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ENCAD T-200, Service Manual

The ENCAD T-200 Service Manual is the essential resource for troubleshooting and maintaining your printer. Download this comprehensive manual for free from our website, and easily find step-by-step instructions and detailed diagrams to keep your machine in optimal working condition.

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ENCAD T-200 and T200+ Service Manual

Parts List

6-6

FIGURE ITEM

PART NAME

PART #

6-3

1

PRINT SERVER (OPTIONAL) ................ 218239-00

6-3

2

SIDE PLATE, RIGHT .............................. 217516-00

6-3

3

MAIN PCB, T-200, SERVICE .................. 2119668-025

6-3

4

DRAM DIMM, 32M .................................. 212456-00

6-3

5

COVER ASSEMBLY, WITH KEYPAD,
RIGHT ..................................................... 217510-00

6-3

6

DISPLAY, HOUSING, ASSY ................... 217543-00

Summary of Contents for T-200

Page 1: ...SERVICE MANUAL ...

Page 2: ...T 200 AND T 200 COLOR INKJET PRINTER PLOTTERS SERVICE MANUAL Part Number 219863 00 ...

Page 3: ...slated in any human or comput ing language in any form or by any means electronic mechanical magnetic or otherwise or disclosed to a third party without the express written permission of ENCAD Inc 6059 Cornerstone Court West San Diego CA 92121 U S A Certain manuals developed by ENCAD are in an elec tronic format to be distributed on CDs or over the internet The registered user of an ENCAD product ...

Page 4: ...n radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communica tions 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 mea...

Page 5: ... 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 ...

Page 6: ...nhazardous 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 858 452 4350 International users should contact their local dealer or distributor ...

Page 7: ...nsequential damages or any other damages or claims whatsoever This Warranty gives Buyer specific legal rights and Buyer may also have other rights that vary from state to state This Warranty applies only to printers purchased from ENCAD or authorized ENCAD distributors or dealers The intent of this Warranty is to repair or replace defective Prod ucts subjected to normal wear and tear when operated...

Page 8: ... 1 T 200 T 200 Printer General Block Diagram 2 1 Paper Media Axis Drive 2 3 The Carriage Axis Drive 2 4 Main Printed Wiring Assembly MPWA 2 5 Microprocessor 2 6 Gate Array 2 6 Memory Circuits 2 7 Flash EEPROM 2 7 DRAM 2 8 Serial EEPROM 2 8 Stepper Motor Controller 2 9 Servo Motor Controller 2 11 Control Panel 2 13 Interface Circuits Serial Parallel 2 14 CarriageAssembly Circuits 2 15 Display Assem...

Page 9: ...ents Adjustments 3 17 Slide Shaft ProfileAdjustment 3 17 Head HeightAlignment Procedure 3 20 Paper SkewAdjustment 3 24 Paper SkewAdjustment Sequence 3 24 Mounting Screw Information 3 25 Other Functional Requirements 3 28 Adjustment of Pinch Roller Supports 3 29 Visual Verification 3 29 Observation of Paper Skew at Rear MediaAlignment Mark 3 30 Observation of Paper Skew at Front MediaAlignment Mark...

Page 10: ...per Skewing 4 9 Printer Output is Banding Horizontal 4 9 Printer Output is Banding Vertical 4 11 Printer Output is Banding Horizontally and Vertically 4 12 Keypad Locked Up or Not Functioning Properly 4 12 Noisy Operation 4 13 Line Quality Degraded 4 14 Fan Does Not Power Up 4 15 Media is Not Measured Properly 4 15 Initialization Troubleshooting 4 16 Chapter 5 Assembly Disassembly 5 1 Introduction...

Page 11: ...r 5 23 Replacing the Carriage Bushings 5 24 Reinstalling the CarriageAssembly Carriage Belt and the Frame Tensioner 5 26 Removing the Trailing Cable 5 28 Reinstalling the Trailing Cable 5 29 Removing the Power Supply and ON OFF Switch 5 30 Reinstalling the Power Supply and ON OFF Switch 5 32 Remove the Stabilizer Bracket and Encoder Strip 5 33 Install the Stabilizer Bracket and Encoder Strip 5 34 ...

Page 12: ...10 Interface Circuits 2 14 2 11 CarriageAssembly Circuits 2 15 2 12 Display Assembly 2 16 Chapter 3 Maintenance 3 1 Encoder Strip Cleaning 3 5 3 2 Cartridge Dimple Region 3 5 3 3 Flex Cable Contacts 3 6 3 4 Main PWA Connection Locations 3 9 3 5 Carriage PWA Connection Locations 3 10 3 6 Ribbon Connector Locking Mechanism 3 11 3 7 Servo Motor 3 12 3 8 Stepper Motor 3 13 3 9 Examples of Banding 3 14...

Page 13: ...ge for Rear MediaAlignment Mark 3 30 3 23 Paper SkewAcceptance Range for Front MediaAlignment Mark 3 31 3 24 Motion of Rollers andAdjustment of Mounting Screws 3 32 3 25 Paper Axis Test 3 34 3 26 Slow Deadband 3 35 3 27 Color Calibration 3 38 3 28 MPWA Connections Diagram 3 45 3 29 Carriage PWA Connections Diagram 3 46 Chapter 4 Troubleshooting 4 1 Carriage Board LED D2 and D5 Locations 4 17 Chapt...

Page 14: ...al 5 25 5 17 Carriage Bushing Installation 5 26 5 18 Revealing the Power Supply Screws 5 31 5 19 Inner Platen Parts 5 32 5 20 Stabilizer Bracket Removal 5 34 5 21 Disassembly of Plotter Prior to Removing the Inner Platen Parts 5 36 5 22 Removal of Lower Drive Shaft Screws 5 37 5 23 Removing the Foam Block 5 38 5 24 Lower Drive Shaft Assembly and Stepper MotorAssembly 5 40 5 25 Removing the Upper P...

Page 15: ...e Chapter 1 General Description Chapter 2 Theory of Operation Chapter 3 Maintenance 3 1 Main PWA Connections Table 3 9 3 2 Carriage PWAConnections Table 3 10 Chapter 4 Troubleshooting 4 1 Troubleshooting Table 4 1 Chapter 5 Assembly Disassembly Chapter 6 Parts List ...

Page 16: ...Color Inkjet Printer Plotters 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 The printers support both pre cut and roll media Media size is auto matically determined and hardclip limits are set accordingly Pre cut ...

Page 17: ...port Windows based PC s 3 XX 95 98 and NT as well as Macintosh and Power PC computers These printers expand upon ENCAD s tradition of delivering fast high quality color or monochrome graphics for a variety of applications ENCAD has made significant advances in designing these printers to respond to and anticipate our customers needs Principal features are summarized below Locally or Remotely Confi...

Page 18: ...information which may be useful in servicing the ENCAD Inc CadJet T 200 Color Inkjet Printers ENCAD Quick Start Guide for the T 200 and T 200 P N 217892 xx ENCAD T 200 and T 200 CD ROM P N 217893 xx Copies of these and other ENCAD Inc publications may be obtained by contacting your nearest authorized ENCAD Inc dealer or by contacting ENCAD s Technical Support and Service Department Electrostatic D...

Page 19: ...owing the proce dures and to exercise standard safety procedures They are indicated by Followed by a paragraph describing the concern CAUTIONS Cautions depict that the following steps or procedures can cause damage to the equipment if not properly followed Extreme care should be observed when following the procedures and to exercise standard safety procedures They are indicated by CAUTION Followed...

