ENCAD 60e User manual

SERVICE MANUAL
60e 42e
P R I N T I N G
TM

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NOVAJET®PROe
SERIES
COLOR INKJET
PRINTER
SERVICE MANUAL
PartNumber209053
®

4
NovajetPROeSeriesServiceManual
Copyright © 1997ENCAD®, Inc. All rights reserved.
ENCAD is a registered trademark of ENCAD, Inc.
NOVAJET PRO™ is a trademark of ENCAD, 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, mag-
netic 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.
Printing history
1stEdition RevA April 1997
2ndEdition RevB June 1997

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NovajetPROeSeriesServiceManual
FCC Statement (U.S.A.)
The United States Federal Communications Commision has specified
that the following notice be brought to the attention of the users of the
NOVAJET PROe series printers.
FEDERAL COMMUNICATIONS COMMISION RADIO AND TELEVI-
SION INTERFERENCE FOR CLASS B DEVICE
This equipment has been tested and found to comply with the limits for a
class B digital device, pursuant to part 15 of the FCC Rules. These
limits are designed to provide reasonable protection against harmful
interference in a residential installation. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions, may cause harmful interfer-
ence to radio communications.
User Instructions:
If the equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on,
the user is encouraged to try to correct the interference by one of the
following measures:
•Reorient or relocate the receiving antenna.
•Increase the separation between the equipment and receiver.
•Connect the equipment into an outlet on a circuit different from
that to which the receiver is connected.
•Consult the dealer or an experienced radio/TV technician for
help.
Changes or modifications not expressly approved by ENCAD, Inc. could
void the user’s authority to operate the equipment.

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NovajetPROeSeriesServiceManual
VDE Statement
Hiermit wird bescheinigt, daß der NOVAJET PROe in Übereinstimmung
mit den Bestimmungen der BMPT-AmstbIVfg 234/1991 funkentstört ist.
Der vorschriftsmäßige Betrieb mancher Geräte (z.B. Meßsender) kann
allerdings gewissen Einschränkungen unterliegen. Beachten Sie
deshalb die Hinweise in der Bedienungsanleitung.
Dem Zentralamt für Zulassungen im Fernmeldewesen würde dan
Inverkehrbringen dieses Gerätes angezeigt und die Berechtigung zur
Überprüfung der Serie auf die Einhaltung der Bestimmungen
eingeräumt.
ENCAD, Inc. U.S.A

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NovajetPROeSeriesServiceManual
Material Safety Data Sheet
NOVAJET PRO e 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
[phone]
International users should contact their local dealer or distributor.

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NovajetPROeSeriesServiceManual
WARRANTY OR DAMAGE CLAIMS
United States
ENCAD®, Inc., warrants its printers ("PRODUCT") to be free from defects in workmanship
and materials for a period of one year from the date of purchase. In order to submit a
Warranty claim, please contact the ENCAD Help Desk at [phone].
ENCAD reserves the right to make changes or improvements to Products, without incurring
any obligation to similarly alter Products previously purchased.
Buyer's sole and exclusive rights pursuant to this Warranty shall be for the repair or
replacement of defective Product. ENCAD specifically disclaims any and all other warran-
ties, expressed or implied, including but not limited to, implied warranties of merchantability
and fitness for a particular purpose. In no event shall ENCAD be liable for any loss of
profit or other commercial damages, special, incidental or consequential damages, or any
otherdamagesorclaims,whatsoever.
This Warranty gives Buyer specific legal rights, and Buyer may also have other rights that
varyfrom state to state.
This Warranty applies only to printers purchased from ENCAD, or authorized ENCAD
distributors or dealers. The intent of this Warranty is to repair or replace defective Prod-
ucts subjected to normal wear and tear, when operated according to ENCAD instructions.
This Warranty does not cover damage to the Product resulting from the following:
• Accident or negligence.
• Unauthorized modification of the Product.
• Adverse environmental conditions.
• Service of the Product by other than an ENCAD authorized service provider.
• Unauthorized or improper use, including but not limited to:
– Use in applications for which the Product was not designed.
– Using cartridges or ink other than those supplied by ENCAD or authorized
ENCAD resellers.
– Using media other than that supplied by ENCAD or authorized ENCAD
resellers.
– Lubricating any part of the printer.
Internationally: Contact your dealer or distributor for warranty information.

