the Left Side Plate See Figure Chapter 3 14 3 Use a 2 Phillips screwdriver to remove the three screws while someone holds the Left Cover Assembly to keep it from falling Hold it level so ink does not spill out of the air vents in the top of the Ink Reservoirs 4 Once the Left Cover Assembly has been removed place it in the Left Cover
229. 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 2 Ensure the print utility is installed on the computer Install the DOS UTILITIES disk At dos prompt A OR B type INSTALL and press ENTER A blue screen will appear with an ENCAD illustration NOVAJET SERIES A 1 Press key each to advance through selections Install to the C drive Choose to load all files Place the file under the directory ie C NJPRO Eventually the dos prompt C NJPRO will be displayed OR If dos utility is already loaded locate dos prompt C NJPRO or subdirectory of utility location 3 Atdos prompt C NJPRO type DIR verify the 3 download files are listed If files are absent reinstall utilities under a different directory name ie NJPRO1 Continue until download files are present 4 Ensure serial download cable RS422 is connected from computer COM 1 2 port to printer plotter serial port if not already performed NOTE A parallel cable may work depending on the cable type Follow steps 5 through 7 below except choose or LPT2 parallel port Type 1 and press ENTER The download will begin If it fails then you must use a serial cable 5 Power off printer plotter At the dos prompt C NJPRO type DOWNLOAD and press ENTER 6 From the four choices type 4 port connections and press ENTER z Disable
230. mbly before removing them 6 40 NOVAJET SERIES Disassembly Assembly 7 6 Reinstalling the Trailing Cable The Trailing Cable which you receive MUST have a 90 degree bend in it If it does not have a bend contact ENCAD s Help Desk see Chapter 1 Section 3 0 to arrange for an exchange The bend cannot be off by even one degree or the Trailing Cable will quickly be damaged by the Strain Relief FAILURE TO OBSERVE THIS WARNING WILL VOID THE WARRANTY After the Trailing Cable has been installed on the Carriage Assembly it is very important that you move the Carriage Assembly to the left end of the Slide Shaft and check to make sure that there is clearance between the edges of the Trailing Cable and the side walls of the Strain Relief It must not rub against the side walls The placement of the two pieces of double sided tape 2 0 x 3 4 which hold the Trailing Cable to the Trailing Cable Support Assembly is important for proper movement of the Carriage Assembly Before removing the old tapes draw a line around them to mark their location and place the new tapes in the same places 1 Before removing the old tapes draw a line around them to mark their location and place the new tapes in the same places 2 There will be a mark 3 75 0 25 from the left end of the Trailing Cable which will already be bent see Warning 1 above Align the mark with the left end of the Trailing Cable Support Assembly 3 Press the Trailing C
231. move the Service Station and thoroughly rinse out any ink in it Put the Service Station back in the plotter cU MV OM Place the Carriage Assembly back over the Service Station See Figure Chapter 6 2 6 6 NOVAJET SERIES Disassembly Assembly Figure Chapter 6 2 Removing Tie Wrap and Foam Rubber 10 11 5 5 If you are shipping plotter to for servicing not for replacement you will need to use the zip tie foam rubber and cardboard wedge NOVAJET PRO only that came with the unit Remove the reusable zip tie do not cut it and foam rubber which is around the Slide Shaft on the new unit which was sent to you See Figure Chapter 6 2 Do not throw these items away You will need them to secure the Carriage Assembly on the unit you are returning to ENCAD Use the foam rubber and the reusable zip tie from the replacement unit to lock the Carriage Assembly in place on the unit being shipped to ENCAD See Figure Chapter 6 2 NOVAJET PRO only Remove the piece of cardboard wedge which is behind the Carriage Assembly of the new unit See Figure Chapter 6 3 Do not throw this away You will need it to pack the unit you are returning to ENCAD 6 7 Disassembly Assembly DN SVS Figure Chapter 6 3 Removing Cardboard Wedge NOVAJET PRO only 12 NOVAJET PRO only Put the cardboard wedge you removed from the replacement unit behind the Carriage Assembly on t
232. n the Platen Press ACCESS CARTRIDGE The Carriage will move out of the Service Station Install all four Ink Cartridges following the procedures in Chapter 3 Section 2 0 If the Left Cover Assembly was removed it will need to be reinstalled and if necessary the Ink Reservoirs will need to be loaded Be sure to use the Priming Pump to prime the Ink Delivery Lines and the Suction Bulb to prime the Ink Cartridges After installing the Ink Cartridges there may be large drops of ink deposited on the paper This is normal and cannot be avoided Feed the paper forward before doing the PRIME plot Proceed to Section 12 0 to do the PRIME plot NOVAJET SERIES Calibration 12 0 Prime Plot 1 Press ACCESS CARTRIDGE The Carriage will automatically return to the Service Station Press MENU The display will read MAIN MENU PRINT MODE 2 Press PRIME The plotter will fire the heads and plot the prime pattern Examine the pattern for the following problems e streaks or white lines within the color bands and or gaps or fuzzy lines in the sloping horizontal lines If these conditions are present a Press the PRIME key at least 3 times to make sure all inkjets are firing b Ifthe inkjets still misfire press ACCESS CARTRIDGE c See Chapter 5 Section 11 7 for Troubleshooting information d Repeat the PRIME test e f misfiring is still observed contact ENCAD s Technical Support and Service department see Chapt
233. nd 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 NOT ON LINE the parallel download is not going to work nore If at this point there is an error message reporting In this case you need to call ENCAD s Help Desk see Chapter 1 Section 3 0 and order ENCAD s 5422 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 the procedure fails follow procedures outlined in Appendix A 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 NOVAJET SERIES
234. nformation about determining the Skew and Chapter 7 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 Universal Asynchronous Receiver Transmitter interface device used to send and receive serial data UNI DIRECTIONAL PRINTING Cartridges on the plotter fire ink on the media during UV EPROM VECTOR VELOCITY NOVAJET SERIES right to left movement only Stores data and needs UV light to be erased A graphic created by geometric lines and HP GL 2 files usually contain vectors The time rate of linear motion in a given direction Commonly referred to as speed 1 29 General Information Chapter 1 GENERAL INFORMATION 1 1 eio A 1 1 1 2 2 1 Related PUDIICSIIOR 1 2 2 2 Features of this Service 0 22222 0000 00101 1 3 22 Subject on ett e t tra 1 3 2 2 2 Figures and Tables uo 1 3 2 2 3 Manual Conventions 53 irent tel Mak e 1 4 3 0 ENCAD Technical Support amp 0 1 5 4 0 Comparison of NJ w
235. nnectors 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 JP3 while inserting the Trailing Cable into the JP3 connector vf Note The silver fingers on the Trailing Cable should be facing down 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 the machine when inserting the Keypad Cable into the 41 connector nore Note The fingers on the Keypad Cable should be facing the back of When inserting the Keypad Cable connector apply pressure on the locking clip towards the 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 If the MPCB is replaced the Flash EEPROM must be programmed because the Flash EEPROM will be blank when the is shipped from ENCAD See Appendix at the end of this manual in order to program the Flash EEPROM NOVAJET SERIES 6 17 Disassembly Assembly 4 Extra Memory SIMM Power must be disconnected Integrated circuits can be weakened or inactivated by electrical discharge You must be grounded to a
236. ns See Chapter 6 Section 7 6 Replace the Servo Motor See Chapter 6 Section 5 0 If replacing the Servo Motor doesn t correct the problem replace the MPCB See Chapter 6 Section 4 0 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 6 Section 9 0 NOVAJET SERIES Troubleshooting 11 5 Media Problems 11 5 1 Cut Sheet Media Won t Load If cut sheet media won t load 1 Checkto 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 2 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 NOVAJET SERIES 5 35 Troubleshooting 5 36 2 4 In media with a preprinted border the optical sensor on the Carriage Assembly may sense the preprinted border as t
237. ns and the control signal DTRCLK meets the RS423 electrical specifications The control signal can be configured as a 1 2 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 9 of this Service Manual for the part number NOVAJET SERIES Theory of Operation 3 14 Keypad Display R O NV MICRO OR LOOVUIN z MEN CONTROL KEYPAD KEY coNTROL 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 NOVAJET SERIES 2 17 Theory of Operation 3 15 Carriage Assembly Circuits CATE ARRAY ENCODER SHIFT l HEAD STROBE MICRO PROCESSOR PSIZE CARRIAGE CONNECTOR TRAILING CABLE 2 18 CARRIAGE FLEX CARTRIDGE 1 CARTRIDGE 2 CARTRIDGE 5 CARTRIDGE 4 OPTICAL ENCODER