Page 20: ...er Requirements Input Voltage 90 246 VAC 47 63 Hz Output Power 20 W idle 50 W typical 100 W maximum Accuracy Dot Placement 0 0017 0 0008 Cut sheet feed accuracy edge shift 0 065 inches as measured over 36 inches Resolution 600x600 dpi or 300x600 dpi Interface Centronics parallel IEEE 1284 Network via 100 Base T Print Server Certifications Safety CSA CSE NRTL equivalent to UL1950 TUV GS EN 50 082 1...

Page 21: ...trations and List of Tables This manual is divided into six chapters as Chapter 1 GENERAL DESCRIPTION Contains a general description of the ENCAD T 200 and T 200 printers This includes printer specifications and related materials Also included is a description of the use of Warnings Cautions and Notes as used in this manual and chapter contents Chapter 2 THEORY OF OPERATION Functional descriptions...

Page 22: ...chniques will have to be implemented to correct the problem Chapter 5 ASSEMBLY DISASSEMBLY Contains detailed procedures to remove and replace printer parts and assemblies Chapter 6 PARTS LIST Contains a complete listing of all field replacable parts and assemblies for the color inkjet printers Illustrated parts breakdown drawings are included to help clarify and identify parts for ordering Special...

Page 23: ...check out ENCAD s Knowledge Base located on ENCAD s website support ENCAD Website http www encad com Additional information is available though our Technical Support and Service Department s Help Desk ENCAD Inc Technical Support Service Dept 6059 Cornerstone Court West San Diego CA 92121 Help Desk Telephone 858 452 4350 or 877 ENCAD TS 362 2387 Help Desk FAX 858 558 4672 International users contac...

Page 24: ...ntronics parallel interface This interface is either connected directly to a computer or through a network print server T 200 T 200 Printers General Block Diagram Figure 2 1 illustrates the major functional areas of the printers The T 200 and T 200 printers consist of two mechanical assemblies 1 Paper Media Axis Drive 2 Carriage Axis Drive and four main electrical assemblies 1 MPWA Main Printed Wi...

Page 25: ...AL CONNECTION MECHANICAL CONNECTION MAIN DATA BUS MPWA DISPLAY CIRCUITS STEPPER MOTOR SERVO MOTOR MICRO PROCESSOR MEMORY CIRCUITS GATE ARRAY CARRIAGE ASSEMBLY CARRIAGE PWA PAPER SENSOR LOWER DRIVE ASSEMBLY LEGEND ENCODER SENSOR PAPER AXIS DRIVE POWER SUPPLY Figure 2 1 General Block Diagram ...

Page 26: ...motor reduction gears lower drive shaft assembly and pinch rollers This can be seen in Figure 2 2 The micro step technology associated with the stepper motor gives the capability of a resolution up to 9600 dpi The reduction gear meshes the stepper motor to the lower drive shaft assembly which allows the media to advance or retract The purpose of the pinch rollers is to apply pressure to the media ...

Page 27: ...The servo motor drives the belt back and forth allowing the attached carriage assembly to be repositioned as required The tensioning assembly is spring controlled and allows the proper amount of tension on the belt The linear optical encoder strip is used to obtain the printers accuracy along the axis of the printer It is made with 150 parallel lines per inch etched into it By utilizing two optica...

Page 28: ...OM DYNAMIC RAM GATE ARRAY SERVO MOTOR CONTROLLER CARRIAGE PWA PARALLEL DATA BUS MEMORY CIRCUITS CONTROL PANEL Figure 2 4 Main Printed Wiring Assembly The Main Printed Wiring Assembly MPWA consists of seven func tional areas 1 Microprocessor CPU 2 Gate Array 3 Memory Circuits 4 Stepper Motor Controller 5 Servo Motor Controller 6 Control Panel 7 Interface Circuits Parallel ...

Page 29: ...ther serial port interfaces to the Control Panel One DMA channel supplies data to the gate array for jet firing the other DMA channel is used to receive data through the parallel port via the gate array or the serial port when using a high speed serial mode One timer generates a servo interrupt every millisecond the other is used for timing the Stepper Motor The system is timed by a 33MHz system c...

Page 30: ...RAM storage Each time power is turned on this information must be downloaded from the system ROM This type of gate array allows for the flexibility of upgrading the logic by simply downloading the new system software Memory Circuits Memory is used to retain large amounts of information This infor mation is stored in the device memory in the form of binary bits Printer memory consists of Flash EEPR...

Page 31: ...e parallel port for PC users See Firmware Downloading in Chapter 3 for the proce dures DRAM DRAM is Dynamic Random Access Memory which provides temporary storage of the microprocessor calculation and input output data It is also a faster type of memory then the Flash EEPROM That s why the printer control program is also copied from the Flash EEPROM to RAM where it can be executed faster The printe...

Page 32: ...ne A waveform generator receives digital data from the CPU and gener ates a sine wave output This signal is fed into a comparator circuit that is measuring the current through the winding of the stepper motor If the current is too low a pulse of 24V is generated When the current goes above the output of the waveform generator the pulse turns off Every time the output of the waveform generator is c...

Page 33: ... the reference waveform generator by two and compares it to the output of the motor current sensor Logic inside the gate array generates the control signals for the power driver that applies voltage across the motor winding in order to make the actual current match the reference waveform 4 Power driver An H bridge allows the supply voltage to be applied across the winding in either polarity used t...

Page 34: ...array which sets the duty cycle to make adjust ments to the Carriage Assembly speed A linear optical encoder is used to monitor the Carriage Assembly position The optical encoder strip runs the length of the Stabilizer Bracket and contains 150 lines and spaces per inch Thus there are 300 edges per inch The detector circuit actually consists of two optical edge detectors They are separated from eac...

Page 35: ... 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 diffe...

Page 36: ...9 Control Panel The Control Panel is located on the right side of the printer and contains two indictors ERROR READY and seven buttons RESET resets all conditions to factory select settings SHORTCUT MENU allows immediate access to common functions cut prime feed media access cartridge pause and clean MENU begins the main menu routine ...

Page 37: ...TOR Figure 2 10 Interface Circuits Data from the host computer is received through the Centronics parallel port The gate array provides the control signals for DMA transfers from the parallel port to DRAM The parallel port is the connection for sending print jobs to the printer This port can be connected to a wide variety of computers running various operating systems It is also used to connect th...

Page 38: ... Assembly contains 1 Carriage PWA 2 Optical Sensors 3 Paper Sensor 4 Inkjet Cartridges The Carriage PWA contains the logic and drive circuitry for the firing of the inkjet cartridges It also establishes an interface path for the optical sensor and paper sensor to communicate with the MPWA The optical sensors receive their inputs from the optical encoder strip and sends this data to the MPWA The MP...

Page 39: ... no paper is sensed the paper sensor sends this information to the MPWA which immediately begins an out of paper subroutine This subroutine stops the printer from printing until more media is loaded The sensor also checks for the size of the media loaded so it can deter mine the proper printing parameters Display Assembly The Display Assembly is located on the right side portion of the platen and ...

Page 40: ... fast blow type fuse The outputs share a common ground which is isolated from earth ground with in the supply itself Earth ground and DC ground are connected external of the power supply The power supply will shut down under overload short circuit conditions on any output over the full range of input voltage Overvoltage protec tion is 20 30 above nominal for the 24V output Beeper and Fans The beep...

Page 41: ...etecting a condition due to a weakened component that has not yet completely failed Below is a list of scheduled maintenance checks and their recom mended periodicity Clean external areas semiannually or as required Clean slide shaft weekly Clean service station daily Clean encoder strip weekly Clean cartridge dimples weekly of if prime fails Clean flex cable contacts weekly or if prime fails or c...