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NovajetPROeSeriesServiceManual
Table of Contents
Chapter 1 General Description ............................................................. 17
Introduction ...............................................................................................................17
Overview ....................................................................................................................19
Related Publications ............................................................................................19
Electrostatic Discharge (ESD) Sensitivity..................................................................19
Warnings, Cautions, and Notes .................................................................................20
Printer Specifications ................................................................................................21
ContentsofthisService Manual ................................................................................22
TechnicalSupport......................................................................................................24
Chapter 2 Theory of Operation ............................................................ 25
Introduction ...............................................................................................................25
NovajetPROePrinterGeneralBlockDiagram ...........................................................25
Paper (Media) Axis Drive ..........................................................................................27
The Carrier Axis Drive ...............................................................................................28
MediaFeedandTake-UpSystem..............................................................................29
Main Printed Circuit Board (MPCB) ..........................................................................30
Microprocessor...................................................................................................31
Gate Array ..........................................................................................................31
Memory Circuits..................................................................................................32
StepperMotorController .....................................................................................34
ServoMotorController ........................................................................................36
Interface Circuits: Serial & Parallel .....................................................................38
Carrier Assembly Circuits .........................................................................................39
Keypad......................................................................................................................40
PowerSupply ............................................................................................................41
Beeper and Fans.......................................................................................................41
Chapter 3 Maintenance ......................................................................... 43
Introduction ...............................................................................................................43
ScheduledMaintenance ............................................................................................43
CleaningProcedures ..........................................................................................44
ExternalCleaning..........................................................................................44
SlideShaftCleaning .....................................................................................44

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NovajetPROeSeriesServiceManual
ServiceStationCleaning ..............................................................................45
Linear Encoder Strip Cleaning .....................................................................46
CartridgeDimplesCleaning ..........................................................................47
FlexCableContactCleaning.........................................................................48
Cleanand Inspect Stepper Motor Gears.......................................................48
Clean and Inspect MPCB .............................................................................49
Clean and Inspect Carrier Assembly ............................................................49
Reseat Connectors on MPCB and Carrier Board................................................50
Replace Carrier Bushings...................................................................................52
Servo Motor Winding Resistance Check ...................................................................53
Stepper Motor Winding Resistance Check ................................................................54
Power Feed and Take-Up Motor Winding Resistance Check .....................................55
Banding:HardwarevsSoftware.................................................................................56
Alignments/Adjustments .............................................................................................57
SlideShaftProfileAdjustment .............................................................................57
HeadHeightAlignment Procedure ......................................................................60
ColorCalibration .................................................................................................63
DeadbandAlignment ...........................................................................................66
PaperAxisCalibration.........................................................................................69
DiagnosticsMenu......................................................................................................71
LimitedAccessMenu ................................................................................................73
FirmwareDownloading ..............................................................................................75
InternalCablingandSignal Flow Diagrams ...............................................................76
Chapter 4Troubleshooting................................................................... 81
Introduction ...............................................................................................................81
NoPower ..................................................................................................................81
MediaDoes Not Move................................................................................................82
InternalERROR“CarriageAxisFailure” ....................................................................83
InternalERROR“EncoderSensor Failure” ................................................................84
InternalERROR“PaperSensor Failure”....................................................................84
InternalERROR“Auto-SensorFailure” ......................................................................84
InternalERROR“TrailingCable Failure” ....................................................................85
Table of Contents (cont)
Chapter 3 Maintenance (cont)