238. nted to validate that all jets are firing correctly unless the key has been pressed during plotting Applies to both the NOVAJET 4 and the NOVAJET PRO 2 On the NOVAJET PRO PRIME also refers to using the Priming Pump to draw ink from the Ink Reservoirs into the Ink Delivery Lines when the Ink Delivery System is being loaded see Chapter 3 Random Access Memory Usually temporary electronic storage for data and programs Information will be lost when power is removed 1 27 General Information RASTER IMAGE REPEATABILITY RESET RESOLUTION ROLLFEED ROM RS 422 RS 423 QUADRANTS SCALING SCALING POINTS SERIAL INTERFACE 1 28 A graphic image created by dots called bitmaps The plot is defined in terms of pixels dots rather than as vectors For monochrome plots each pixel is defined by a bit For color plots each pixel has several bits A bit that is on will print a dot on the media A bit that is off will leave the area blank In plotting the ability of a plotter to return to a predetermined location on the plot with a given amount of accuracy The plotters menu driven instruction to return the plotter to its default 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 el
239. ntil the latch on the right end snaps into place You may need to push the latch to the right to get it to snap into place Park the Carriage Assembly on the Service Station and turn on the plotter NOVAJET SERIES 4 5 Maintenance LEFT NE IUN STA THE PUSH THIS TAB Figure Chapter 4 1 Removal of Service Station NOVAJET SERIES 4 6 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 1 Disconnect the power cord and the interface cable 2 Slightly dampen a cotton swab with isopropyl alcohol and wipe along the length of the Encoder Strip on both sides of the Encoder Strip 3 Reconnect the power cord and the interface cable NOVAJET SERIES 4 7 Maintenance 6 0 Ink Delivery System Maintenance The information in this section concerns maintenance of the NOVAJET 4 Refillable Cartridges and the NOVAJET PRO Extended Ink Supply which includes the Cartridges Ink Reservoirs and Ink Delivery Lines See Chapter 3 for the installation instructions for the NOVAJET 4 Refillable Cartridges and the NOVAJET PRO Extended Ink Supply 6 1 Cleaning the Cartridges
240. o reduce or enlarge the printed image See the NOVAJET Series User s Guide Chapter 7 A scaling point used by the plotter that specifies the location of the plot s lower left corner On NOVAJET plotters this point will either be NORMAL or MAX NOVAJET SERIES 2 PAPER MEDIA AXIS PARALLEL INTERFACE PARITY PLATEN PLOT AREA PLOTTER POROSITY PRIME RAM NOVAJET SERIES General Information A scaling point used by the plotter that specifies the location of the plot s upper right corner On NOVAJET plotters this point will either be NORMAL or MAX The long side of the plot area measured at right angles to the platen the Vertical Axis An interface type in which a separate line is used for each data bit in a byte All bits in the byte are transferred simultaneously 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 The surface on which the media moves The area in which the plotter prints the image 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 and or filled areas A measure of the flow of ink through the media 1 Pressing the PRIME key on the Right Cover Assembly to clear the ink cartridges by forcing them to fire rapidly may be done during plotting test pattern will be pri
241. o Section 7 3 Step 11 and finish the reinstallation procedure NOVAJET SERIES Disassembly Assembly 7 7 Removing the Carriage Belt from Carriage Assembly NOTE Note 1 You must do the procedures in Sections 7 1 and 7 2 in this chapter before the Carriage Belt can be removed 2 After the Carriage Belt is installed Section 7 8 follow the procedures in Sections 7 3 and 7 4 in this chapter to reinstall the Carriage Assembly Replace the Carriage Belt if it is frayed cracked worn or otherwise damaged 1 Read Note 1 above and perform the necessary procedures 2 Once the Carriage Assembly is removed from the Slide Shaft turn it over so that you can see the Belt Clamp See Figure Chapter 6 18 3 disengage the Carriage from the Belt Clamp push the Carriage Belt away from the left post of the Belt Clamp and gently lift up until the bottom edge of the Carriage Belt clears the top of the left post 4 Push the Carriage Belt away from the right post of the Belt Clamp and gently lift up to finish removing the Carriage Belt from the Belt Clamp NOVAJET SERIES 6 43 Disassembly Assembly Figure Chapter 6 18 Carriage Belt and Belt Clamp 6 44 NOVAJET SERIES Disassembly Assembly 7 8 Installing the Carriage Belt on Carriage Assembly The placement of the Carriage Belt on the Belt Clamp is very important There are three bumps on the Carriage Belt near a number stamped on the Belt The two
242. of it is facing up Route the flex on the Encoder through the slot in the Carriage Assembly as shown in Figure Chapter 6 21 Push down on the plastic clip and slide the back of the Encoder over it Push the Encoder in past the ridges until the Encoder snaps into place Turn the Carriage Assembly over and insert the Encoder flex cable into the connector at J7 See Figure Chapter 6 19 Push both sides of the connector lock shut at the same time Follow all procedures in Sections 7 3 and 7 4 in this chapter to reinstall the Carriage Assembly NOVAJET SERIES Disassembly Assembly Figure Chapter 6 21 Installing Paper Sensor and Encoder NOVAJET SERIES 6 51 Disassembly Assembly 7 13 Replacing the Carriage Bushings 1 Follow all procedures in Sections 7 1 and 7 2 in this chapter to remove the Carriage Assembly from the Slide Shaft 2 Use a flat tip screwdriver to push up on the latch which holds the Carriage Bushing in place See Figure Chapter 6 22 3 Pull the Carriage Bushing out of the Carriage Assembly 4 Repeat Steps 2 and 3 for the other Carriage Bushing 5 Orient the new Bushing as shown in Figure Chapter 6 22 so that the metal tab on top of the Bushing goes into the Carriage Assembly first 6 Push the Bushings in until they snap into place 7 Follow all procedures in Sections 7 3 and 7 4 in this chapter to reinstall the Carriage Assembly 6 52 NOVAJET SERIES Disassembly Assembl
243. on P N 202010 are not included They must be ordered separately These parts make up the entire Display Keypad The Assy Keypad Top P N 203488 1 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 203457 for NJ 4 or NJP 36 or P N 205111 for NJP 50 or the Keypad Label included in P N 204994 are needed they must be ordered in addition to P N 203488 1 The MPCB has the Flash EEPROM already mounted but it is not programmed The 10 Stand Screws P N 203485 2 are not included in the Assy Hardware Kit Service P N 205440 9 8 NOVAJET SERIES Replacement Parts List 4 0 Alphabetical Listing with Drawings DESCRIPTION PART NJ4D NJ4E NJP 36 NJP 50 Figure Chapter 9 1 Assy Bracket Drive Shaft P N 204916 left bracket w bushing ALSO INCLUDED ARE 2 PAPER SENSOR W FLEx Mim IASSY ENCODER W FLEX ee CARRIAGE BOARDS S us PN ma A 7 BUSHING 2 x VA p Figure Chapter 9 2 Assy Carriage complete P N 204996 NOVAJET SERIES 9 9 Replacement Parts List Uus Se 2 ASSEMBLED VIEW Figure Chapter 9 4 Assy Cover Right P N 203476 4 Figure Chapter 9 5 Assy Encoder w Flex P N 204999 9 1
244. on e Servo Motor e Color Test e Paper Motor e Key Pad e Fan e LCD This option tests the Paper Sensor and reports the available plotting area in inches and millimeters This option tests the serial port and reports any errors You must have the Loopback plug in place to perform this test See Section 11 3 1 This option tests the parallel port and reports any errors You must have the Loopback plug in place to perform this test See Section 11 3 1 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 5 15 Troubleshooting kh DIAGNOSTICS COLOR TEST XX DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS ROM DIAGNOSTICS RAM DIAGNOSTICS DIAGNOSTICS m 0 m lt lt gt 79 A gt m X V 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 tha
245. on the Trailing Cable Support Assembly place the back of the Electronics Cover under the Trailing Cable Support Assembly and gently press down on the ends of the Electronics Cover until the latches snap into the Carriage Assembly 10 Put the screws back into the Trailing Cable Support Assembly and tighten all the screws Torque to 6In Lb if using a torque screwdriver 11 Slide the Carriage Assembly to the middle of the Slide Shaft and stretch out the Carriage Belt Note 1 You may want to refer to Figure Chapter 6 17 while doing Step 12 through Step 17 One side of the Idler Pulley Assembly has a thicker outer 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 outer ring of plastic must face up See Figure Chapter 6 17 NOVAJET SERIES 16 17 20 5 5 Disassembly Assembly Insert the Carriage Belt into the Frame Tensioner so that the belt extends about an inch past the Frame Tensioner 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 outer ring of plastic is facing up 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 t