Page 42: ...any sort on the surfaces of the printer Damage to the surface may result The exterior surfaces of the printer may be cleaned with a soft cloth which has been dampened For more persistent stains a small amount of liquid detergent may be used Cleaning intervals are determined by the environment in which the printer is used Slide Shaft Cleaning CAUTION Use only isopropyl alcohol on the slide shaft of...

Page 43: ...er lid 3 Moisten a clean cloth or paper wipe with isopropyl alcohol 4 Wipe the length of the slide shaft with the moistened cloth or wipe 5 Manually move the carriage assembly from side to side 6 Wipe the shaft again to remove any deposits left from the carriage 7 Close the cover and reconnect the power cord and interface cable turn the printer ON and perform the PRIME procedure Be sure that the c...

Page 44: ...vice station and lift out Wash dry thoroughly and replace by placing the left side in first then pushing down on the right side until the tab locks it in place Linear Encoder Strip Cleaning Clean the linear encoder strip weekly or as necessary to remove any buildup of debris Distilled water or isopropyl alcohol may be used You may notice that it tends to fog the encoder strip however no detrimen t...

Page 45: ...ENCAD T 200 and T 200 Service Manual Maintenance 3 5 Figure 3 1 Encoder Strip Cleaning Cartridge Dimples Cleaning CARTRIDGE DIMPLE AREA Figure 3 2 Cartridge Dimple Region ...

Page 46: ...ing the cartridges Avoid touching the cartridges on the dimple area or on the inkjet holes on the bottom The oils and dirt on fingers and hands can contaminate the area and result in misfiring of the inkjets Clean the cartridge dimple area by gently dabbing the area with a lint free cloth or cotton swab saturated with isopropyl alcohol Be sure to clean the yellow cartridge because it is not readil...

Page 47: ... Stepper Motor Gears The stepper motor gears can become dirty and after time if not cleaned up it could cause wide banding in the print This will reduce the quality of the intended output Clean the motor gears with a stiff brush to knock off any debris A cotton swab soaked isopropyl alcohol can be used to remove any ink that may have accumulated on the gears Clean and Inspect MPWA Foreign material...

Page 48: ... let anything to fall into the printer as you clean or it could cause a new problem later Inspect the carriage assembly for any damage to the boards connec tions or any of the components on the assembly Reseat Connectors on MPWA and Carriage Board CAUTION Integrated circuits may become weakened or damaged by electrical discharge Do not touch or work near integrated circuits without wearing an ESD ...

Page 49: ...Figure 3 4 Main PWA Connection Locations Table 3 1 Main PWA Connections J1 not used J7 Servo Motor J2 Parallel Port J8 not used J3 Display Circuits J9 Power Supply J4 PC133 DIMM socket J10 Stepper Motor J5 Vacuum Cooling Fan J11 not used J6 Trailing Cable ...

Page 50: ...Cable J3 Cyan Drivers J7 Paper Sensor J4 Black Drivers Figures 3 4 3 5 and Tables 3 1 3 2 show the locations of all the connectors on the MPWA and carriage board respectively To remove the ribbon cables from their connectors lift the connector s ribbon locking mechanism as shown in Figure 3 6 To reattach depress the locking mechanism back into the locking position after inserting the ribbon cable ...

Page 51: ...actors including but not limited to hours day used cleanliness of the slide shaft and general ambient environ ment make it impossible to calculate the average time that the carriage bushings to last If not replaced the wear on the bushings can result in erratic car riage motion and or carriage axis failures It can even cause the cartridge head height to become uneven To replace the carriage bushin...

Page 52: ...nection from J7 on the MPWA 2 Using a standard ohmmeter or multimeter connect the meter leads to the two wires going to the motor 3 While manually rotating the servo motor monitor the readings on the meter The acceptable range is 4 10 ohms Typically the reading is 5 8 ohms 5 If the measurement is found to be unsatisfactory replace the servo motor ...

Page 53: ...otor 1 Disconnect the stepper motor connection from J10 on the MPWA 2 Using a standard ohmmeter or multimeter measure between pins 1 red wire and 3 3 The reading should indicate 7 2 8 0 ohms 4 Continue by measuring between pins 4 and 6 5 Reading should also indicate 7 2 8 0 ohms 6 If either measurement is out of tolerance replace the stepper motor ...

Page 54: ... on the back of the printer All these possible faulty areas deal with a rotational movement that if faulty will gener ate a consistent banding pattern The MPWA and Carriage PWA can also cause this type of error to incur Software banding is characterized by inconsistent banding lines These banding lines are generated by the software when the application incorrectly interprets the media advancing in...

Page 55: ...es We recommend printing to a file first and then queuing the file to the printer to avoid the RIP and print cycle delays that can cause banding while printing 2 Uneven inkjet kogation partial clogging or orifice restriction on the inkjet cartridge head nozzles Run the 100 color test and re prime or replace the cartridge if necessary 3 Lower quality print modes normally cause slight banding to red...

Page 56: ...per cartridge with minimal degradation of the output 9 Media width variations causing the media to drag on the media guides can cause banding Check the edges of the media for evidence of media drag and edge anomalies 10 Lower quality dithering Select the highest quality dithering pattern in the printer driver i e stochastic dithering 11 Deadband and cartridge calibrations If the deadband calibrati...

Page 57: ... minimum of maintenance requirements in mind Calibrations include color calibration deadband alignment and X axis calibration The mechani cal adjustment requirements include the slide shaft profile and car tridge head height adjustments They do not require any electrical alignments Slide Shaft Profile Adjustment The T 200 and T 200 printer Slide Shaft height is factory set and is firmly mounted on...

Page 58: ...ge Card 0 011 Not used There are two basic measurements that are to be made using this kit ensure power is off prior to performing these procedures 1 Slide Shaft Profile Adjustment 2 Carriage Cartridge Head Height Setting 1 Connect the dial gauge micrometer to the Shaft mounting block as shown in Figure 3 10 ZERO GAUGE SHAFT MOUNTING BLOCK TIGHTEN SET SCREW NOT SHOWN Figure 3 10 Dial Gauge Microme...

Page 59: ...k and note the difference Divide this amount by two 4 Measure just off the center of the slide shaft and adjust the center turnbuckle with an open ended wrench if required for the average value the value found in step 3 See Figure 3 12 THIS IS THE INNER SCREW POSITION GAUGE DIRECTLY IN FRONT OF IT THIS IS THE TURNBUCKLE SCREW POSITION GAUGE AS CLOSE TO THE SCREW AS POSSIBLE Figure 3 12 Slide Shaft...

Page 60: ...stabilizer has been removed from the Y Arm or whenever the alignment is in question The head height alignment procedure is to ensure that the correct amount of distance exists between the cartridge jet plate and the Platen See Figure 3 13 HEAD HEIGHT CARTRIDGE JET PLATE PLATEN Figure 3 13 Carriage Head Height Tolerance 1 Remove the lid and the right cover of the printer See Chapter 5 for procedure...

Page 61: ...IDGE MEASURING TIP EXTENDER Figure 3 14 Setting Up Tools from Height Gauge Kit 3 Place the test cartridge upright on a flat surface and zero the gauge by loosening the knob near the top and turning the dial until the needle is at the 0 position on the dial Tighten the knob See Figure 3 15 ZERO GAUGE ENSURE PRESSURE IS PLACED ON THE REAR OF THE CARTRIDGE 0 Figure 3 15 Zeroing the Micrometer Gauge ...

Page 62: ...ometer gauge if the Carriage is moved without lifting up on the measuring tip This ac tion could also take the micrometer out of alignment and foul the results of the alignment 6 While lifting up the measuring tip of the micrometer slide the Carriage to the left side of the stabilizer Position it as close to the screw as possible and drop the measuring tip onto the platen Do this a couple of times...