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NovajetPROe Series Service Manual
InternalERROR“MPCB Failure”................................................................................85
DoesNotPrint ...........................................................................................................85
Ink Cartridge Misfiring ...............................................................................................85
PaperSkewing ..........................................................................................................87
Printer Output is Banding ..........................................................................................87
Keypad Locked-Up or Not Functioning Properly........................................................88
NoisyOperation.........................................................................................................89
LineQualityDegraded...............................................................................................90
FanDoes Not Power Up ............................................................................................91
MediaTake-Up Motor Not Operating, SensorWorks..................................................91
Media Feed Motor Not Operating, Sensor Works ......................................................92
Media Feed and Take-Up Motors Not Operating, Both Sensors Working ...................92
MediaFeedorTake-Up Sensor(s) Not Operating ......................................................93
Chapter 5Assembly\Disassembly ........................................................ 95
Introduction ...............................................................................................................95
RemovetheLeft,Top,andRightCovers ....................................................................96
InstalltheLeft,Top,andRightCovers........................................................................99
Remove the Keypad, Display, and Display Power Converter ...................................100
Install the Keypad, Display, and Display Power Converter....................................... 102
RemoveExtra Memory (SIMM) ................................................................................103
InstallExtraMemory(SIMM).................................................................................... 104
Remove the MPCB (Main Printed Circuit Board) ..................................................... 104
Installthe MPCB ...................................................................................................... 107
Remove Power Supply, Cooling Fan, and AC Entry Module ....................................108
Install the Power Supply, Cooling Fan, and AC Entry Module .................................. 110
RemoveServoMotor ............................................................................................... 111
InstallServo Motor ................................................................................................... 113
RemovetheInkDeliverySystem ............................................................................. 114
InstalltheInk Delivery System................................................................................. 117
Remove the Carrier Assembly, Carrier Belt, and the Frame Tensioner .................... 117
Install the Carrier Assembly, Carrier Belt, and the Frame Tensioner.......................120
Remove the Carrier PCB ......................................................................................... 122
Table of Contents (cont)
Chapter 4 Troubleshooting (cont)

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NovajetPROe Series Service Manual
Install the Carrier PCB.............................................................................................124
Remove the Paper Sensor or the Encoder Sensor ..................................................124
Install the Paper Sensor or the Encoder Sensor...................................................... 126
Replacing the Carrier Bushings............................................................................... 127
Remove the Service Station, Seals, and Wipers ......................................................129
Install the Service Station, Seals, and Wipers .........................................................130
Removethe TrailingCable Assembly .......................................................................131
InstalltheTrailingCable Assembly ...........................................................................132
Remove the Stabilizer Bracket and Encoder Strip ................................................... 133
Install the Stabilizer Bracket and Encoder Strip ....................................................... 135
Remove the Y-Arm Assembly, Pinch Rollers, Slide Shaft, and Auto-Load Sensor ... 135
Install the Y-Arm Assembly, Pinch Rollers, Slide Shaft, and Auto-Load Sensor .......137
RemovetheLowerRollerAssembly,Stepper Motor and VacuumFan .....................139
InstalltheLower Roller Assembly,Stepper Motor and VacuumFan ......................... 142
RemovetheMediaTake-Up and Feed Sensor Brackets and Sensors......................145
Installthe Media Take-Up and FeedSensor Brackets and Sensors .........................146
Removethe Media Take-Up and FeedMotors..........................................................147
InstalltheMediaTake-Upand Feed Motors ............................................................. 148
RemovetheMediaDrying Fans...............................................................................149
Install the Media Drying Fans .................................................................................. 150
Chapter 6 Parts List .............................................................................151
Index ......................................................................................................161
Table of Contents (cont)
Chapter 5 Assembly/Disassembly (cont)

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NovajetPROe Series Service Manual
List of Illustrations
Figure Page
Chapter 1 General Description
1-1. NovajetPROeSeries Inkjet Printers .................................................................17
Chapter 2 Theory of Operation
2-1. GeneralBlockDiagram....................................................................................26
2-2. Paper (Media) Axis Drive.................................................................................27
2-3. Carrier Axis Drive ............................................................................................28
2-4. PowerFeedandTake-UpSystem....................................................................29
2-5. Main Printed Circuit Board ..............................................................................30
2-6. Gate Array.......................................................................................................31
2-7. StepperMotorController ..................................................................................34
2-8. ServoMotorController .....................................................................................36
2-9. QuadratureSignal Generation..........................................................................37
2-10. Interface Circuits .............................................................................................38
2-11. Carrier Assembly Circuits................................................................................39
2-12. MainMenu.......................................................................................................40
Chapter 3 Maintenance
3-1. Encoder Strip Cleaning....................................................................................46
3-2. CartridgeDimpleRegion..................................................................................47
3-3. FlexCable Contacts .........................................................................................48
3-4. MPCBConnectionLocations ...........................................................................51
3-5. Carrier Connection Locations ..........................................................................51
3-6. RibbonConnectorLockingMechanism............................................................52
3-7. ServoMotor .....................................................................................................53
3-8. StepperMotor ..................................................................................................54
3-9. PowerFeedandTake-UpMotor.......................................................................55
3-10. ExamplesofBanding .......................................................................................56
3-11. DialGauge Micrometer Assembly ....................................................................58
3-12. MeasurementPositionsforSlide Shaft ............................................................58
3-13. SlideShaftProfileAdjustment ..........................................................................59
3-14. CarrierHeadHeightTolerance.........................................................................60
3-15. SettingUpToolsfromHeightGaugeKit............................................................61
3-16. ZeroingtheMicrometerGauge ........................................................................61