246. once The display will read UTILITIES SERVICE 4 Press SELECT amp the DOWN ARROW twice The display will read CALIBRATION m 2 lt m 5 Press SELECT The display will read DEADBAND XxX 6 Press the DOWN ARROW three times The display will read SLOW DEADBAND X 7 52 NOVAJET SERIES NOVAJET SERIES Calibration Load a sheet of D Size paper turned sideways along the 36 length Press SELECT The plotter will print 2 rows of lines in 16 regions See Figure Chapter 7 11 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 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 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 5 of the Calibration Worksheet 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 5 of the Calibration Worksheet 7 53 Cal
247. otor driver 5 Servo Motor driver 6 Interface Circuits Serial amp 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 NOVAJET SERIES 2 3 Theory of Operation 2 4 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 NOVAJET SERIES 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 CRYSTAL 1 STEPPER CONTROLLER PAPER SENSOR CARRIAGE FLASH PCB EEPROM OAS OAT GATE DY ds ARRAY ADDRESS MULTIPLEXER MICRO PROCESSOR ENCODER SERIAL SERVO CONTROLLER SERIAL EEPROM aX ADDRESS BUS PARALLEL Figure Chapter 2 1 Major Functional Areas of the Plotter NOVAJET SERIES 2 5 Theory of Operation 2 6 3 3 Power Supply An internal UL recognized switching power module supplies power for the NOVAJET plotter 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 p
248. over and lay it with the top side facing down c Push down on the plastic clip and at the same time push down on the Encoder until the plastic pieces on each side of the Encoder clear the ridges which hold it in place Then pull it straight out See Figure Chapter 6 20 4 See Section 7 12 for the procedure for installing the new Paper Sensor or Encoder 6 48 NOVAJET SERIES Disassembly Assembly Figure Chapter 6 20 Removing Paper Sensor and Encoder NOVAJET SERIES 6 49 Disassembly Assembly 7 12 6 50 Installing the Paper Sensor the Encoder 1 To install the Paper Sensor a f Turn the Carriage Assembly so that the bottom side of it is facing up Route the flex on the Paper Sensor through the slot in the Carriage Assembly Make sure that the silver strips on the flex are oriented as shown in Figure Chapter 6 21 Also make sure the flex goes all the way through and does not curl under the Carriage PCB Grasp the Paper Sensor between thumb and index finger and guide the sides of the board into the grooves on each side of the opening Push the Paper Sensor board down into the Carriage Assembly until it snaps into place Turn the Carriage Assembly over and insert the Paper Sensor flex cable into the connector at J6 See Figure Chapter 6 19 Push both sides of the connector lock shut at the same time To install the Encoder a f Turn the Carriage Assembly so that the bottom side
249. per Skew Acceptance Range for Rear Media Alignment Mark 7 39 Figure 7 9 Paper Skew Acceptance Range for Front Media Alignment Mark 7 40 Figure 7 10 Motion of Rollers and Adjustment of Mounting Screws 7 41 Figure 7 11 Deadband Alignment akc iac cocido 7 51 Figure 7 12 Vertical Lines dixe ee 7 55 Fig re 7 13 Vertical Eines OD cito oa coe o e e heo die el e cte eeu 7 56 Figure 7 14 NOVAJET PRO Calibration 7 68 Table 7 1 Mounting Screw Actions and Results 7 32 7 70 NOVAJET SERIES Chapter 8 POWER MEDIA FEED AND TAKE UP SYSTEM 1 0 Introduction This chapter provides instructions for installing the Power Media Feed and Take Up System on the plotter s stand Figure Chapter 8 1 NOVAJET PRO 50 with Power Media Feed and Take Up System NOVAJET SERIES 8 1 Power Media Feed Take Up System 2 0 Power Media Feed and Take Up System Installation Please read the instructions in this section carefully to ensure proper installation of the Power Media Feed and Take Up System on the plotter s stand It is recommended that the assembly procedure be done by two people The items in the Inventory List are provided with each new system Required Tool 2 Phillips Screwd
250. platen surface and for response efficiency 2 Depress ACCESS CARTRIDGE function Maually move carriage assembly slowly and carefully to extreme left until locked cutter latches Turn the multimeter on and set it at 20 volt range 3 Connect the aligator clip of the black patch cord to an Allen head screw on the Y Arm this will be the ground 4 Connect the red patch cord to the red Flexible adapter Attach the adapter to the Plated Through Hole Test Point 1 see Figure Chapter 7 3 5 The multimeter should read 1 45 to 1 55 Volts 6 If the display does not read within this range adjust the Potentiometer using flat blade screwdriver Set the Potentiometer to 1 5 05 Volts 1 45 1 55 Volts 7 Measure the voltage after the adjustment has been done Record the voltage in Part4 of the Calibration Worksheet see Figure Chapter 7 14 8 Use torque sealer gliptal to seal the pot NOVAJET SERIES 7 27 Calibration CARRIAGE ASSEMBLY Y ARM CMM SS j p y POTENTIOMETER ATEST POINT 1 VIEW IS FROM BEHIND THE PLOTTER NEAR THE LEFT END Figure Chapter 7 3 Paper Sensor Voltage Adjustment 7 28 NOVAJET SERIES Calibration NOTE Note 1 Readjust the Paper Sensor voltage if the Carriage Height is readjusted The adjusted
251. push the SIMM down until the two side clips snap into place Make sure the SIMM is fully seated 3 See Section 4 6 of this chapter for instructions on replacing the Right Cover Assembly Figure Chapter 6 9 Side View of SIMM Installation 6 20 NOVAJET SERIES Disassembly Assembly 4 6 Reinstalling the Right Cover Assembly 1 NOVAJET SERIES 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 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 Reinsert the bottom back screw on the inside of the Right Cover Assembly See Figure Chapter 6 4 Using a 2 Phillips screwdriver tighten the bottom back screw and the top and front screws All three screws should be firmly tightened Do overtighten Put the Top Cover back on 6 21 Disassembly Assembly 5 0 Servo Motor 5 1 Removing the Servo Motor While removing the Carriage Belt and the screws on the Servo Motor don t touch the Encoder Strip with any tools Note NJP 50 only Because of the Carriage Belt s length an assistant may need to do Step 4 while you do Step 5 To remove the Servo Motor proceed as follows 1 Disconnect the power cord and the interface cables 2 Remove the Top
252. r 4 1 NOVAJET PRO Cartridge Jet Area Cleaning Procedures METHOD PROCEDURE 1 Suction Bulb Remove the Cartridge from the Carriage Assembly but do not disconnect the Ink Delivery Line Use the Suction Bulb to draw ink through the jets as described in Chapter 3 Section 2 4 Gently blot press lightly against the jets to remove any excess ink before reinstalling the Cartridge Reinstall the Cartridge and run the PRIME plot If the plot is unsatisfactory repeat this procedure one more time before proceeding to Method 2 2 Blotting Remove the Cartridge from the Carriage Assembly but do not disconnect the Ink Delivery Line Gently blot press lightly against the jets to remove any excess ink before reinstalling the Cartridge 3 Reinstall the Cartridge and run the PRIME plot If the plot is unsatisfactory repeat this procedure one more time before proceeding to Method 3 3 Ultrasonic Cleaner Remove the Cartridge from the Carriage Assembly Close the Tubing Clamp and disconnect the Ink Delivery Line Put a small amount of distilled water or R O water into the ultrasonic cleaner Hold the bottom end jet area of the Cartridge in the water Do not allow the Cartridge to rest on the bottom of the ultrasonic cleaner Set the timer for 10 20 seconds then remove the Cartridge Dry the Cartridge body with a clean lint free cloth avoid touching the jet area or the Flex Contacts Reinstal
253. r Support Proceed to Section 11 0 3 If the gauge penetrates between the rollers that Upper Roller Support has failed the test If the Upper Roller Support has failed the test a Remove it from the Y Arm and replace it with another Upper Roller Support See Chapter6 Section11 0 for the replacement procedure b Perform the Paper Skew Adjustment procedure again Section 10 4 of this chapter c Perform the Minimum Pull Force Verification procedure again Section 10 5 of this chapter d Proceed to Section 11 0 7 42 NOVAJET SERIES Calibration 11 0 Setting the Print Mode 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 CALIBRATION gt 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 NOVAJET SERIES 7 43 Calibration 7 44 7 8 11 Press the UP ARROW until the display reads MAIN MENU PRINT MODE Load a sheet of D Size paper with the 36 side up against the rollers o