Page 63: ...e screw as possible and drop the measuring tip onto the platen Do this a couple of times to ensure an accurate reading 11 Move the left end of the stabilizer bracket until a correct reading is observed Read only the RED numbers on the micrometer gauge 12 Tighten the screw on the stabilizer that is next to the Carriage 13 Continue performing steps 10 through 12 until all four of the stabilizer scre...

Page 64: ... left or to the right when the Lower Roller is rotated forward for two full revolutions Slow drifting is acceptable Use the torque screwdriver with the P0 bit to adjust the Pinch Roller mounting screws NOTE Read and follow ALL of the information in the following pages before you begin the actual ajustments Paper Skew Adjustment Sequence It is very important that the sequence for the adjustment giv...

Page 65: ...ent of Pinch Roller Supports section 3 Load a sheet of E Size paper and adjust Rollers 3 2 and 1 following the directions in the Adjustment of Pinch Roller Supports section Mounting Screw Information 1 The torque requirements for the Pinch Roller Support mounting screws is 3 In Lbs 0 5 2 Turning the mounting screw clockwise will tighten the screw Turning the mounting screw counterclockwise will lo...

Page 66: ...ned counterclockwise the roller will move to the right NEVER LOOSEN OR TIGHTEN BOTH MOUNTING SCREWS AT THE SAME TIME ON THE SAME UPPER ROLLER SUPPORT 5 If you have loosened one of the mounting screws and the roller has moved and you need to move the roller in the opposite direction you must tighten that mounting screw BEFORE loosening the other screw to move the roller in the opposite direction Wh...

Page 67: ...r Roller Support will not be perfectly level and will not perform its function properly 7 Following all of the information in this section precisely will ensure that the Pinch Roller Support springs are deflected and the lower tail of the springs will always be pressed against the Pinch Roller Spacer without a gap as shown in Figure 3 19 PINCH ROLLER ASSEMBLY Y ARM PINCH ROLLER ASSEMBLY MUST TOUCH...

Page 68: ... 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 3 20 Avoid adjusting the Pinch Roller Supports so that they touch the Y Arm s cut outs THE MINIMUM ACCEPTABLE GAP BETWEEN THESE TWO POINTS EQUALS THE THICKNESS OF A PIECE OF B...

Page 69: ...e adjustment according to the se quence given in Figure 3 17 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 3 21 GAP GAP Figure 3 21 Visual Verification of Gap between Roller and Y Arm ...

Page 70: ...t edge of the paper and the left edge of the Front Media Alignment Mark on the Platen 2 Hold the media and press LOAD The paper will be pulled in past the Platen s groove The paper will roll forward out and stop 3 Check to make sure that the gap between the right edge of the paper and the left edge of the Rear Media Alignment Mark on back of the Platen is within 2 line widths 0 12 See Figure 3 22 ...

Page 71: ...ent Mark 2 The paper should be returning to its preloading location preferably without any skew gap Engineering specification requires the skew to be within 0 00 0 06 approximately one width of Platen s line See Figure 3 23 PAPER LEFT PAPER RIGHT 0 00 0 06 PAPER SLEW ACCEPTANCE RANGE ONE LINE WIDTH LOCATED ON THE FRONT SIDE OF THE PLATEN FRONT MEDIA ALIGNMENT MARK Figure 3 23 Paper Skew Acceptance...

Page 72: ...ller is rotated forward IF ROLLER MOVES TO THE RIGHT AND TOUCHES THEN TIGHTEN THE LEFT MOUNTING SCREW 1 2 TURN AT A TIME IF ROLLER MOVES TO THE LEFT AND TOUCHES 1 2 TURN AT A TIME RIGHT MOUNTING SCREW THEN TIGHTEN THE NO GAP NO GAP ORIENTATION STANDING BEHIND THE PLOTTER FACING THE BACK OF THE PLOTTER Figure 3 24 Motion of Rollers and Adjustment of Mounting Screws Once you have completed the adjus...

Page 73: ...5 is a representation of how a color calibration looks when printed 6 5 4 3 2 1 0 1 2 3 4 5 6 COLOR VERTICAL HEAD TO HEAD CALIBRATION Y M C COLOR HORIZONTAL HEAD TO HEAD CALIBRATION C M Y Current Heads Y M C Figure 3 25 Color Calibration The Current Heads Y M C view represents the alignment of the heads as they are currently entered This is just an overview of all heads and how they are aligned Do...

Page 74: ...ning the correct color by observing the C cyan M magenta and Y yellow on the right side of the plot To perform the Color Calibration Depress the Menu key on the control panel to begin the main menu subroutine Using the Up Arrow Down Arrow and Select keys on the control panel select Utility Menu Color Calib Print Test This will print the color calibration plot as shown in Figure 3 25 When the plot ...

Page 75: ...a series of vertical lines printed No difference between the top and bottom set of lines to the center set of lines would be apparent The SLOW DEADBAND calibration is a precision test that checks the firing time of the jets as related to the forward and reverse direction Allowable values for the Slow Deadband calibration is 2 1 0 1 and 2 The Fast Deadband test will print a display similiar to Figu...

Page 76: ...ne greater then the current value Press Select to accept the selection and rerun the Slow Db Test Continue performing these steps until the slow deadband adjustment is correct Color Deadband Alignment The color deadband alignments are necessary to ensure that the output images are being produced with the highest quality standards available while using the ENCAD printer in a bidirectional mode Thes...

Page 77: ...test is run it will print out a pattern of 5 calibration lines for each of the 12 settings It will print this pattern in black first followed by cyan magenta and then yellow Also printed will be the current settings for each of the four colors as well as the slow deadband setting When the plot is complete select K Fast DB XX Observe the plot and using either Up Arrow or Down Arrow rotate through t...

Page 78: ... Menu key on the control panel to begin the main menu subroutine Using the Up Arrow Down Arrow and Select keys on the control panel select Utility Menu Paper Calib Calib XY On or Off Ensure that Calib XY is set to ON and press Select This allows the printer to store the data that is entered in the following steps Then select Paper Axis Test This runs the paper axis test which prints out two T figu...

Page 79: ...asure the exact distance from each of the T intersections Select Paper Axis XX The XX will read 33 00 if the plotter is set in English units or 83 82 if in metric units Using either Up Arrow or Down Arrow rotate through the selections until the exact value of the measurement found is selected Press Select to accept the selection ...

Page 80: ...rvo PWM Test Servo Cycle Test Carriage Test Color Test and Continuous Test Servo PWM Test Monitors the PWM pulse width modulation signal applied to the servo motor from the driver on the MPWA to check the amount of force required to move the Carriage The test performs three complete cycles of the carriage assembly and lists the average PWM the maximum PWM and the position of the carriage where the...

Page 81: ...the printer is the only way of exiting this test loop The Continuous Test will first prime the cartridges followed by a serial port test parallel port test a fast deadband display and a color calibration display The deadband and color calibration displays are used only as a visual inspection of the operating condition of the printer No adjustments can be performed while in the Continuous Test mode...

Page 82: ...mware for your printer Save both of the files to the same directory on the hard drive Double click on XXXX EXE file to inflate the compressed files The file name might be different then listed above 5 Go to a DOS environment and from within that same directory type GO XXXX ROM and press Enter The firmware is sent to the printer as an ordinary print job NOTE For NT3 5x or NT4 0 systems click on Sta...

Page 83: ...Menu About menu Verify firmware has been incorporated 8 If the firmware download is not successful you may hear more than 1 beep or complete silence Check parallel port connections and return to step 5 Internal Cabling and Signal Flow Diagrams Figures 3 28 and 3 29 are schematics of the major components and the cabling associated between them The diagrams depicts component boards or assemblies jac...