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NovajetPROe Series Service Manual
List of Illustrations (cont)
Figure Page
Chapter 3 Maintenance (cont)
3-17. TestCartridgeInstalled.....................................................................................62
3-18. ColorCalibration ..............................................................................................64
3-19. UtilityMenu ......................................................................................................65
3-20. ColorCalibMenu .............................................................................................65
3-21. CyanVertical Options Menu.............................................................................66
3-22. DeadbandSlow/Fast ........................................................................................66
3-23. ServiceMenu...................................................................................................67
3-24. Calibration(Deadband)Menu ..........................................................................68
3-25. CalibrationMenu..............................................................................................70
3-26. PaperAxis Test ................................................................................................70
3-27. DiagnosticsMenu ............................................................................................71
3-28. Accessory Menu..............................................................................................72
3-29. NVRAMClearandClockResetMenu ..............................................................74
3-30. J Tag Connection on MPCB.............................................................................75
3-31. MPCBConnectionsDiagram ...........................................................................77
3-32. Carrier PCB Connections Diagram..................................................................78
3-33. LegHarnessConnectionsDiagram .................................................................79
Chapter 4 Troubleshooting
Chapter 5 Assembly/Disassembly
5-1. RightCoverAssemblyRemoval/Installation ......................................................97
5-2. LeftCover AssemblyRemoval/Installation ........................................................98
5-3. Keypadand Display Removal/Installation ....................................................... 101
5-4. KeypadGroundingConnection......................................................................102
5-5. ExtraMemory (SIMM)Removal/Installation ....................................................103
5-6. MPCBRemoval ..............................................................................................106
5-7. PowerSupplyRemoval ..................................................................................109
5-8. CoolingFan/ACEntry Module Removal ......................................................... 110
5-9. Slacken Carrier Belt....................................................................................... 112
5-10. ElectronicsCover Removal ............................................................................ 115
5-11. Disconnect Ink Delivery System Link............................................................. 116
5-12. StrainReliefRemoval/Installation ................................................................... 118

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NovajetPROe Series Service Manual
List of Illustrations (cont)
Figure Page
Chapter 5 Assembly/Disassembly (cont)
5-13. FrameTensioner............................................................................................ 119
5-14. Carrier Belt Clamp ......................................................................................... 119
5-15. CarrierPCB Removal/Installation ................................................................... 123
5-16. PaperandEncoderSensorRemoval .............................................................125
5-17. Paper and Encoder Sensor Installation ..........................................................126
5-18. CarrierBushingRemoval ............................................................................... 128
5-19. CarrierBushingInstallation............................................................................ 128
5-20. ServiceStation,Exploded View...................................................................... 129
5-21. StabilizerBracket Installation/Removal ...........................................................134
5-22. Y-ArmInstallation/Removal ............................................................................136
5-23. PinchRoller ...................................................................................................137
5-24. InnerPlaten Assembly/Disassembly .............................................................. 140
5-25. StepperMotorRemoval/Installation ................................................................142
5-26. InsidePlaten, Right Side................................................................................144
5-27. MediaTake-UpandFeedSensorRemoval..................................................... 146
5-28. MediaTake-UpandFeed Motor Removal .......................................................149
Chapter 6 Parts List
6-1. Left Side Parts Breakdown ............................................................................ 154
6-2. PlatenandAbove Parts Breakdown ............................................................... 155
6-3. RightSidePartsBreakdown ..........................................................................156
6-4. InnerPlatenPartsBreakdown........................................................................157
6-5. Carrier Assembly Parts Breakdown ...............................................................158
6-6. PowerFeedandTake-UpPartsBreakdown ...................................................159