254. re instructions and data constants which the microprocessor can access and interpret with no loss of information when power is off DRAM is Dynamic 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 EEPROM to RAM where it can be executed faster Serial 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 installable memory is as follows DRAM 132 MB Flash EEPROM 1 MB Serial EEPROM 1KB NOVAJET SERIES 2 9 Theory of Operation 3 7 Flash EEPROM 2 10 The system firmware is stored a Flash EEPROM The Flash EEPROM 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 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 req
255. river Inventory List e 6 Phillips screws 2 for Idler Side Cradle 4 for Drive Plate e 1 Reflector Bracket amp 1 Bracket Mount pre assembled e 1 Drive Plate e 2 Media Guides e 2 Rail Cradles e 2 Adjustable Roll Guides e 2 Rails 427103 Core Adaptors 2 1 Installation Procedure 1 Install the Idler Side Cradle on the two lower holes of the left leg on the plotter Two Phillips screws are provided for the installation See Figure Chapter 8 2 as vw Figure Chapter 8 2 Idler Side Cradle 8 2 NOVAJET SERIES Power Media Feed Take Up System 2 Install the Drive Plate on the right leg of the plotter using the 4 Phillips screws provided The star washers and thumbnuts used in Steps 3 and 4 of Figure Chapter 8 3 are already mounted on the posts on the Drive Plate 1 ROTATE EACH CLEAR ROLL GUIDE AS NEEDED TO ACCESS BOTH TOP SCREW HOLES INSERT PHILLIPS SCREWS AND TIGHTEN ON ADADR y ALIGN CRADLE WITH BOTH 8 BOTTOM SCREW A MILES IN E INSERT PHILLIPS REWS AND TIGHTEN 3 USE STAR WASHERS AND HUMBNUTS TO INSTALL AKE UP SENSOR BRACKET 4 USE STAR WASHERS AND THUMBNUTS TO INSTALL FEEDER SENSOR BRACKET Figure Chapter 8 3 Install
256. rked over the Service Station 3 Place the Block Support in the position which you marked before removing it f the Block Support was taped onto the Trailing Cable Support Assembly make sure the Chain is behind the Block Support and press the Block Support down onto the Trailing Cable Support Assembly b f the Block Support was anchored in the Chain pinch together the appropriate links in the Chain and reinsert the Block Support s anchor between the links 4 Insert the Left Extrusion Cap into the left end of the Trailing Cable Support Assembly 5 Press the Chain against the double sided tape on the back wall of the left half of the Trailing Cable Support Assembly 6 Attach the connectors for the Ink Delivery Lines to the appropriate Ink Reservoirs 7 Follow all procedures in Chapter3 Sections 2 2 and 2 4 to establish the flow of ink from the Ink Reservoirs to the Cartridges 6 56 NOVAJET SERIES Disassembly Assembly and ON OFF Switch 8 1 Removing the Power Supply and ON OFF Switch Make sure that the Power Cord is disconnected from the plotter before beginning this procedure NOTE Note 1 The Cartridges can remain on the plotter during this procedure The Top Cover Left Cover Assembly including the Ink Reservoirs if the plotter is a NOVAJET PRO and Left Side Plate must be removed in order to remove either the Power Supply or the ON OFF Switch or to access the Fuse on the Power Supply For the
257. roblems 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 HOLT oa ihe toa oe DECISION Logie Tables EM EHE 2 1 Procedure for Using Decision Logic 2 2 Decision oua toic i e dun SOS VIC Bii Service Menu Description 22 082 0 4 1 Soervice InfOrmalloby 4 1 1 Information Display Settings 4 1 2 Information Print 5 4 2 Service oe o 4 3 Service GalllY Allon 22 DD mem ECD Rev PAG ait eoa Keypad Messades s eate cdi edge 7 1 PIOGLBOOBIVOU cce REL OR RR HG 7 2 Lon EU LM 7 3 7 4 7 5 AO dra 7 6 i tS LIA 7 7 Plotter 7 8 Ready 9 c Initialization Sequence
258. rs are worn If the Upper Roller Supports need to be replaced see Chapter 6 Section 11 0 NOVAJET SERIES Troubleshooting 11 17 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 may be loose Check the connections at J1 on the Main Printed Circuit Board see Chapter 6 Figure 6 6 and J1 on the Keypad PCB see Chapter 6 Section 6 0 vof For Step 2 below 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 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 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 below 2 For LCD or LED keys f a particular key appears to be inoperative test that key for operation to the SERVICE DIAGNOSTICS menu see your Service Menu chart and press the DOWN ARROW or the UP 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 th
259. s The user may release the media at any time Data has been received but no media has been loaded Load media for plotting The 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 SIMM module to a larger size maximum of 64MB Refer to the NOVAJET Series User s Guide Appendix for the acceptable sizes manufacturers and installation procedures 5 21 Troubleshooting 75 RAMOK SANE TS The plotter stops at this point in the initialization REV X 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 SIMM may also cause this problem See the NOVAJET Series User s Guide Appendix B for acceptable SIMM sizes and the replacement procedure 7 6 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 6 Sections 4 0 of this manual for the replacement procedures 7 7 Plotter Error 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
260. sembly in the Service Station 2 Disconnect the power cord and interface cable 3 Raise the 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 To prevent damage to the plotter do not slide the Carriage CAUTION Assembly on the Slide Shaft until the alcohol is completely dry 6 Manually move the Carriage Assembly from end to end 7 Wipe the Slide Shaft with a dry cloth to remove any deposits left by the Carriage Assembly NOVAJET SERIES 4 3 Maintenance 4 4 Reconnect the power cord and interface cable turn on the plotter and run the PRIME plot The bands should be smooth without dark streaks or white lines The diagonal lines should not look fuzzy or contain gaps During plotting make sure that a the Carriage Assembly slides freely on the Slide Shaft and b there is no Carriage Assembly vibration or any noise If the Carriage Assembly does not move freely or if there is Carriage Assembly vibration and or any noise clean the Slide Shaft again and repeat the PRIME plot If the problem is not resolved refer to Chapter 5 Section 11 15 Carriage Assembly Moves Erratically for additional troubleshooting steps If it is necessary the bushings can be replaced without having to replace the entire Carriage Assembly See Chapter 6 Section 7 0 for the replacement procedure NOVAJET SERIES Maintenance 4 0 Service Station
261. ssembly See Chapter 6 Section 7 0 Replace the MPCB See Chapter 6 Section 4 0 Call ENCAD s Technical Support Department Nozzle may have become clogged See Chapter 4 Section 6 1 2 for cleaning instructions If Step 1 does not help spray from plotting may have contaminated the Flex Contact Perform the Cartridge Swapping Procedure in Table Chapter 5 8 if cleaning the Flex Contact does not help Replace the Carriage Assembly See Chapter 6 Section 7 0 Replace the MPCB See Chapter 6 Section 4 0 Call ENCAD s Technical Support Department Nozzles may have become clogged possibly from a substandard Service Station wipe See Chapter 4 Sections 4 0 and 6 1 2 for cleaning instructions for the Service Station and the Cartridge NOTE the Service Station should be cleaned weekly If Step 1 does not help spray from plotting may have contaminated the Flex Contact Perform the Cartridge Swapping Procedure in Table Chapter 5 8 if cleaning the Flex Contact does not help Replace the Carriage Assembly See Chapter 6 Section 7 0 Replace the MPCB See Chapter 6 Section 4 0 Call ENCAD s Technical Support Department 5 47 Troubleshooting 4 14 nozzles stop firing when 1 Spray from plotting may have contaminated the Flex the PRIME plot is run there Contact or a quadrant of jets has failed Cleaning the will be a ONE ON ONE OFF Flex Contact will not solve the problem To be cer
262. ssembly and the Top Cover See Section 7 4 NOVAJET PRO only a Reinstall the Left Side Plate Left Cover Assembly with the Ink Reservoirs and the Top Cover See Section 7 4 b After you reconnect the Ink Delivery Lines to the Ink Reservoirs you may need to reestablish the siphon in the lines If this is necessary see Chapter 3 Section 2 2 and possibly Section 2 4 6 59 Disassembly Assembly 9 0 Stabilizer Bracket and Encoder Strip Note 1 If the Encoder Strip is not damaged do not remove it cannot be reused If the Encoder Strip is damaged the entire Stabilizer Bracket must be replaced Follow the directions under Sections 9 1 and 9 2 in this chapter Contact ENCAD s Help Desk to obtain an RMA number see Chapter 1 Section 3 0 A new Stabilizer Bracket will be sent to you which will already have the new Encoder Strip installed on it The person taking your call will explain the procedure for the exchange The Encoder Strip is attached to the Stabilizer Bracket with double sided 3M tape The Stabilizer Bracket is held on the Y Arm by means of Allen head 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 Figure Chapter 6 24 Stabilizer Bracket with Encoder Strip 6 60 NOVAJET SERIES Disassembly Assembly 9 1 Removing the Stabilizer Bracket Refer to the appropriate sections of this c