Page 84: ...ections Diagram LINE NEUT GND AC INPUT PWR SWITCH 1 2 3 SWITCHING POWER SUPPLY 1 2 3 4 P1 P2 J9 1 2 3 4 24V GND GND 24V 1 2 J5 0V 24V 24V VACUUM COOLING FAN DISPLAY J3 PARALLEL J2 TRAILING CABLE J6 MAIN PRINTED WIRING ASSEMBLY 1 2 3 4 5 6 J10 1 2 3 J7 STEPPER MOTOR SERVO MOTOR ...

Page 85: ...J6 J6 CARRIAGE PWA 1 2 3 4 5V EXB GND EXA J5 1 2 3 4 J1 OPTICAL ENCODER SENSOR YELLOW MAGENTA CYAN CARTRIDGE DRIVERS BLACK J1 J2 J3 J4 DATA 2 GND GND HEAD STROBE PAPER PSIN PWM LATCH CLK CLK DATA 1 DATA 1 DATA 2 GND GND GND EXA EXB GND 5V 24V 24V TRAILING CABLE 1 2 3 4 5V PSIN 5V GND J7 1 2 3 4 J1 PAPER SENSE PWA MAIN PRINTED WIRING ASSEMBLY 21 22 23 24 25 26 21 22 23 24 25 26 DAN 5V 24V GND 24V G...

Page 86: ... identification troubleshooting fault isolation and repair of the printer when using this table Ensure that all applicable software diagnostic tests have been properly executed all visual indications including LED status have been observed and all applicable pushbuttons have been depressed to obtain a complete list of symptoms to be applied to the table below Use the table in conjunction with Chap...

Page 87: ...for pin out DC voltage replace MPCB present at MPCB Initialization Failure SIMM unseated reseat or replace defective or missing SIMM power supply replace power defective supply trailing cable replace trailing defective cable Media Does Not Move perform Stepper replace stepper Motor Winding motor if out of Resistance check tolerance rough motion bad bearings while spinning replace stepper stepper m...

Page 88: ...mware corrupted bad MPWA replace MPWA ESD electro ensure that all ESD static discharge components are properly installed then replace MPWA Internal ERROR Carriage Axis Failure dirty or perform Slide Shaft lubricated slide Cleaning procedure shaft perform Servo replace servo motor Motor Winding Resistance check check servo bad bearings motor for smooth replace servo motor movement obstruction in re...

Page 89: ...ings bushings and clean damaged replace encoder encoder strip strip bad encoder reseat or replace sensor encoder sensor worn carriage replace carriage bushings bushings loose trailing remove power and cable connections reseat trailing cable connections at the MPWA and the carriage assembly cutter assembly replace cutter malfunction assembly damaged 1 check idler carriage drive tension assembly bel...

Page 90: ...r replace encoder sensor sensor Internal ERROR Paper Sensor Failure servo motor reattach connections and vacuum fan correctly use Figure connections to 3 4 for reference MPWA are switched paper sensor reseat paper cable unseated sensor cable bad paper replace paper sensor sensor servo motor check servo motor disconnected connections trailing cable reseat trailing cable connection is faulty bad tra...

Page 91: ...dge ID chip to flex cable wrong cartridges check cartridges installed carriage flex check flex driver cable disconnected cable connections trailing cable reseat trailing connections cable faulty trailing replace trailing cable cable MB version verify correct MB incorrect version ie 18 27 0 faulty carriage replace carriage PWA PWA Image Skews or Moves dirty encoder clean encoder strip strip top and...

Page 92: ...r connections on and printer computer and printer firmware is refresh EEPROM corrupted firmware with new download faulty quad flex replace quad flex cable cable or complete carriage assembly bad MPWA replace MPWA Ink Cartridge Misfiring nozzles clogged perform clean cartridge low on refill or replace ink cartridge cartridge filter replace cartridge clogged ink drop out replace ink ink starvation c...

Page 93: ...ocedures 2 replace carriage assembly cartridge dimple 1 perform area dirty or Cartridge Dimple damaged Cleaning procedure 2 replace cartridge cartridge not reseat cartridge seated correctly bad cartridge replace cartridge service station 1 perform Service dirty or not Station Cleaning properly sealing procedures cartridge jet area 2 replace service station bad carriage replace carriage assembly as...

Page 94: ...s down loose securing lower roller Printer Output is Banding Horizontal low print pass increase print pass mode mode if banding is 1 inspect and or consistent replace stepper motor perform Stepper Motor Winding Resistance Check 2 inspect and or replace stepper motor gears and or lower roller assembly 3 replace MPWA check amount replace or refill of ink in cartridges cartridges cartridges need perf...

Page 95: ...place bushings worn or damaged defective carriage replace bushings bushings faulty or corrupt reload firmware firmware cartridge dimple 1 perform area dirty or Cartridge Dimple damaged Cleaning procedure 2 replace cartridge flex cable 1 perform Flex contacts dirty or Cable Contact damaged Cleaning 2 replace carriage assembly carriage check carriage assembly assembly for proper obstructed movement ...

Page 96: ...head height and perform calibrations incompatable or replace memory defective memory module module Printer Output is Banding Vertical dirty carriage clean bushings bushings defective carriage replace bushings bushings trailing cable reseat trailing connections cable faulty trailing replace trailing cable cable lower roller check lower roller height incorrect dirty encoder clean encoder strip strip...

Page 97: ...d Vertically dirty encoder clean encoder strip strip defective encoder replace encoder strip strip bad MPWA replace MPWA Keypad Locked Up or Not Func tioning Properly firmware 1 reset printer problem 2 refresh or up grade firmware keypad assembly replace keypad damaged assembly faulty connection reseat or replace between MPWA connector and keypad bad MPWA replace MPWA ...

Page 98: ...riage replace carriage bushings worn bushings debris or clean fan assembly obstruction in fan drive belt replace frame slipping on idler tensioner spring or idler hardware or tighten hardware assemblies loose or assemblies carriage height perform Carriage too low Head Height Adjustment lower drive clean and or realign shaft gears are lower drive shaft dirty or misaligned gears noisy servo replace ...

Page 99: ... cartridge damaged color calibration perform Color needed Calibration deadband perform Deadband calibration needed Calibration in bidirectional printing mode debris or clean slide shaft lubrication on slide shaft leaks or bubbles 1 reseal prime ink in ink delivery delivery lines on lines both sides 2 replace ink delivery lines dirty encoder clean encoder strip strip defective encoder replace encod...

Page 100: ...y Fan Does Not Power Up MPWA has 1 reseat connection 24 VDC at J3 at MPWA to fan pins 1 2 2 replace fan power not being 1 reload firmware applied to fan 2 replace MPWA Media is Not Measured Prop erly normal carriage dirty platen clean platen surface function is observed surface but media reverses out the rear of defective platen recoat platen surface printer or continually surface with applicable ...

Page 101: ... Loads gate array on the carriage board LED D2 goes out as soon as the carriage board gate array is programmed 10 Turns on power supply cooling fan 11 Moves carriage 12 Checks and measures media size if loaded 13 Turn on display To troubleshoot using the D2 and D5 LEDs With the power off move the carriage away from the service station and snap the carriage cover off just enough to view the LEDs lo...

Page 102: ... stated in step 11 Snap the cover back onto the carriage LED D5 signifies that bias voltage is available on the carriage board If LED D2 does not go out setup the printer and download new firmware as discussed in Chapter 3 Repeat these procedures If LED D2 still does not go out possible areas to suspect is the MPWA carriage board or the trailing cable D5 GREEN D2 YELLOW Figure 4 1 Carriage Board L...