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NovajetPROe Series Service Manual
List of Tables
Table Page
Chapter 1 General Description
Chapter 2 Theory of Operation
Chapter 3 Maintenance
Chapter 4 Troubleshooting
4-1. TroubleshootingTable.......................................................................................81
Chapter 5 Assembly/Disassembly
Chapter 6 Parts List
6-1. PartsList .......................................................................................................151

1
GENERAL
DESCRIPTION
17
GeneralDescription
Figure 1-1. Novajet PROe Series Inkjet Printers.
Introduction
This manual provides service information for the ENCAD®, Inc.
Novajet®PROe Series Color Inkjet Printer. There are two ver-
sions of the Novajet PROe printer: Novajet PRO 42e
and Novajet PRO 60e.
It is written for service personnel who possess analog and digital
circuitry experience. Chapter 2, Theory of Operation, should be read
and thoroughly understood before troubleshooting/calibrating the
printers.

18 GeneralDescription
NovajetPROe Series Service Manual
The printers support pre-cut and roll media. Media size is auto-
matically determined and hardclip limits are set accordingly. Pre-
cut media uses different maximum plotting areas than roll media.
See the Printer Specifications for more details.
Both RS-422 serial and Centronics parallel connections are provided
to interface with the host computer. Commands sent from the host
computer can be in several forms including HP-RTL, and Encad
RTL formats.
Drivers are supplied to support Windows-based PC’s (3.XX, 95, and
NT) as well as Macintosh and Power PC computers.
These printers expand upon ENCAD’s tradition of delivering fast,
high-quality color or monochrome graphics for a variety of applica-
tions. ENCAD has made significant advances in designing these
printers to respond to and anticipate our customers’ needs. Princi-
pal features are summarized below.
Locally or Remotely Configured via Host Computer
Powered Media Take-Up and Feed System
Media Drying System
Quick Ink Changeover
Self-Aligning Pinch Rollers
PowerPC 33 MHz Microprocessor
8 User Configurable Settings
104 Jet Ink Cartridges
Ink Priming System
500ml Ink Reservoirs
Smart Cartridges

GeneralDescription 19
GENERAL
DESCRIPTION
NovajetPROe Series Service Manual
Overview
Printers draw according to instructions issued from a “host” com-
puter. Every printer is engineered to understand a specific set of
instructions and to execute each instruction in a precise manner.
In addition, most printers are designed to execute predetermined
characters automatically without a specific line-by-line instruction
from the program. These characters are part of the printer’s
permanent memory.
Related Publications
The following publication contains additional information which may
be useful in servicing the ENCAD, Inc. Novajet PROe Color
Inkjet Printers:
•ENCAD, Inc. Novajet PROe User Guide,
P/N 208713-1
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.
Electrostatic Discharge(ESD)Sensitivity
All PCBs (Printed Circuit Boards) associated with the Novajet
PROe printers have components sensitive to ESD (electrostatic
discharge). Care must be taken to avoid damage to any of the
components by following current ESD handling procedures and
practices.
Always use an approved ESD grounding strap when handling or
working with PCBs.

20 GeneralDescription
NovajetPROe Series Service Manual
Warnings,Cautions,and Notes
Warnings, cautions, and notes are used when additional informa-
tion, instructions, or care should be observed. In this manual,
warnings cautions, and notes precede the text to which each ap-
plies. The definition of each is provided below.
WARNINGS - Warnings are used to stress that the following steps
or procedure has the potential to cause serious harm or death to
service personnel. Extreme care should be observed when following
the procedures and to exercise standard safety procedures. They
are indicated by:
Followed by a paragraph describing the concern.
CAUTION - Cautions depict that the following steps or procedures
can cause damage to the equipment if not properly followed. Ex-
treme care should be observed when following the procedures and
to exercise standard safety procedures. They are indicated by:
Followed by a paragraph describing the concern.
NOTE - Notes are placed before a procedure to inform the service
personnel of specific details to improve quality, to give reminders of
interrelated parts, and to provide other helpful information. They
are indicated by: NOTE
Followed by a paragraph describing the concern.