263. st strap to prevent ESD damage For storage or shipment of printed circuit boards anti static bags are highly recommended Failure to use an anti static bag for storage or shipment may damage the MPCB and may affect the Warranty NOTE Note Remove any extra SIMM 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 Puton 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 JP3 and to the right of JP1 See Figure Chapter 6 5 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 See Warning 3 above NOVAJET SERIES 6 15 Disassembly Assembly 4 3 2 Reinstalling the MPCB To reinstall the MPCB reverse the steps followed when removing the MPCB 1 Puton 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 JP3 and to the right of JP1 See Figure Chapter 6 5 Use a 2 6 Phillips screwdriver to tighten the screws until firmly tightened 6 16 NOVAJET SERIES Disassembly Assembly 4 4 Reinstalling the MPCB Co
264. stalled so do not discard it b other units the Block Support is anchored between two links of the Chain To remove this type pinch together the links of the Chain on each side of the Block Support and pull the Block Support towards the front of the plotter until it is removed It will be reused when the new Chain is installed so do not discard it Remove the Left Extrusion Cap from the left end of the Trailing Cable Support Assembly Moving from right to left gently pull the left half of the Chain away from the double sided tape which holds it against the back wall of the Trailing Cable Support Assembly Dislodge only one link at a time The tape will be reused when the new Chain is installed Place the Chain which has been removed in a large plastic bag for disposal in case there is any ink left in the tubing 6 55 Disassembly Assembly 7 15 Installing the Tubing Chain Assembly NOTE Note This section applies only to the NOVAJET PRO 36 and NOVAJET PRO 50 Installation procedure see Figure Chapter 6 23 as necessary 1 Stretch out the new Tubing Chain Assembly on the Trailing Cable Support Assembly and reattach the Electronics Cover on the top of the Carriage Assembly See Section 7 3 Steps 8 10 of this chapter 2 Move the Carriage Assembly so that it is parked over the Service Station Make sure the Chain does not extend past the right end of the Trailing Cable Support Assembly when the Carriage Assembly is pa
265. 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 40 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 6 6 Figure Chapter 6 7 and Figure Chapter 6 6 Location of SIMM Figure Chapter 6 8 Figure Chapter 6 7 Closeup 6 18 NOVAJET SERIES Disassembly Assembly Figure Chapter 6 8 Side View of SIMM NOVAJET SERIES 6 19 Disassembly Assembly 45 2 Extra Memory SIMM Installation For proper specifications and dimensions for the SIMM please refer to the NOVAJET Series User s Guide Appendix B The SIMM must be within ENCAD s specifications and tolerances Note 1 If you are installing two SIMM you must install the bottom one first Location SIMM 2 If you are installing two SIMM the SIMM in the top slot Location SIMM 1 MUST contain AS MUCH OR MORE capacity than the SIMM in the bottom slot Location SIMM 2 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 40 angle Place the SIMM straight into the connector as shown in Figure Chapter 6 9 2 Slowly
266. sure 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 THE _ STABILIZER BRACKET To help center the Upper Roller Support we suggest you 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 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 Repeat Steps 1 through for the rest of the Upper Roller Supports If the Carriage Belt was loosened put the Carriage Belt back into place in the Y Bracket NOVAJET PRO 50 only you may need to have an assistant compress the Frame Tensioner a See Section 7 3 Steps 10 through 18 and Figure Chapter 6 17 for the correct assembly of the Frame Tensioner Assembly b sure that the Carriage Belt is not twisted by moving the Carriage Assembly as far as possible to the left end of the Slide Shaft C 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 slid
267. t see Figure 7 2 Calibration Worksheet Cartridge Height Adjustment LEFT CENTER RIGHT NOTE ALL VALUES MUST BE BETWEEN 050 AND 070 Adjust to 0 065 003 for NJ4 Pro Pro 50 NOVAJET SERIES 7 23 Calibration 7 2 7 24 Adjust the Stabilizer Bracket s center screw until the desired height is reached Tighten the screw using the torque screwdriver pre set at 12 in lbs with 3 32 Allen bit Repeat for the right screw and then for the left screw Fine Adjustment and Torque 1 After the above adjustment has been done measure the heights in the three positions again At each position perform any necessary fine adjustment to the required height and torque the screw until the screwdriver releases Record the cartridge heights in Part 3 of the Calibration Worksheet Figure 7 14 Remove the micrometer gauge and the NJ test cartridge NOVAJET SERIES Calibration 7 3 Encoder Strip Check 1 Visually check that the Encoder Strip clears both sides and the bottom of the Encoder If contact is detected or a squeaking noise is heard the height may need to be readjusted to eliminate the problem 7 4 Frame Tensioner and Carriage Belt Position Check 1 Visually check clearance by running the Carriage Assembly from left to right and back Observe the motion of the Carriage Belt The Idler Pulley must be in a horizontal position It must not be misaligned or move up and down causing the belt to rub a
268. t of the Keypad Bottom and the three screws which hold the Keypad Bottom to the Platen See Figure Chapter 6 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 Figure Chapter 6 13 Display Assembly 6 28 NOVAJET SERIES Disassembly Assembly 4 With thumb and index finger release the connector lock on the Keypad Cable connector at J1 See Figure Chapter 6 14 5 Remove the Keypad Cable 6 Leave the Keypad Bottom attached to the plotter unless it is damaged Figure Chapter 6 14 Keypad PCB part of the Keypad Top Assembly See Chapter 9 for the part number nore Note The Keypad is not available separately It is included as 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 NOVAJET SERIES 6 29 Disassembly Assembly 7 0 Left Cover Assembly Left Side Plate Carriage Assembly and components Trailing Cable Carriage Belt and NOVAJET
269. t 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 NOVAJET SERIES DIAGNOSTICS PAPER MOTOR gt DIAGNOSTICS FAN NOVAJET SERIES Troubleshooting 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 5 17 Troubleshooting I SERVICE CALIBRATION CALIBRATION DEADBAND XX CALIBRATION VERT LINES ONE CALIBRATION VERT LINES ALL CALIBRATION SLOW DEADBAND 3 Service Calibration This level contains firmware instructions performing the electrical calibration of the plotter See Chapter 7 Sections 9 0 through 17 0 of this manual for the procedures for performing the electrical calibration 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 This option prints 1 line of deadband across all 16 regions
270. t 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 attached to it Refer to Figure Chapter 6 24 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 Allen Head screws which go through the back of the Y Arm into the Stabilizer Bracket lt 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 Cartridge Head Height Adjustment in Section 7 0 of Chapter 7 2 Position the Trailing Cable Support Assembly on the Y Bracket Align the holes and insert the Phillips screws Tighten the screws until snug If you are using a torque screwdriver torque to 6 In Lb 3 Route the right end of the Trailing Cable through the Right Side Plate see Figure Chapter 6 33 4 Connect the right end of the Trailing Cable to the JP3 connector on the MPCB see Figure Chapter 6 6 5 Reattach the Right Cover Assembly see Section 4 6 6 62 NOVAJET SERIES Disassembly Assembly 6 Follow all procedures in Sections 7 3 and 7 4 of this chapter to finish reassembling the plotter 7 sure to slide the Carriage Assemb
271. tain pattern or evenly spaced that the problem is caused by the Cartridge perform the gaps in the Cartridge s Cartridge Swapping Procedure in Table Chapter 5 8 diagonal line on the PRIME 2 Replace the Carriage Assembly See Chapter 6 plot Section 7 0 Replace the MPCB See Chapter 6 Section 4 0 Call ENCAD s Technical Support Department 5 The Cartridge spits small The jet plate on the Cartridge is flooded because the amounts of ink onto the Firing Rate has been set too high Reset the Firing paper during printing Rate 7 000 Hz is the optimum setting 5 48 NOVAJET SERIES Troubleshooting Table Chapter 5 7 NOVAJET PRO Cartridge Swapping Procedure The purpose of this procedure is to identify the cause of misfiring by a NOVAJET PRO Cartridge CAUSE SYMPTOM SOLUTION Defective Cartridge A defective Cartridge will misfire with Replace Cartridge the same pattern regardless of which slot it occupies in the Carriage Assembly Defective slot in the A Cartridge which is not defective will Return to the next Carriage Assembly misfire only if it is in a slot in the E in Table Chapter Carriage Assembly which is defective PROCEDURE Put the suspected Cartridge in the slot to its right as described below If suspected Cartridge is Put it in the slot normally occupied by Black Fill the spare Cartridge which came with the plotter and substitute it for the Black Cartridge currently in the plotter This is necessary