Page 103: ... the printer 1 Phillips Torque Screwdriver 2 Phillips Torque Screwdriver 1 Slotted Torque Screwdriver 2 Slotted Torque Screwdriver 1 Phillips Screwdriver 2 Phillips Screwdriver 1 Slotted Screwdriver 2 Slotted Screwdriver 5 16 Hex Nut Driver 7 64 Hex Nut Driver Wrench 1 4 Screwdriver Socket Head 1 4 Wire Cutters Needle Nose Pliers X ACTO Knife ESD Wrist Strap Fixture Trailing Cable Tape Location P ...

Page 104: ...des access to the Memory Module MPWA and all MPWA connectors Stepper Motor Servo Motor Fan Display Power Supply and Trailing Cable To remove the Right Cover Assembly 1 Remove the Top Cover Keep the right end of the Top Cover tilted up so that the Retracting Stop and Compression Spring don t fall out 2 You may find it helpful to wrap a rubberband around the connector clips on the parallel port to h...

Page 105: ...cessed by inserting the screwdriver into the groove on the Display Assembly as shown on the lower right side of Figure 5 1 REMOVE SCREWS LOOSEN CAPTIVE FASTENER SCREWS Figure 5 1 Removal of Right Cover Assembly 5 Remove the Right Cover Move the Right Cover towards the back of the unit as you remove it so that it clears the parallel port on the back of the unit Be very careful when removing the Rig...

Page 106: ...use damage to the cable Do not pull the lock too hard as you unlock the connectors or the lock may break off Disconnect all 6 connectors on the MPWA so that the MPWA can be removed see Figure 5 2 for positions of the connectors as follows J3 DISPLAY ASSEMBLY J7 SERVO MOTOR J9 POWER SUPPLY J5 VACUUM COOLING FAN J10 STEPPER MOTOR J6 TRAILING CABLE CAPTIVE FASTENER SCREW SCREW CAPTIVE FASTENER SCREW ...

Page 107: ...th 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 J10 location Grasp the Stepper Motor connector with the thumb and forefinger and pull straight out 6 Disconnect the Power Supply connector at the J9 locatio...

Page 108: ...ocations Hold the top of the MPWA while removing the screws 3 Place the MPWA 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 Removing the Right Side Plate Figure 5 3 Removal of the Right Side Plate To remove the Right Side Plate 1 Remove the Top Cover 2 Remove the Right Cover Assembly 3 Disconnect the...

Page 109: ...he Right Side Plate to the Platen by securing with the screws Torque to 15 in lbs 3 Reinstall the MPWA and all MPWA connections 4 Reinstall the Right Cover Assembly and the Top Cover Reinstalling the MPWA To reinstall the MPWA reverse the steps followed when removing the MPWA 1 Put on an ESD wrist strap 2 Remove the MPWA from the ESD bag 3 Hold the MPWA in place on the Right Side Plate while putti...

Page 110: ...ut Memory Module Removal This printer ships with a 32MB memory module installed on the MPWA If the MPWA is to be returned to ENCAD it will be returned with a factory installed 32MB module If a module of higher capacity has been installed by the customer it is recommended that this memory module be replaced with the original module before returning the MPWA to ENCAD CAUTION Integrated circuits can ...

Page 111: ...the wires are pinched between the Right Cover Assembly and the Right Side Plate 2 Align the back of the Right Cover Assembly over the connector clips on the parallel port Remove the rubber band holding the connector clips together 3 Reinsert all three screws on the inside of the Right Cover Assembly See Figure 5 1 All three screws should be torqued to 15 in lbs Do not overtighten 4 Put the Top Cov...

Page 112: ...ver The four screws are reinserted as shown on Figure 5 4 All screws should be torqued to 15 in lbs Do not overtighten 2 Put the Top Cover back on Removing the Servo Motor To remove the Servo Motor proceed as follows 1 Disconnect the power cord and the interface cables 2 Remove the Top Cover 3 Remove the Trailing Cable Cover from the Y Arm Assembly in order to have easier access to the Frame Tensi...

Page 113: ...crewdriver to remove the back screw on the Servo Motor See Figure 5 5 While using extreme care not to damage the Trailing Cable align the screwdriver through the cut out on the Stabilizer Bracket to get a good angle on the screwhead 6 Loosen the front screw on the Servo Motor 7 See Figures 5 5 and 5 6 While you compress the back of the Frame Tensioner with your left index finger use your right han...

Page 114: ...sh the Servo Motor pulley through the top of the Platen and Y Arm and at the same time rotate the Servo Motor so that the connector is facing the BACK side of the Platen Align the screw holes with the screw hole openings 4 Insert one screw into the Servo Motor and tighten it slightly 5 Insert the second screw into the Servo Motor and tighten it Make sure both screws are torqued to 15 in lbs 6 Comp...

Page 115: ... the Display Assembly 1 Disconnect the power cord and the interface cables 2 Remove the Right Cover Assembly 3 Disconnect the Display Cable connector at the J3 location on the MPWA Pull forward on the connector lock and remove the flex cable from the connector Figure 5 7 Removal of Display Assembly 4 Using a 1 Phillips screwdriver remove the 2 screws from the bottom of the Display Assembly See Fig...

Page 116: ...cable face the Display PWA Route the Display Cable over the groove on the top of the Right Side Plate down between the Right Side Plate and the MPWA and around to the front of the MPWA near the J3 connector Torque Display Assembly screws to 6 in lbs Removing the Service Station Assembly SERVICE STATION RELEASE TAB Figure 5 8 Service Station Removal 1 Place the Top Cover in the open position 2 Move...

Page 117: ...ten and remove the Service Station Moving the Service Station farther to the right might be required to release the left side of the Service Station Reinstalling the Service Station Assembly 1 To install the Service Station position the Service Station inside the Right Cover and place the left side of the Service Station into the Platen 2 Push down on the right side of the Service Station until th...

Page 118: ...rvice Manual Assembly Disassembly 5 16 Remove the Carriage Assembly Carriage Belt and the Frame Tensioner 1 Remove the Top Cover and Trailing Cable Cover 2 Remove the Left and Right Covers Figure 5 9 Electronics Cover Removal ...

Page 119: ...lears the Back Support Bracket 4 Lift up on the connector lock to unlock the Trailing Cable connector J6 on the Carriage PWA and remove the end of the Trailing Cable LATCH Figure 5 10 Strain Relief Removal Installation 5 Remove the Trailing Cable and Strain Relief from the Carriage Assembly by releasing the latch on the left lower side of the Strain Relief and lifting it off of the Carriage Assemb...

Page 120: ...OUTER RING OF PLASTIC MUST FACE UP THIS NOTCH IN THE FRAME TENSIONER MUST FIT OVER THIS NOTCH IN THE END OF THE C BRACKET CARRIAGE BELT Figure 5 11 Frame Tensioner 9 Slide the Carriage Assembly and Drive Belt off the left side of the Slide Shaft 10 Once the Carriage Assembly is removed from the Slide Shaft turn it over so that you can see the Belt Clamp See Figure 5 12 11 To disengage the Carriage...

Page 121: ... right post of the Belt Clamp and gently lift up to finish removing the Carriage Belt from the Belt Clamp CAUTION Failure to use an approved antistatic bag for storage or shipment may cause damage to the MPWA and affect the Warranty 13 Place the Carriage Assembly in an ESD antistatic bag in preparation for shipment to ENCAD for replacement or repair or if it is to be stored for repair at your faci...

Page 122: ...t touch or work near integrated circuits without wearing an ESD wrist strap 1 Perform the Carriage Assembly Carriage Belt and the Frame Tensioner Removal procedures to remove the Carriage Assembly from the Slide Shaft 2 Put on an ESD wrist strap 3 Unlock the connectors and remove all flex cables on the Carriage PWA TAB SLOT LATCH Figure 5 13 Carriage PWA Removal Installation ...

Page 123: ... ENCAD for replacement or repair or if it is to be stored at your facility for repair Install the Carriage PWA 1 Put the tab on the left end of the Carriage PWA into the slot in the left side of the Carriage Assembly See Figure 5 13 2 Ensure that no flex cables are underneath the Carriage PWA 3 Push down the right end of the Carriage PWA until the latch snaps into place 4 Reattach all flex cables ...

Page 124: ...PULL OUT TO REMOVE PAPER SENSOR BOARD GRASP HERE AND PULL UP Figure 5 14 Paper and Encoder Sensor Removal 2 To remove the Paper Sensor a Unlock the connector at J3 and remove the flex cable b Turn the Carriage Assembly over and hold it while firmly grasping the Paper Sensor between thumb and index finger See Figure 5 14 c Pull straight up on the Paper Sensor and remove it from the Carriage Assembl...

Page 125: ...See Figure 5 14 Install the Paper Sensor or the Encoder Sensor ROUTE FLEX THROUGH SLOT INSIDE THE CARRIAGE ASSEMBLY 1 2 GROOVES 1 PUSH DOWN ON CLIP PUSH ENCODER IN OVER CLIP ENCODER MUST SLIDE PAST THE RIDGES AND SNAP INTO PLACE ALIGN SIDES OF PAPER SENSOR BOARD BETWEEN GROOVES AND PUSH STRAIGHT DOWN Figure 5 15 Paper and Encoder Sensor Installation 1 To install the Paper Sensor a Turn the Carriag...

Page 126: ...m side of it is facing up b Push down on the plastic clip and slide the back of the Encoder Sensor over it c Push the Encoder Sensor in past the ridges until the Encoder Sensor snaps into place d Turn the Carriage Assembly over and insert the Encoder flex cable into the connector at J5 e Push both sides of the connector lock shut at the same time 3 Perform the Carriage Assembly Carriage Belt and t...

Page 127: ... BUSHING LATCH Figure 5 16 Carriage Bushing Removal 2 Use a flat tip screwdriver to push up on the latch which holds the Carriage Bushing in place See Figure 5 16 3 Pull the Carriage Bushing out of the Carriage Assembly 4 Repeat Steps 2 and 3 for the other Carriage Bushing ...

Page 128: ...Belt and the Frame Tensioner 1 To install the Belt onto the Carriage Assembly the bumps on the belt where the ends of the belt are joined together to make the belt continuous must be positioned between the left and right posts of the Belt Clamp See Figure 5 12 2 Slide the Carriage Belt between the right post and the middle post and guide it down into the Belt Clamp Then slide the Carriage Belt bet...

Page 129: ...hut at the same time 9 Place the right side of the back of the Electronics Cover under the Trailing Cable Support Assembly and gently press down on the ends of the Electronics Cover until the latches snap into the Carriage Assembly 10 Slide the Carriage Assembly to about the middle of the Slide Shaft and stretch out the Carriage Belt 11 Insert the Carriage Belt into the Frame Tensioner so that the...

Page 130: ...d forefinger to pull forward on the connector lock and remove the Trailing Cable from the connector 5 With a flathead screwdriver press the Electronics Cover tab located in the upper slot on the left side of the Carriage Assembly See Figure 5 9 Lift up on the front left side of the Carriage Cover until it comes part way off of the Carriage Assembly Then lift up on the front right side of the Carri...

Page 131: ...le to the J6 connector on the Carriage PWA Slide both sides of the connector lock shut at the same time 6 Press the Trailing Cable down onto the double sided tape on the Carriage PWA 7 Move the Carriage Assembly to the very left end of the Slide Shaft 8 Remove the top protective cover on the 2 double sided tape on the right end of the Stabilizer Bracket and press the right end of the Trailing Cabl...

Page 132: ...led tighten the leg assembly to support the plotter 1 Remove the Top Cover and the Left Cover 2 Using a 2 Phillips screwdriver remove the 4 screws on the bottom of the Platen which hold the Power Supply in place 3 Pull the Power Supply part way out of the Platen grasp the connector on the black and white ON OFF Switch Cable and remove the cable from the Power Supply 4 Pull the Power Supply the res...

Page 133: ...ENCAD T 200 and T 200 Service Manual Assembly Disassembly 5 31 REMOVE LOOSEN Figure 5 18 Revealing the Power Supply Screws ...

Page 134: ...VE SHAFT FOAM BLOCK STEPPER MOTOR ASSY POWER SUPPLY CABLE POWER SUPPLY Figure 5 19 Inner Platen Parts 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 Connect the ground wire to the inside of the Platen Torque to 6 in lbs NOTE The ground wire from the power entry module must be on the bottom an...

Page 135: ...ector on the Power Supply 5 Position the Power Supply in place inside the Platen and insert the screws through the bottom of the Platen and into the Power Supply Use a 2 Phillips screwdriver to torque the screws to 6 in lbs Do not overtighten them 6 Reinstall the Left Cover and the Top Cover Removing the Stabilizer Bracket and Encoder Strip 1 Remove the Cartridges and the Top Cover 2 Remove the Le...

Page 136: ...zer Bracket and Encoder Strip The new Stabilizer Bracket will already have the new Encoder Strip as well as new tapes for the Trailing Cable attached to it Refer to Fig ure 5 20 during this procedure To reinstall the Stabilizer Bracket 1 Attach the Stabilizer Bracket to the Y Arm with the three screws which go through the back of the Y Arm into the Stabilizer Bracket It is easier to do this if you...

Page 137: ...ce you have checked the movement of the Carriage Assembly follow the procedures for attaching the Trailing Cable to the tapes on the Stabilizer Bracket 5 Reattach the Trailing Cable Cover 6 Reattach the Left Cover 7 Reinstall the Cartridges and the Top Cover 8 Perform the Carriage Height Adjustment procedure located in Chapter 3 Disassembly of Plotter Before Removing the Inner Platen Parts Refer t...

Page 138: ...T ROLLGUIDE CAUTION DO NOT REMOVE SCREWS TO Y ARM ASSY Figure 5 21 Disassembly of Plotter Prior to Removing the Inner Platen Parts 7 Remove the Left and Right Rollguides from the back of the Platen 8 Remove the Trailing Cable Cover 9 Remove the Power Supply 10 Remove the Servo Motor 11 Clean and remove the entire Service Station ...

Page 139: ... 22 Removal of Lower Drive Shaft Screws 1 Lay Platen on its back 2 Use a flat screwdriver to pry out the Snap Plug on the bottom side of the Platen 3 Using a 1 6 or 8 Phillips screwdriver remove the four screws on the bottom of the Platen which hold the Exhaust in place 4 Insert your left hand into the opening for the Exhaust and hold the Fan Assembly in place while using a 2 6 or 8 Phillips screw...

Page 140: ...hrough the left end of the Platen and the middle Drive Shaft Support through the Snap Plug opening NOTE Be very careful when removing the Foam Block so that it does not tear If it does tear however it must be replaced with a new one so that the Inner Platen has sufficient vacuum 8 Remove the Foam Block which is beside the Stepper Motor Assembly by putting your index finger into the opening in the ...

Page 141: ...rs 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 Removing the Stepper Motor NOTE If removing only the Stepper Motor do not remove the Bowed Washer Washer and Retaining Ring which are between the end of the Lower Drive Assembly and the Stepper Motor Bracket NOTE D...