272. tal plotter that receives plotting instructions from a host computer through the RS 422 423 serial interface or the Centronics parallel interface NOVAJET SERIES 2 1 Theory of Operation 20 Mechanical Operation 2 1 Paper Media Axis Drive The Paper 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 plotters Carriage Assembly along the length of the plotter The drive consists of a Servo Motor Linear Encoder Strip Drive Belt and Tensioning Assembly The Stepper and Servo Motors are controlled from the main printed circuit assembly by the microprocessor which also supplies the Carriage Assembly with the signals necessary to cause the ink cartridge nozzles to fire the desired colors of ink onto the media 2 2 NOVAJET SERIES Theory of Operation operation 31 Circuit Assemblies Four circuit assemblies are contained in the NOVAJET plotters 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 Gate Array Memory Circuits 2 3 4 Stepper M
273. tall Select 2 or 3 to install NJPRO100 ROM MENUTREE RTL BDM CODE BDC GO EXE BDM DATA BDT BDM2CODE BDC BDM2DATA BDT DOWNLOAD EXE DOWNLOAD HLP DOWNLOAD CFG USERGUID TXT To use the Emergency Flash ROM Boot Procedure see Appendix A of the NOVAJET PRO Service Manual To do a Printer Firmware Upgrade see Appendix B of the NOVAJET PRO Service Manual The file NJPTEST PLT is used for the Line Quality Plot Computer Test see Section 17 0 You need to decompress the file NJPTEST EXE by typing at the C prompt NJPTEST and press ENTER The file will decompress 7 13 Calibration 5 0 Numbering Sequence of Upper Roller Supports NOTE Note When performing the adjustments be aware that the Upper Roller Supports are numbered as shown in Figure Chapter 7 zd Figure Chapter 7 1 Upper Roller Supports Numbering Sequence 7 14 NOVAJET SERIES 6 0 Slide Shaft Profile Adjustment 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 Height Gauge Kit Assembly P N 205660 Torque screwdriver pre set at 12 in Ibs with 3 32 Allen bit 1 4 open and box end wrench 110 thick Height Gauge Alignment Kit Contents ASSY KIT HEIGHT GAUGE 205660 CADJET 2 NOVAJET SERIES Dial Gauge Micrometer Measuring Tip Extension Modified Novajet 4 Pro Pro 50 Cartridge Platen Carriage Shaft Mounting Blo
274. that nothing drips out of the end Remove the Depriming Attachment from the Priming Pump and discard the ink in the Priming Pump and the cup of water Since some ink releases into the cup of water when you begin to drain out the ink you should get another cup of clean water and draw more water through the line to make sure that as much ink is flushed out as possible Thoroughly rinse out the Priming Pump and the Depriming Attachment with distilled water or R O water Reverse Osmosis before working with another color Follow the same procedure until all of the lines are drained Use a clean cup of water for each color of ink Proceed to Section 3 3 NOVAJET SERIES Ink Delivery System _ m DEPRIMING ATTACHMENT ics 55 _ 72 N t f Vi 06 Figure Chapter 3 13 Purging Ink Delivery Lines NOVAJET SERIES 3 21 Ink Delivery System 3 3 Removing the NOVAJET PRO Left Cover Assembly Assembly It must be held level so that the ink does not spill note Note 1 You will need someone to help you remove the Left Cover out of the air vents in the top of the Ink Reservoirs Have the Left Cover packing foam that came with your plotter near the plotter before you remove the Left Cover Assembly You will need to place the Left Cover Assembly in it so that ink does not spill out of the Ink Reservoirs Se
275. 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 NOVAJET SERIES 5 5 Troubleshooting 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 Chapter6 Section5 0 for the removal and reinstallation procedures 2 The MPCB Servo Driver may be defective Replace the MPCB See Chapter 6 Section 4 0 If the Carriage Assembly does not move freely check the following 1 The Carriage Belt tension may be incorrect See Chapter 6 Section 7 8 2 The Slide Shaft may be dirty See Chapter 4 Section 3 0 for cleaning procedures 3 There may be debris on the Encoder Strip See Chapter 4 Section 5 0 for cleaning procedure 4 The Upper Roller Supports may be at an angle and are hitting the Carriage Assembly See Chapter 6 Section 11 0 if they need to be replaced 5 There may be a loose bushing on the Carriage Assembly See Chapter 6 Section 7 13 for instructions on the proper installation of the Bushings Replace if necessary 6 The Cartridge Head Height may not be correct See Chapter 7 Section 7 0 5 33 Troubleshooting 5 34 If NO the problem is most likely in the Servo Motor the Main PCB or the Encoder strip 1 2 Check the Trailing Cable connectio
276. the Ink Delivery Lines 3 18 NOVAJET SERIES Ink Delivery System W AJ m Y Y UP ON META a Ty Figure Chapter 3 12 Releasing Ink Reservoir Connector NOVAJET SERIES 3 19 Ink Delivery System 3 20 After an Ink Delivery Line has been disconnected the ink needs to be drained from the line You will need a cup of clean distilled water or R O water Reverse Osmosis and someone to assist you with this part of the procedure There is a Depriming Attachment about two inches long in the NOVAJET PRO Maintenance Kit Screw the clear end of it into the end of the Priming Pump Then attach the white end of it to the connector which was disconnected from the Ink Reservoir See Figure Chapter 3 13 Have your assistant place the end of the needle into the cup of water and open the Tubing Clamp for that line See Figure Chapter 3 13 Draw the ink into the Priming Pump Keep drawing out the ink until clean water enters the Priming Pump At this point your assistant can remove the needle from the cup of water See Figure Chapter 3 13 Continue drawing the water in the Ink Delivery Line into the Priming Pump until all the water is emptied out of the line Press the metal plate on the connector to release the Ink Delivery Line from the Priming Pump Be sure to hold the end of the Priming Pump up so
277. the Inner Platen Parts The screws which hold the brackets for the Lower Drive Shaft Assembly have been secured with Loctite 222 It is possible that the head of the screws may break off during removal If this occurs it will be necessary to replace the bracket s When you remove the Lower Drive Shaft Assembly make sure that the Lower Rollers do not catch on any of the openings screws or cap nuts inside the Platen 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 Shaft Assembly Refer to Figure Chapter 6 25 Figure Chapter 6 26 Figure Chapter 6 27 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 Note the NOVAJET PRO 50 has two snap plugs 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 black flat head screws which hold the left and middle Drive Shaft Supports in place
278. 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 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 Push the Trailing Cable up through the opening in the Strain Relief See Figure Chapter 6 16 Fold the Trailing Cable and press it down onto the tape Slide the fold in the Trailing Cable under the triangular portion of the Strain Relief See Figure Chapter 6 16 6 35 Disassembly Assembly 6 36 7 Place the Trailing Cable into the J5 connector lock on the Carriage PCB Make sure the silver fingers on the Trailing Cable are fully inserted into the lock and slide both sides of the connector lock shut at the same time See Figure Chapter 6 16 After the Trailing Cable has been installed on the Carriage Assembly it is very important that you move the Carriage Assembly to the far left end of the Slide Shaft and check to make sure that there is clearance between the edges of the Trailing Cable and the side walls of the Strain Relief It must not rub against the side walls 8 Move the Carriage Assembly to the far left end of the Slide Shaft NOVAJET PRO only As you do Step 9 make sure that all four Tubing Clamps are in place and that none of the Ink Delivery Lines are pinched 9 Lift up
279. ting Table 5 43 Number Title Page Table 7 1 Carriage Height Settings 7 18 Table 7 2 Mounting Screw Actions and 7 28 xxviii NOVAJET SERIES Chapter 1 GENERAL INFORMATION 1 00 Introduction This manual provides service information for four models of ENCADS Inc NOVAJETe Color Inkjet Plotters e NOVAJET 36 NJP 36 NOVAJET PRO 50 50 and NOVAJET 4 NJ4 D and E Sizes It is written for service personnel with analog and digital circuitry experience Chapter 2 Theory of Operation should be read and thoroughly understood before troubleshooting calibrating the plotters These plotters expand upon NOVAJET s tradition of delivering fast high quality color or monochrome graphics for a variety of applications ENCAD has made significant advances in designing these plotters to respond to and anticipate our customers needs Principal features are summarized below Section 4 0 of this chapter details other differences Feature NJP 36 NJP 50 NJ4D NJ4E Extended Ink Supply X X Refillable Cartridges X 24 Maximum Media Width X 36 Maximum Media Width X _ 50 Maximum Media Width a System Like the NJ all three plotters support pre cut and roll media Media size is automatically determined and