Page 142: ... 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 5 24 2 Unscrew the Retainer Spring Post from the Spring Post and remove them from the Stepper Motor Bracket and Stepper Motor Assembly 3 Unscrew the Pivot Screw and Pivot Nut and remove them from the Stepper Motor Bracket and Stepper Motor As...

Page 143: ...rs are meshing with each other 3 Use the Pivot Screw and Pivot Nut to secure the Stepper Motor Assembly to the Stepper Motor Bracket Torque to 6 in lb 4 Hook the Extension Spring onto the Spring Post 5 Place the Spring Post through the Stepper Motor Assembly and the Stepper Motor Bracket and secure it with the Retainer Spring Post Torque to 6 in lb 6 Hook the Extension Spring onto the post on the ...

Page 144: ...in the left end of the Platen so that the shaft goes through the brass bushing in the support The support should be oriented in the same manner as the support which is by the Stepper Motor See Figure 5 22 Align it with the screw holes and insert the screws Using a 2 6 or 8 Phillips screwdriver tighten them slightly 7 Torque all the screws in the supports to 6 in lbs 8 Insert the Foam Block Make su...

Page 145: ... Make sure the Ground from the Power Cable is still connected to the inside of the Platen at the same location as the ON OFF Switch Ground Reinstall the Power Supply 5 Reinstall the Left and Right Rollguides 6 Route all the wires from the Servo Motor Assembly Stepper Motor Assembly Fan Assembly and Power Supply through the bottom opening on the Right Side Plate See Figure 5 23 Secure the Right Sid...

Page 146: ...Plate 15 Reinstall the Left Cover 16 Reinstall the Top Cover The entire plotter is now reassembled Removing the Upper Pinch Roller Supports 1 Remove the Top Cover and Left Cover 2 Use the 1 Phillips Screwdriver to remove the 3 screws which secure the Trailing Cable Cover to the back of the Y Bracket and remove the Trailing Cable Cover 3 Depress the back of the Frame Tensioner see Figure 5 6 and sl...

Page 147: ...racket Make sure the Upper Pinch Roller Support does not catch on the front edge of the Trailing Cable and that it does not damage the Slide Shaft or the encoder strip PINCH ROLLER SUPPORT PINCH ROLLER SPACER Figure 5 25 Removing the Upper Pinch Roller Support 7 Working from the far left Upper Pinch Roller Support to the far right Upper Pinch Roller Support follow Steps 4 through 7 for each of the...

Page 148: ...on Ensure that the tab on the back of the spacer is inserted into the hole in the Y Bracket 3 Move the Upper Pinch Roller Support into place Make sure the point on top back of the Upper Pinch Roller Support is in its hole in the Pinch Roller Spacer See Figure 5 25 4 Keep pressure on the front of the Upper Pinch Roller Support while putting in the screws Make sure the Upper Pinch Roller Support is ...

Page 149: ...twisting of the Carriage Belt slide the Carriage back and forth a few times to make sure that it slides smoothly 7 Reattach the Trailing Cable Cover to the Y Bracket 8 Reattach the Left Cover 9 Because you have replaced the Upper Pinch Roller Supports it is necessary to perform the following portions of Chapter 3 z Paper Skew Setup z Paper Skew Adjustment Because the Carriage Belt was loosened dur...

Page 150: ...The list is in order of part name as identified in the assembly disassembly chapter This list is to be used in conjunction with the assembly disassembly procedures to aquire the necessary parts and properly install them into the printer The parts and assemblies may be ordered through your local authorized dealer or ENCAD Inc s Technical Support and Service department ...

Page 151: ... 5 6 1 2 ROLLGUIDE LEFT ASSY 204969 6 6 1 3 COVER ASSY LEFT 217512 00 6 1 4 POWER ENTRY ASSY 207508 6 1 5 POWER SUPPLY ASSY 150W 218759 00 6 1 6 CABLE POWER SUPPLY TO MPWA 218762 00 HARDWARE KIT 205188 ASSY HEIGHT GAGE KIT 209996 1 LOOPBACK TEST CABLE 205462 FIGURE ITEM PART NAME PART ...

Page 152: ...ENCAD T 200 and T200 Service Manual Parts List 6 3 Figure 6 1 Left Side Parts Breakdown ...

Page 153: ... 3 COVER ASSY TOP 217860 00 6 2 4 BELT 205678 6 2 5 SPRING COMPRESSION IDLER 203999 6 2 6 IDLER ASSEMBLY 203405 1 6 2 7 FRAME TENSIONER 203870 1 6 2 8 TRAILING CABLE ASSY 209269 01 6 2 9 PINCH ROLLER ASSEMBLY 204773 6 2 10 STABILIZER ASSY WITH ENCODER STRIP 204550 6 2 11 SLIDE SHAFT 217506 01 6 2 12 KNIFE DAMPER ASSY 202000 6 2 13 PLATEN ASSY 214495 02 ...

Page 154: ...ENCAD T 200 and T200 Service Manual Parts List 6 5 Figure 6 2 Platen and Above Parts Breakdown ...

Page 155: ...IGURE ITEM PART NAME PART 6 3 1 PRINT SERVER OPTIONAL 218239 00 6 3 2 SIDE PLATE RIGHT 217516 00 6 3 3 MAIN PCB T 200 SERVICE 2119668 025 6 3 4 DRAM DIMM 32M 212456 00 6 3 5 COVER ASSEMBLY WITH KEYPAD RIGHT 217510 00 6 3 6 DISPLAY HOUSING ASSY 217543 00 ...

Page 156: ...ENCAD T 200 and T200 Service Manual Parts List 6 7 Figure 6 3 Right Side Parts Breakdown ...

Page 157: ...568 00 6 4 3 MOTOR ASSY STEPPER W FERRITE AND GEAR 210848 1 6 4 4 BRACKET ASSY DRIVE SHAFT RIGHT 204916 1 6 4 5 LOWER DRIVE E ASSY COMPLETE WITH STEPPER MOTOR AND RIGHT BRACKET 204845 1 6 4 6 BRACKET ASSY DRIVE SHAFT LEFT 204916 6 4 7 SUPPORT DRIVE SHAFT 203556 2 6 4 8 FAN ASSEMBLY VACUUM 210139 6 4 9 EXHAUST GRILL 204976 6 4 10 PLUG PLATEN 203742 ...

Page 158: ...ENCAD T 200 and T200 Service Manual Parts List 6 9 Figure 6 4 Inner Platen Parts Breakdown ...

Page 159: ... 05 6 5 3 ENCODER SENSOR W FLEX 209578 101 6 5 4 STRAIN RELIEF 215659 00 6 5 5 PEN CARRIER 208 PARTIAL 210004 6 5 6 CARRIAGE BUSHING SET 2 209568 6 5 7 PAD BUSHING 212426 00 6 5 8 SPRING PAD 208 JET 207572 6 5 9 FERRITE FLEX CABLE 210809 6 5 10 PWB FLEX QUAD 215174 00 6 5 11 PAPER SENSOR W FLEX 207180 PEN CARRIER ASSY COMPLETE ASSEMBLY 217619 00 ...

Page 160: ...ENCAD T 200 and T200 Service Manual Parts List 6 11 Figure 6 5 Carriage Assembly Parts Breakdown ...

Page 161: ...ENCAD T 200 and T200 Service Manual Parts List 6 12 FIGURE ITEM PART NAME PART 6 6 1 SEAL 104 208 206502 6 6 2 WIPER 209276 SERVICE STATION COMPLETE ASSEMBLY 207611 03 ...

Page 162: ...ENCAD T 200 and T200 Service Manual Parts List 6 13 Figure 6 6 Service Station Assembly Parts Breakdown ...

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