280. tioned above is only a general guideline and may need to be adjusted for areas of high temperatures or low humidity 4 12 NOVAJET SERIES Maintenance 6 3 Ink Reservoirs and Delivery Lines only Do not use tap water to rinse the Ink Reservoirs or Ink Delivery Lines Minerals in the water may contaminate the ink and corrode the jet plate of the Cartridges Use only distilled water or R O water Reverse Osmosis Very little maintenance is required for the Ink Reservoirs If the Ink Reservoirs are to be emptied they must be thoroughly rinsed with distilled or R O water to remove all traces of ink The Ink Delivery Lines also are very low maintenance Anytime the Ink Delivery System is unloaded the Ink Delivery Lines must be thoroughly flushed with distilled or R O water to remove all traces of ink You will need someone to assist you with this operation Follow the procedure given in Chapter 3 Section 3 2 for purging the lines You should also use this procedure in the event that the ink in the lines dries out due to a leak in the system If the lines cannot be completely flushed out they will need to be replaced See Chapter 6 Section 7 14 for the replacement procedure The Tubing Clamps on the Carriage Assembly should always remain open unless you are changing Cartridges or are otherwise working with the Ink Delivery System Keeping the Tubing Clamps open prevents the Ink Delivery Lines from developing a crimp which co
281. tting Area Normal 0 59 15 mm margin on each of 3 sides and 1 38 35 mm margin on the fourth side Expanded 0 197 5 mm margin on each of 3 sides and 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 depending on software application used Frame to Frame Registration 01 Distance Accuracy 0 296 of total length RAM 4 MB permanently installed Two 72 pin 32 bit wide DRAM SIMM sockets User upgradable to 68 MB with 4 8 16 or 32 MB with 70 ns or faster SIMMS ENCAD approved See Chapter 2 Section 3 8 Language Emulation HP GL HP 7440 7470 7475 7550 7570 7575 7576 7580 7585 7586 7596 HP GL 2 HP RTL EN RTL Ink and Media Types Full range of inks and media provided by ENCAD Quality Imaging Supplies call for current product listings Rasterization Internal rasterizer Resolution 300 x 300 DPI monochrome gray and color 600 x 600 DPI monochrome NJ 4 only Interfaces Centronics bi directional parallel RS 422 serial RS 232 requires adaptor cable AppleTalk Baud Rates 300 600 1200 2400 4800 9600 19200 38400 Power Universal Power Supply 100 240 10 Vac 50 60 3 Hz AC Input DC Output Consumption 24
282. uires code to be running in the plotter to interpret the file If for some reason the EEPROM 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 works through the serial port and requires a special host utility It is a mode that allows some registers and DRAM to be written to based upon commands sent through the serial port The special host utility provides user instructions as it runs NOVAJET SERIES Theory of Operation 3 8 DRAM The plotter also has two 72 pin 32 bit wide SIMM sockets for DRAM The plotter is supplied with 4 Megabytes of DRAM permanently installed on the Main Board The following SIMM sizes are supported 4MB 1Mx32 8MB 2Mx32 16MB 4 32 and 32MB 8Mx32 The SIMMS must have an access time of 7Ons or less and conform to JEDEC Standard Number 21 D Release 4 or later Remove the Right Cover Assembly to install additional memory see Chapter 6 Section 4 0 for installation procedures Refer to the User s Guide for specifications and requirements NOTE The NOVAJET PRO and NOVAJET 4 have been designed to operate with 64MB SIMMs using information contained JEDEC 21 However 64MB SIMMs not currently available When they become available contact ENCAD for recommended sources 3 9 Serial EEPROM An 8K bit serial non volatile
283. uld impair the proper operation of the system NOVAJET SERIES 4 13 Maintenance 7 0 Upper and Lower Rollers Do not use alcohol or any other cleansers to clean the Upper and Lower Rollers Use only distilled water and a lint free cloth 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 we recommend cleaning the Upper and Lower Rollers once a week To clean the Upper and Lower Rollers 1 Parkthe 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 4 14 NOVAJET SERIES Maintenance Chapter 4 MAINTENANCE 4 1 1 0 IBIFOQUCHOF DU p URLUEE 4 1 2 0 External Cleaning 4 2 3 0 Slide Shaft Maintenance 4 3 4 0 Service Station 404 42244
284. ure 5 2 Figure 5 3 Figure 5 4 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Table 5 5 Table 5 6 Table 5 7 Table 5 8 5 64 PED KEYS MP EE 5 19 ES DAG ret 5 20 Cable and Schematic for Parallel and Serial Loop Back 5 30 Correct Usage of Cable for Parallel and Serial Loop Back Tests 5 31 Decision Logic Table One 1 0 08 5 4 Decision Logic Table Two 2 5 5 Decision Logic Table Three DLT 3 5 6 Decision Logic Table Four DLT 4 uer t o tto 5 8 NOVAJET PRO Extended Ink Supply Troubleshooting Table 5 44 NOVAJET 4 Refillable Cartridges Troubleshooting Table 5 47 NOVAJET PRO Cartridge Swapping 5 49 NOVAJET 4 Cartridge Swapping Procedure 5 50 NOVAJET SERIES Chapter 6 DISASSEMBLY ASSEMBLY 1 0 Introduction Chapter 6 contains the removal and replacement procedures for the NOVAJET PRO 36 NOVAJET PRO 50 and NOVAJET 4 E and D Size plotter assemblies and mechanisms Illustrations are provided for clarity It is recommended that you read through each procedure before beginning the removal or replacement Unless otherwise indicated all procedures apply to all plotters Table Chapter 6 1 summarizes major differences which af
285. ure the sensors light is on and reposition the Take Up Reflector Bracket slightly See Figure Chapter 8 5 NOVAJET SERIES Power Media Feed Take Up System fry MEDIA GUIDE 2 Used instead of kem 12 ber 20 Section 2 2 below 1 SUPPLY SIDE 7 WIND UNWIND SWITCHES lt AKE UP SIDE OWER CORD JACK AKE UP REFLECTOR gt SWITCH CUT SWITCH AKE UP SENSOR EDER REFLECTOR 1 ADJUSTABLE ROLL GUIDE 6 FEEDER SENSOR 2 THUMBSCREW FOR LOCKING GUIDE IN PLACE d Figure Chapter 8 6 Fully Assembled Power Media Feed and Take Up System NOVAJET SERIES 8 7 Power Media Feed Take Up System 8 8 2 2 Usage of Media Guides Power Media Feed and Take Up System includes 2 Media Guides see Figure Chapter 8 6 inset which are to be used as follows 1 The Media Guides are used only when a Cut Sheet Media is loaded or b if the Rollfeed Demand Mode is being used with Rollfeed Media The Take Up Side s Adjustable Roll Guide is not used if the Media Guides are being used Both Media Guides are to be used only in the Take Up Side s Rail never in the Supply Side s Rail The Media Guides should be positioned far enough under the media about 3 to 4 from the left and right edges of the media so that the media does not bend in the middle
286. urn the computer on At the C prompt type on the keyboard GO NJPTEST PLT 4 Press RETURN to send the plot file to the plotter COMPUTER screen will show GO NJTEST PLT SENDING 5 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 NOVAJET SERIES 7 65 Calibration 7 66 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 knife edge 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 examine the plot produced from running the file NJPTEST PLT for the quality of the circles and lines The plotter is now fully calibrated and ready to use NOVAJET SERIES Calibration 18 0 Production Gold Standard Computer Test The purpose of this test is to allow you to examine the quality of the color and the interaction of the ink and media when the file PRODGS RTL is plotted To obtain this file s
287. use a release of the fluid in the Extended Ink Supply 1 Hold the Cartridge Figure Chapter 3 8 Item 1 upright so that no ink comes out of the top of the Cartridge 2 Insert the needle on the end of the Ink Delivery Line into the hole in the top of the Cartridge 3 Screw the Tube Fitting Figure Chapter 3 8 Item 2 onto the Cartridge Gently tighten it to prevent air leaks not overtighten not place the Cartridge in the Carriage Assembly yet i TUBE FITTING ON INK DELIVERY LINE 97 DPARTIALLY FILLE CARTRIDGE CAUTION PRI RELEASING TUBING CLAMPS 7 INVERT CARTRIDGE gt RAISE CARTRIDGE AB HURIZUNTAI E PLANE IHE TUBING CLAMP N THERWISE INK MAY BE RELEASED Figure Chapter 3 8 Connecting Cartridge to Ink Delivery Line NOVAJET SERIES 3 11 Ink Delivery System 4 Open Tubing Clamp on the Ink Delivery Line see Figure Chapter 2 5 After the blue tape is removed from the bottom of the Cartridge CAUTION some ink may drip out of the jet area Be careful not to allow the ink to drip onto any unprotected area of the plotter Remove the blue tape Figure Chapter 3 9
288. ve the carriage assembly slowly in direction firmware must be downloaded to the plotter using the Serial Port and the Emergency Flash ROM Boot Procedure on the NOVAJET PRO Utilities Disk See Appendix A of this manual for the procedure nore If the plotters Flash EEPROM is blank or corrupt the If the plotter s Flash EEPROM is not blank or corrupt but the latest firmware version has not been loaded the firmware may be loaded through the Parallel Port or the Serial Port parallel is faster using the Printer Firmware Upgrade on the NOVAJET PRO Utilities Disk See Appendix B of this manual for the procedure If you have to download the firmware to the plotter allow the download to finish before you adjust the Paper Sensor Potentiometer If the Carriage Assembly has been removed or changed or if the Cartridge Head Height has been changed you must adjust the Paper Sensor Potentiometer see the procedure directly below this Note It must also be adjusted if the media is not being detected or if the edge of the media is not being detected due to pre printed borders on the media 7 26 NOVAJET SERIES Calibration Paper Sense Adjustment Procedure changed or if the cartridge head height has been changed includes slide shaft adjustment nore Perform when the carriage assembly has been removed or 1 Remove Paper or back up paper from below carriage assembly you are adjusting sensor to detect
289. voltage may vary as temperature varies However the adjusted voltage should always read between 1 45 to 1 55 Volts at all times If you are unable to obtain a value between 1 45 to 1 55 Volts Encad s Technical Support and Service department See Chapter 1 Section 3 0 9 Depress Access Cartridges function and return to normal operation 10 Proceed to Section 9 0 Paper Skew Setup NOVAJET SERIES 7 29 Calibration 9 0 Paper Skew Setup 1 Power must be on The menu should be at 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 equals sign will blink Press the Down Arrow The display will read PRINTER SETUP ROLL FEED OFF 6 Press SELECT then MENU and then the Down Arrow 4 times until the display reads MAIN MENU PRINT MODE 7 Proceed to Section 10 0 Paper Skew Adjustment 7 30 NOVAJET SERIES Calibration oer Skew Adjustment 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 t
290. w ink through the Cartridge s jet plate to remove any trapped air bubbles inside the Cartridge See Chapter 3 Section 2 4 Make sure that the Flex Contacts on the Cartridge and on the Carriage Assembly are clean and dry See Chapter 4 Section 6 1 1 for cleaning instructions Perform the Cartridge Swapping Procedure in Table Chapter 5 7 Replace the Carriage Assembly See Chapter 6 Section 7 0 Replace the MPCB See Chapter 6 Section 4 0 Call ENCAD s Technical Support Department Nozzle may have become clogged See Chapter 4 Section 6 1 2 for cleaning instructions If Step 1 does not help spray from plotting may have contaminated the Flex Contact Perform the Cartridge Swapping Procedure in Table Chapter 5 7 if cleaning the Flex Contact does not help Replace the Carriage Assembly See Chapter 6 Section 7 0 Replace the MPCB See Chapter 6 Section 4 0 Call ENCAD s Technical Support Department NOVAJET SERIES Troubleshooting CONDITIONS 3 Many nozzles stop firing 4 14 nozzles stop firing when the PRIME plot is run there will be ONE ON ONE OFF pattern or evenly spaced gaps in the Cartridge s diagonal line on the PRIME plot 5 The jet plate leaks when a Cartridge without tape on the jet plate is reconnected that is a used Cartridge is being reconnected 6 The Cartridge spits small amounts of ink onto the paper during printing 7 Cannot draw any ink
291. wered 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 NOVAJET PRO and is receiving power PROCEDURE 1 After reviewing all information at the top of Table Chapter 5 1 DLT 1 it has been determined that DLT 1 is the proper table to use NOVAJET SERIES 2 Troubleshooting 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 answer to the condition is NO nore Note In some of the DLT s you proceed to the next condition if the When a question condition is answered NO N look across the row for the letter N Look down the column containing the letter 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 you look for the letter in that row and then look down the nore Note In some of the DLT s if the answer to the condition is YES column containing the
292. y Figure Chapter 6 22 Replacing the Carriage Bushings NOVAJET SERIES 6 53 Disassembly Assembly 7 14 Removing the Tubing Chain Assembly NOTE Note This section applies only to the NOVAJET PRO 36 and PRO 50 The NOVAJET PRO Tubing Chain is available as an assembly see Chapter 9 for the part numbers The assembly consists of the Tubing Ink Delivery Lines the Chain the Tubing Clamps the Cartridge Needles the CPC Fittings Ink Reservoir Connectors and the Left Extrusion Cap See Figure Chapter 6 23 Figure Chapter 6 23 Trailng Cable Support and Tubing Chain Assembly 6 54 NOVAJET SERIES Disassembly Assembly Removal procedure 1 5 5 Follow the procedures given in Chapter 3 Sections 3 1 and 3 2 to remove the Cartridges and drain the ink out of the Ink Delivery Lines Since the Ink Delivery Lines are going to be replaced do not purge the lines with water After draining out the ink remove the Electronics Cover from the top of the Carriage Assembly See Section 7 2 Steps 2 5 of this chapter for the procedure Mark the location of the Block Support which is in the middle of the Chain see Figure Chapter 6 23 Then remove the Block Support as follows a some units the Block Support is taped onto the Trailing Cable Support Assembly Carefully use a small screwdriver to pry up the edge of it It should pop right off It will be reused when the new Chain is in
293. y Leave them attached to the Plotter They do not need to be removed for this procedure Refer to the indicated Sections and Figures of this chapter as necessary during this procedure To access the Inner Platen Parts 1 Remove the Top Cover 2 Remove the Service Station and clean it if necessary See Chapter 4 Section 4 0 3 NOVAJET 4 only See Section 7 1 of this chapter to remove the Cartridges the Left Cover Assembly and the Left Side Plate NOVAJET PRO only See Section 7 1 of this chapter to remove the Cartridges drain the Ink Delivery Lines remove Left Cover Assembly and Ink Reservoirs and remove the Left Side Plate 4 Remove the Plotter from the Stand See Section 3 1 Steps 1 2 16 and 17 Place it on foam blocks on a stable work surface Remove the Right Cover Assembly See Section 4 1 Disconnect all the connectors from the MPCB See Section 4 2 Remove the MPCB See Section 4 3 1 N em Remove the Right Side Plate There four screws which hold it onto the Platen If the Power Cable has a Grounding Braid disconnect it from the inside of the Right Side Plate 9 Remove the Servo Motor See Section 5 1 Steps 4 16 10 Remove the Display Assembly See Section 6 1 11 If applicable remove the Left and Right Rollguides from the back of the Platen 12 Remove the Power Supply See Section 8 1 13 Go to Section 10 2 below NOVAJET SERIES 6 67 Disassembly Assembly 10 2 Removing
294. y need to push the latch to the right as you push downward on the right end of the Service Station in order to get it to lock 6 26 NOVAJET SERIES 10 5 5 Disassembly Assembly Insert the screws into the back of the Trailing Cable Support Assembly Tighten all of the screws including the far left screw See Figure Chapter 6 12 If you are using a torque screwdriver torque to 6 In Lb Push the slack on the right end of the Trailing Cable back down into the Right Side Plate so that it does not get pinched between the Carriage Assembly and Right Side Plate Move the Carriage Assembly to the middle of the Slide Shaft 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 guides on the inside of the belt are inserted in the pulley grooves and that the belt is not twisted NOVAJET PRO 50 only you may need to have an assistant compress the Frame Tensioner Move the Carriage Assembly back and forth to check the Carriage Belt tension Reinstall the Right Cover Assembly and the Top Cover 6 27 Disassembly Assembly 6 0 Display Assembl 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 fron
295. y of Plotter Before Removing the Inner Platen Parts 6 67 10 2 Removing the Inner Platen 224 2 6 68 10 3 SIGDDOL ii ooo Edel ir t M dat 6 72 10 3 1 Removing the Stepper 6 72 10 3 2 Reinstalling the Stepper 4 680 6 74 10 4 Reinstalling the Inner Platen 6 75 10 5 Reassembly of Plotter After Reinstalling the Inner Platen Parts 6 79 11 0 Upper Roller SUDDOLFLIs x ord cd oc uet e verc AA 6 83 11 1 Removing the Upper Roller 6 83 11 2 Installing the Upper Roller 6 85 NOVAJET SERIES 6 89 Disassembly Assembly Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 6 9 Figure 6 10 Figure 6 11 Figure 6 12 Figure 6 13 Figure 6 14 Figure 6 15 Figure 6 16 Figure 6 17 Figure 6 18 Figure 6 19 Figure 6 20 Figure 6 21 Figure 6 22 Figure 6 23 Figure 6 24 Figure 6 25 Figure 6 26 Figure 6 27 Figure 6 28 Figure 6 29 Figure 6 30 Figure 6 31 Figure 6 32 6 90 Recommended abaco ede dee 6 5 Removing Tie Wrap and Foam 6 7 Removing Cardboard Wedge NOVAJET PRO

NJ PRO 36 NJ PRO 50 NJ 4 Service Manual

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